TM 5-2410-241-23-1

TM 5-2410-241-23-1 TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR

D7R SERIES II DOZER TYPE I WITH WINCH (NSN 2410-01-565-2605) D7R SERIES II DOZER TYPE II WITH RIPPER (NSN 2410-01-565-2603)

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY 29 FEBRUARY 2012

Warning Summary

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WARNING SUMMARY This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. In the event of injury, seek medical attention in accordance with FM 4-25.11. Also included in the summary are explanations of safety and hazardous materials icons used within the technical manual. EXPLANATION OF SAFETY WARNING ICONS

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EAR PROTECTION - headphones over ears show that noise level will harm ears.

ELECTRICAL - electrical wire to arm with electricity symbol running through human body shows that shock hazard is present.

EYE PROTECTION - person with goggles shows that the material will injure the eyes.

FLYING PARTICLES - arrows bouncing off face with face shield show that particles flying through the air will harm face.

HEAVY OBJECT - human figure stooping over heavy object shows physical injury potential from improper lifting techniques.

HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush and harm.

HEAVY PARTS - heavy object on human figure shows that heavy parts present a danger to life or limb.

HEAVY PARTS - foot with heavy object on top shows that heavy parts can crush and harm.

HOT AREA - hand over object radiating heat shows that part is hot and can burn.

PINCH POINT - Object crushing human figure shows that areas between vehicles or parts present a danger to life or limb.

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EXPLANATION OF SAFETY WARNING ICONS - CONTINUED

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SLICK FLOOR - wavy line on floor with legs prone shows that slick floor presents a danger from falling.

EXPLANATION OF HAZARDOUS MATERIALS ICONS BIOLOGICAL - abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.

CHEMICAL - drop of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.

FIRE - flame shows that a material may ignite and cause burns.

HIGH-PRESSURE FLUID - high-pressure fluid spraying human hand shows that fluid escaping under great pressure can cause injury or death.

RADIOACTIVE - identifies a material that emits radioactive energy and can injure human tissue or organs.

VAPOR - human figure in a cloud shows that material vapors present a danger to life or health.

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FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11. GENERAL SAFETY WARNINGS DESCRIPTION

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WARNING

COMPRESSED AIR

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• Compressed air for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi (207 kPa). Wear protective clothing (goggles/shield, gloves, etc.) and use caution to avoid injury to personnel.

WARNING

HEARING PROTECTION

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Hearing protection is required when standing within 26 ft (8 m) of the machine while it is operating. Failure to wear hearing protection may result in hearing loss.

WARNING

HOT COMPONENTS

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Components with metal parts can cause severe burns at operating temperature. Allow components to cool before performing maintenance on them. Wear insulated gloves, long sleeves, and eye protection when working with heated parts. MACHINE OPERATION Use of seat belt while operating machine is mandatory. Failure to follow this warning may result in injury or death to personnel in the event of an accident or machine overturn.

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GENERAL SAFETY WARNINGS DESCRIPTION - CONTINUED

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WARNING

PRESSURIZED COOLING SYSTEM

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• DO NOT service cooling system unless engine has cooled. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns. • DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure to follow this warning may cause serious burns. • Wear effective eye, hand, and skin protection when handling coolants. Failure to follow this warning may cause injury to personnel.

WARNING

SLAVE STARTING ENGINE When slave starting the engine: –

Use NATO slave cable that does NOT have loose or missing insulation.

–

DO NOT proceed if suitable cable is not available.

–

DO NOT use civilian-type jumper cables.

–

DO NOT allow disabled machine and booster vehicle to come in contact with each other at any time during slave starting.

Failure to follow these warnings may result in injury or death to personnel.

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HAZARDOUS MATERIALS WARNINGS DESCRIPTION

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WARNING

BATTERIES • To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating or electric shock, damage to equipment, and injury to personnel. • Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may result in death or injury to personnel. –

EYES. Flush with cold water for no less than 15 minutes and seek medical attention immediately.

–

SKIN. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required.

–

INTERNAL. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately.

–

CLOTHING/EQUIPMENT. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.

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HAZARDOUS MATERIALS WARNINGS DESCRIPTION - CONTINUED

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WARNING

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!!!! • Carbon monoxide is a colorless, odorless, deadly poison, which, when breathed, deprives the body of oxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death can result from severe exposure. • Carbon monoxide occurs in the exhaust fumes of internal combustion engines. Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation. The following precautions must be observed to ensure safety of personnel when the engine is operated. –

DO NOT operate engine in enclosed areas.

–

DO NOT idle engine without adequate ventilation.

–

BE ALERT for exhaust poisoning symptoms. They are: • Headache • Dizziness • Sleepiness • Loss of muscular control

–

If you see another person with exhaust poisoning symptoms: • Remove person from area. • Expose to fresh air. • Keep person warm. • DO NOT permit physical exercise. • Administer Cardiopulmonary Resuscitation (CPR) if necessary. • Notify a medic.

–

BE AWARE. The field protective mask for Chemical, Biological, Radiological, and Nuclear (CBRN) protection will not protect you from carbon monoxide poisoning.

The Best Defense Against Carbon Monoxide Poisoning is Good Ventilation!

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HAZARDOUS MATERIALS WARNINGS DESCRIPTION - CONTINUED

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WARNING

CARC PAINT

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• Take the following precautions before grinding, cutting, or welding any equipment that has been CARC-coated: –

Wear protective equipment (e.g., goggles, gloves, apron) when grinding or sanding CARC-coated equipment. DO NOT leave any skin exposed.

–

Use high-efficiency air-purifying respirators when grinding or sanding CARCcoated equipment.

–

Never weld or cut CARC-coated equipment; grind or sand off CARC paint completely before welding.

–

CARC paint contains isocyanate (HDI), which is highly irritating to the skin and respiratory system. High concentrations of HDI can produce itching and reddening of the skin, a burning sensation in the throat and nose, and watering of the eyes. In extreme concentrations, HDI can cause coughing, shortness of breath, pain during respiration, increased sputum production, and chest tightness.

• Failure to follow these warnings may result in injury or death to personnel.

WARNING

HAZARDOUS WASTE DISPOSAL

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• When servicing this equipment, performing maintenance, or disposing of materials such as engine/ hydraulic oils, coolant, and fuel, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. • Engine/hydraulic oils, coolant, and fuel can be very slippery. Immediately wipe up any spills. • Failure to follow these warnings may result in injury to personnel.

WARNING

HYDRAULIC SYSTEM PRESSURE • DO NOT disconnect or remove any hydraulic system line or fitting unless the engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing injury or death to personnel. • Use a piece of cardboard, newspaper, or wood to check for pressurized leaks to prevent fluid from penetrating the skin. Failure to do so may cause injury or death to personnel.

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HAZARDOUS MATERIALS WARNINGS DESCRIPTION - CONTINUED

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WARNING

CBRN EXPOSURE

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If CBRN exposure is suspected, personnel wearing protective equipment must handle all air cleaner media. Contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. Consult your CBRN Officer or CBRN NCO for appropriate handling or disposal procedures. Failure to follow this warning may cause injury or death to personnel.

WARNING

SOLVENT CLEANING COMPOUND

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Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to do so may result in injury or death to personnel.

WARNING WORK SAFETY • Improper cleaning methods and use of unauthorized cleaning liquids or solvents can injure personnel and damage equipment. To prevent this, refer to your unit’s authorized cleaning and solvents list for further instructions. • Solvents can burn easily, give off harmful vapors, and are harmful to skin and clothing. To avoid injury or death to personnel, keep away from open fire and use in a well-ventilated area. If solvent gets on skin or clothing, wash immediately with soap and water.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES NOTE: Zero in the “Change No.” column indicates an original page or work package. Date of issue for the original manual is: Original.... 29 February 2012 TOTAL NUMBER OF VOLUMES IS THREE. TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IN VOLUME I IS 118. TOTAL NUMBER OF WORK PACKAGES FOR ALL VOLUMES IS 304, CONSISTING OF THE FOLLOWING: Page/WP No.

Volume I

Change No.

Page/WP No. Change No. WP 0029 (16 pgs) . . . . . . . . . . . . . . . . . 0 WP 0030 (2 pgs) . . . . . . . . . . . . . . . . . . 0

Front Cover (2 pgs) . . . . . . . . . . . . . . . . 0

WP 0031 (8 pgs) . . . . . . . . . . . . . . . . . . 0

Warning Summary (8 pgs) . . . . . . . . . . . 0

WP 0032 (22 pgs) . . . . . . . . . . . . . . . . . 0

TOC (80 pgs) . . ... . . . . . . . . . . . . . . . . . 0

WP 0033 (10 pgs) . . . . . . . . . . . . . . . . . 0

Chapter 1 title page (2 pgs) . . . . . . . . . . 0

WP 0034 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0001 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0035 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0002 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0036 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0003 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0037 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0004 (14 pgs) . . . . . . . . . . . . . . . . . 0

Chapter 3 title page (2 pgs) . . . . . . . . . . 0

WP 0005 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0038 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0006 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0039 (26 pgs) . . . . . . . . . . . . . . . . . 0

WP 0007 (4 pgs) . . . . . . . . . . . . . . . . . . 0

Chapter 4 title page (2 pgs) . . . . . . . . . . 0

WP 0008 (30 pgs) . . . . . . . . . . . . . . . . . 0

WP 0040 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0009 (24 pgs) . . . . . . . . . . . . . . . . . 0

WP 0041 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0010 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0042 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0011 (52 pgs) . . . . . . . . . . . . . . . . . 0

WP 0043 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0012 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0044 (10 pgs) . . . . . . . . . . . . . . . . . 0

Chapter 2 title page (2 pgs) . . . . . . . . . . 0

WP 0045 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0013 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0046 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0014 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0047 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0015 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0048 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0016 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0049 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0017 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0050 (16 pgs) . . . . . . . . . . . . . . . . . 0

WP 0018 (132 pgs) . . . . . . . . . . . . . . . . 0

WP 0051 (22 pgs) . . . . . . . . . . . . . . . . . 0

WP 0019 (96 pgs) . . . . . . . . . . . . . . . . . 0

WP 0052 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0020 (236 pgs) . . . . . . . . . . . . . . . . 0

WP 0053 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0021 (50 pgs) . . . . . . . . . . . . . . . . . 0

WP 0054 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0022 (150 pgs) . . . . . . . . . . . . . . . . 0

WP 0055 (22 pgs) . . . . . . . . . . . . . . . . . 0

WP 0023 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0056 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0024 (6 pgs) . . . . . . . . . . . . . . . . . . 0

Index (10 pgs) . . . . . . . . . . . . . . . . . . . . 0

WP 0025 (30 pgs) . . . . . . . . . . . . . . . . . 0

Back Cover (2 pgs) . . . . . . . . . . . . . . . . 0

WP 0026 (18 pgs) . . . . . . . . . . . . . . . . . 0

Volume II

WP 0027 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0028 (4 pgs) . . . . . . . . . . . . . . . . . . 0

Front Cover (2 pgs) . . . . . . . . . . . . . . . . 0 A

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Page/WP No.

Change No.

Page/WP No.

Change No.

Warning Summary (8 pgs) . . . . . . . . . . . 0

WP 0096 (6 pgs) . . . . . . . . . . . . . . . . . . 0

TOC ( 32 pgs) . . . . . . . . . . . . . . . . . . . 0

WP 0097 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0057 (66 pgs) . . . . . . . . . . . . . . . . . 0

WP 0098 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0058 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0099 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0059 (64 pgs) . . . . . . . . . . . . . . . . . 0

WP 0100 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0060 (20 pgs) . . . . . . . . . . . . . . . . . 0

WP 0101 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0061 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0102 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0062 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0103 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0063 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0104 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0064 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0105 (16 pgs) . . . . . . . . . . . . . . . . . 0

WP 0065 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0106 (20 pgs) . . . . . . . . . . . . . . . . . 0

WP 0066 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0107 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0067 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0108 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0068 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0109 (16 pgs) . . . . . . . . . . . . . . . . . 0

WP 0069 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0110 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0070 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0111 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0071 (16 pgs) . . . . . . . . . . . . . . . . . 0

WP 0112 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0072 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0113 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0073 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0114 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0074 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0115 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0075 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0116 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0076 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0117 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0077 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0118 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0078 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0119 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0079 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0120 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0080 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0121 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0081 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0122 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0082 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0123 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0083 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0124 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0084 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0125 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0085 (16 pgs) . . . . . . . . . . . . . . . . . 0

WP 0126 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0086 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0127 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0087 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0128 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0088 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0129 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0089 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0130 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0090 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0131 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0091 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0132 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0092 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0133 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0093 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0134 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0094 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0135 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0095 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0136 (14 pgs) . . . . . . . . . . . . . . . . . 0 B

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Page/WP No.

Change No.

Page/WP No.

Change No.

WP 0137 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0178 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0138 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0179 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0139 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0180 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0140 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0181 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0141 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0182 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0142 (20 pgs) . . . . . . . . . . . . . . . . . 0

WP 0183 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0143 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0184 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0144 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0185 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0145 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0186 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0146 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0187 (38 pgs) . . . . . . . . . . . . . . . . . 0

WP 0147 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0188 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0148 (28 pgs) . . . . . . . . . . . . . . . . . 0

WP 0189 (16 pgs) . . . . . . . . . . . . . . . . . 0

WP 0149 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0190 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0150 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0191 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0151 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0192 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0152 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0193 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0153 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0194 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0154 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0195 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0155 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0196 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0156 (14 pgs) . . . . . . . . . . . . . . . . . 0

Index (6 pgs) . . . . . . . . . . . . . . . . . . . . . 0

WP 0157 (18 pgs) . . . . . . . . . . . . . . . . . 0

Back Cover (2 pgs) . . . . . . . . . . . . . . . . 0

WP 0158 (6 pgs) . . . . . . . . . . . . . . . . . . 0

Volume III

WP 0159 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0160 (14 pgs) . . . . . . . . . . . . . . . . . 0

Front Cover (2 pgs) . . . . . . . . . . . . . . . . 0

WP 0161 (6 pgs) . . . . . . . . . . . . . . . . . . 0

Warning Summary (8 pgs) . . . . . . . . . . . 0

WP 0162 (8 pgs) . . . . . . . . . . . . . . . . . . 0

TOC (30 pgs) . . . . . . . . . . . . . . . . . . . . 0

WP 0163 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0197 (22 pgs) . . . . . . . . . . . . . . . . . 0

WP 0164 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0198 (18 pgs) . . . . . . . . . . . . . . . . . 0

WP 0165 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0199 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0166 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0200 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0167 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0201 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0168 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0202 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0169 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0203 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0170 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0204 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0171 (26 pgs) . . . . . . . . . . . . . . . . . 0

WP 0205 (18 pgs) . . . . . . . . . . . . . . . . . 0

WP 0172 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0206 (36 pgs) . . . . . . . . . . . . . . . . . 0

WP 0173 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0207 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0174 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0208 (16 pgs) . . . . . . . . . . . . . . . . . 0

WP 0175 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0209 (26 pgs) . . . . . . . . . . . . . . . . . 0

WP 0176 (18 pgs) . . . . . . . . . . . . . . . . . 0

WP 0210 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0177 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0211 (28 pgs) . . . . . . . . . . . . . . . . . 0 C

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WP 0212 (26 pgs) . . . . . . . . . . . . . . . . . 0

WP 0253 (16 pgs) . . . . . . . . . . . . . . . . . 0

WP 0213 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0254 (22 pgs) . . . . . . . . . . . . . . . . . 0

WP 0214 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0255 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0215 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0256 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0216 (32 pgs) . . . . . . . . . . . . . . . . . 0

WP 0257 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0217 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0258 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0218 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0259 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0219 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0260 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0220 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0261 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0221 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0262 (22 pgs) . . . . . . . . . . . . . . . . . 0

WP 0222 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0263 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0223 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0264 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0224 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0265 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0225 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0266 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0226 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0267 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0227 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0268 (26 pgs) . . . . . . . . . . . . . . . . . 0

WP 0228 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0269 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0229 (20 pgs) . . . . . . . . . . . . . . . . . 0

WP 0270 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0230 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0271 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0231 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0272 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0232 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0273 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0233 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0274 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0234 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0275 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0235 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0276 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0236 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0277 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0237 (30 pgs) . . . . . . . . . . . . . . . . . 0

WP 0278 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0238 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0279 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0239 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0280 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0240 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0281 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0241 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0282 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0242 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0283 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0243 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0284 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0244 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0285 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0245 (18 pgs) . . . . . . . . . . . . . . . . . 0

WP 0286 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0246 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0287 (20 pgs) . . . . . . . . . . . . . . . . . 0

WP 0247 (24 pgs) . . . . . . . . . . . . . . . . . 0

WP 0288 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0248 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0289 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0249 (22 pgs) . . . . . . . . . . . . . . . . . 0

WP 0290 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0250 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0291 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0251 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0292 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0252 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0293 (12 pgs) . . . . . . . . . . . . . . . . . 0 D

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Change No.

WP 0294 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0300 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0295 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0301 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0296 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0302 (18 pgs) . . . . . . . . . . . . . . . . . 0

WP 0297 (44 pgs) . . . . . . . . . . . . . . . . . 0

WP 0303 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0298 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0304 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0299 (2 pgs) . . . . . . . . . . . . . . . . . . 0

Index (4 pgs) . . . . . . . . . . . . . . . . . . . . . 0

Chapter 5 title page (2 pgs) . . . . . . . . . . 0

Foldouts (68 pgs)

................ 0

Back Cover (2 pgs) ...............................0

E/(F Blank)

TM 5-2410-241-23-1 TECHNICAL MANUAL TM 5-2410-241-23-1

HEADQUARTERS DEPARTMENT OF THE ARMY Washington, D.C., 29 February 2012 FIELD MAINTENANCE MANUAL FOR D7R Series II Dozer TYPE I WITH WINCH (NSN 2410-01-565-2605) D7R Series II Dozer TYPE II WITH RIPPER (NSN 2410-01-565-2603)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet on the T ACOM Uniq ue L ogistics Support Applica tions (TULSA) W ebsite. The Inter net address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUB MIT. Using this form on the TULSA Website will enable us to respond more quickly to your comments and better manage the DA Fo rm 20 28 program. You may also mail, e- mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTALCL-MPP/TECH PUBS, M S 72 7, 6 501 E. 1 1 M ile Road, W arren, MI 48 397-5000. Th e e -mail address is [email protected]. The fax number is DSN 786-1856 or Commercial (586) 282-1856. A reply will be furnished to you. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

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Volume I How To Use This Technical Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lxxix Chapter 1 - General Information, Equipment Description, and Theory Of Operation General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001 Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

D7R Dozer Left Side 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002-2 D7R Dozer Left Side 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002-3 D7R Dozer Right Side 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002-4 D7R Dozer Right Side 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002-5 D7R Dozer with Ripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002-6 D7R Dozer with Winch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002-7

Theory of Operation: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003 Theory of Operation: Engine and Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11.

Cylinder Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-1 Piston, Rings, Connecting Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-2 Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-3 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-5 Low Fuel Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-7 Unit Injector Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-9 Unit Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-10 Pre-Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-11 Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-12 End of Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-13 Fill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-14

Theory of Operation: Air Inlet and Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005 Figure 1. Figure 2. Figure 3.

Air Inlet and Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005-3 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005-4 Valve System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005-5

Theory of Operation: Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006 Figure 1. Table 1. Figure 2. Table 2.

Lubrication System Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006-3 Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006-3 Oil Flow through Filter Housing to Engine. . . . . . . . . . . . . . . . . . . . 0006-5 Oil Flow through Filter Housing to Engine. . . . . . . . . . . . . . . . . . . . . 0006-5

Theory of Operation: Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0007 Figure 1. Figure 2.

Cooling System Components and Flow Schematic. . . . . . . . . . . . . 0007-3 Aftercooler Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007-4

Theory of Operation: Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0008 Figure 1. Figure 2. Table 1. Figure 3. Table 2.

Grounding Stud To Battery Ground. . . . . . . . . . . . . . . . . . . . . . . . . 0008-1 Alternator Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008-3 Alternator Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008-3 Starter Motor Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008-5 Starter Components.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008-5 ii

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Figure 4. Table 3. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Table 4. Figure 19. Table 5. Figure 20.

Powertrain ECM Control System. . . . . . . . . . . . . . . . . . . . . . . . . . .0008-6 Transmission Gear and Solenoid Valve Logic. . . . . . . . . . . . . . . . . .0008-7 Inputs to the Powertrain ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008-9 Ignition Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008-10 Mechanical Parking Brake Switch Actuator. . . . . . . . . . . . . . . . . .0008-12 FNR Direction Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008-14 Autoshift/Auto Kickdown Switch. . . . . . . . . . . . . . . . . . . . . . . . . . .0008-14 Hydraulic Lockout Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008-16 Service Brake Pedal Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008-17 Speed Sensor Torque Converter Output. . . . . . . . . . . . . . . . . . . .0008-18 Speed Sensor Transmission Output 1 and 2. . . . . . . . . . . . . . . . .0008-19 Position Sensor for the Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . .0008-20 Position Sensor for the FNR Direction Handle. . . . . . . . . . . . . . . .0008-21 ECM Connectors and Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . .0008-22 Powertrain ECM Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008-24 Electronic Brake Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008-25 Electronic Brake Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008-25 Proportional Brake Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008-26 Machine Solenoids.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008-27 Blade Float. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008-28

Theory of Operation: Primary Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0009 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Table 1. Figure 12. Table 2. Figure 13. Figure 14. Figure 15. Figure 16. Table 3. Figure 17. Figure 18.

Powertrain Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0009-1 Schematic for the Powertrain Hydraulic System. . . . . . . . . . . . . . . .0009-3 Electronic Control System of the D7R Dozer Powertrain. . . . . . . . .0009-4 Location of Magnetic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0009-5 Powertrain Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0009-6 Relief Valve (Main). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0009-7 Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0009-7 Torque Divider. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0009-9 Torque Divider. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0009-10 Relief Valve (Torque Converter Inlet and Outlet). . . . . . . . . . . . . .0009-11 Clutch Operation (Typical Example). . . . . . . . . . . . . . . . . . . . . . . .0009-12 Transmission Clutch Engagement. . . . . . . . . . . . . . . . . . . . . . . . . .0009-13 Section View of the Transmission. . . . . . . . . . . . . . . . . . . . . . . . . .0009-14 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0009-14 Planetary Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0009-16 Oil Filter Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0009-17 Transfer and Bevel Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0009-18 Brake Control Valve (Side View of Valve). . . . . . . . . . . . . . . . . . . .0009-19 Brake Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0009-19 Brake Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0009-20 Steering Differential and Brake with Planetary Gears and Brake. .0009-23

Theory of Operation: Final Drive and Undercarriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0010 Figure 1. Figure 2.

Final Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0010-1 Undercarriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0010-2 iii

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Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11.

One Side of Pivot Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-3 Lubrication of Pivot Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-4 Equalizer Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-5 Track Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-6 Recoil Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-7 Track Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-8 Master Links and Master Shoe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-9 Idlers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-9 Track Roller (Double Flange). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-10

Theory of Operation: Implement and Steering Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0011 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35.

Hydraulic Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-1 Components of the Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . 0011-2 Steering Control Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-3 Counterbalance Valve And Steering Motor. . . . . . . . . . . . . . . . . . . 0011-3 Pilot Control Levers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-4 Solenoid for the Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-5 Valve Stack for Machine without Ripper. . . . . . . . . . . . . . . . . . . . . . 0011-6 Hydraulic Oil Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-7 Oil FIlter (Case Drain). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-8 Oil Filter (Implement Return Oil). . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-9 Oil Cooler and Bypass Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-10 Pump and Compensator Operation (Engine Off). . . . . . . . . . . . . . 0011-11 Pump and Compensator Operation (Upstroking). . . . . . . . . . . . . . 0011-12 Pump and Compensator Operation (Destroking). . . . . . . . . . . . . . 0011-13 Pump and Compensator Operation (Low Pressure Standby). . . . 0011-14 Pump and Compensator Operation (High Pressure Stall). . . . . . . 0011-15 Pump and Compensator Operation (Constant Flow). . . . . . . . . . . 0011-16 Piston Motor (Steering) Location. . . . . . . . . . . . . . . . . . . . . . . . . . 0011-17 Piston Motor (Steering). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-19 Counterbalance Valve (Steering) Location. . . . . . . . . . . . . . . . . . . 0011-20 Counterbalance Valve (Steering). . . . . . . . . . . . . . . . . . . . . . . . . . 0011-21 Implement Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-23 Steering Control Valve (HOLD). . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-25 Steering Control Valve (STEER LEFT). . . . . . . . . . . . . . . . . . . . . . 0011-26 Steering Control Valve (STEER RIGHT). . . . . . . . . . . . . . . . . . . . 0011-27 Bulldozer Lift Control Valve (General Information). . . . . . . . . . . . . 0011-29 Bulldozer Lift Control Valve (HOLD). . . . . . . . . . . . . . . . . . . . . . . . 0011-30 Bulldozer Lift Control Valve (RAISE). . . . . . . . . . . . . . . . . . . . . . . 0011-31 Bulldozer Lift Control Valve (LOWER). . . . . . . . . . . . . . . . . . . . . . 0011-32 Bulldozer Lift Control Valve (FLOAT). . . . . . . . . . . . . . . . . . . . . . . 0011-33 Bulldozer Tilt Control Valve (HOLD). . . . . . . . . . . . . . . . . . . . . . . . 0011-35 Bulldozer Tilt Control Valve (Tilt Left and Tilt Right). . . . . . . . . . . . 0011-37 Ripper Lift Control Valve (HOLD). . . . . . . . . . . . . . . . . . . . . . . . . . 0011-39 Ripper Lift Control Valve (RIPPER RAISE). . . . . . . . . . . . . . . . . . 0011-40 Ripper Lift Control Valve (RIPPER LOWER). . . . . . . . . . . . . . . . . 0011-41

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Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41. Figure 42. Figure 43.

Ripper Tip Control Valve (HOLD). . . . . . . . . . . . . . . . . . . . . . . . . .0011-43 Ripper Tip Control Valve (RIPPER TIP IN). . . . . . . . . . . . . . . . . . .0011-44 Ripper Tip Control Valve (RIPPER TIP OUT). . . . . . . . . . . . . . . . .0011-45 Winch Control Valve (REEL IN). . . . . . . . . . . . . . . . . . . . . . . . . . .0011-47 Winch Control Valve (REEL OUT). . . . . . . . . . . . . . . . . . . . . . . . .0011-48 Main Relief Valve in Inlet Manifold. . . . . . . . . . . . . . . . . . . . . . . . .0011-49 Main Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0011-50 Ripper Tilt Control Valve Activated. . . . . . . . . . . . . . . . . . . . . . . . .0011-51

Theory of Operation: Air Conditioning and Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0012 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Refrigerant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-3 Orifice Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-4 Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-4 Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-5 Condenser Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-6 Evaporator Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-7 Refrigerant Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-8 Heating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-9

Chapter 2 - Troubleshooting Procedures Troubleshooting Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0013 Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0014 How to Use On-Board Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0015 Figure 1. Figure 2. Figure 3. Figure 4.

Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0015-3 Messenger Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0015-4 Diagnostic Code Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0015-4 Diagnostic Code Detail Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0015-5

How to Use Electronic Technician (ET). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0016 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Electronic Technician (ET). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0016-2 Diagnostic Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0016-3 Diagnostic Connector Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0016-4 What’s New Dialog Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0016-4 ECM Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0016-5 Diagnostic Code Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0016-6 Status Group and Parameter List. . . . . . . . . . . . . . . . . . . . . . . . . . .0016-7

Electronic Control Module (ECM) Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0017 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.

Active Code Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0017-2 ECM Configuration Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0017-3 ECM Select Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0017-4 ECM Configuration Save. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0017-5 Diagnostic Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0017-7 Utilities Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0017-8 Win Flash Quick Help Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0017-8 Flash File Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0017-9 Flash File Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0017-10 Configuration Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0017-11 v

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Figure 11. Configuration File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017-12 Connector End Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0018 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41.

V-C4 Engine ECM Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-6 N-C1 Engine ECM Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-7 X-C3 Powertrain ECM Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-8 X-C2 Powertrain ECM Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-9 E-C7 Dash Monitor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-10 M-I-C1 Messenger Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-10 N-C2 Engine Harness Side Connector. . . . . . . . . . . . . . . . . . . . . . 0018-11 NN-C1 Valve Cover Side Connector. . . . . . . . . . . . . . . . . . . . . . . 0018-12 E-C28 Deceleration Position Sensor Connector Dash Harness Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-13 Sensor Pigtail - Decelerator Sensor Connector. . . . . . . . . . . . . . . 0018-14 MA-C22 Platform Harness (Platform to Engine) Connector. . . . . . 0018-14 V-C1 Engine Harness (Engine to Platform) Connector. . . . . . . . . 0018-15 R-C4 Throttle Switch Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-16 RW-C1 RH Console Harness Connector (Black). . . . . . . . . . . . . . 0018-17 MA-C1 RH Platform Harness Connector (Black). . . . . . . . . . . . . . 0018-18 Throttle Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-19 YY-C4 Arctic Kit Heater Harness to Arctic Kit Heater. . . . . . . . . . . 0018-20 B2 Connector Arctic Kit Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-20 N-C3 ECM Harness Connector at Oil Pressure Sensor. . . . . . . . . 0018-21 N-C11 ECM Harness Connector at Coolant Temperature Sensor. 0018-22 MA-C3 Platform Harness Connector. . . . . . . . . . . . . . . . . . . . . . . 0018-22 A-C1 Fuse Panel Wiring Harness Connector. . . . . . . . . . . . . . . . . 0018-23 N-C10 Intake Manifold Temperature Connector. . . . . . . . . . . . . . . 0018-24 N-C9 Fuel Temperature Connector. . . . . . . . . . . . . . . . . . . . . . . . 0018-24 NC-C2 Intake Manifold Jumper to Sensor Connector. . . . . . . . . . 0018-25 NC-C1 Intake Manifold Jumper to N-C10 Connector. . . . . . . . . . . 0018-25 N-C13 Crankshaft Position Connector. . . . . . . . . . . . . . . . . . . . . . 0018-26 Crankshaft Position Sensor (with Pigtail). . . . . . . . . . . . . . . . . . . . 0018-27 V-C12 Engine ECM Resistor - Can/Data Link. . . . . . . . . . . . . . . . 0018-28 Resistor Can/Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-29 X-C10 Powertrain ECM Resistor - Can/Data Link. . . . . . . . . . . . . 0018-30 Resistor Can/Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-31 MA-C14 Platform Harness Connector. . . . . . . . . . . . . . . . . . . . . . 0018-32 X-C1 Steering Control Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-33 N-C4 Atmospheric Pressure Sensor Connector. . . . . . . . . . . . . . . 0018-34 N-C5 Air Inlet Manifold Pressure Sensor Connector/ Turbocharger Outlet Pressure Sensor Connector. . . . . . . . . . . . . 0018-34 V-C20 Turbocharger Inlet Pressure Sensor Connector. . . . . . . . . 0018-35 CV-C1 Crank Normal Mode Connector. . . . . . . . . . . . . . . . . . . . . 0018-35 CV-C2 Crank without Injection Connector. . . . . . . . . . . . . . . . . . . 0018-35 V-C3 Harness Connector to Crank without Injection Connector. . . 0018-36 N-C14 Camshaft Position Connector. . . . . . . . . . . . . . . . . . . . . . . 0018-36

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Figure 42. Figure 43. Figure 44. Figure 45. Figure 46. Figure 47. Figure 48. Figure 49. Figure 50. Figure 51. Figure 52. Figure 53. Figure 54. Figure 55. Figure 56. Figure 57. Figure 58. Figure 59. Figure 60. Figure 61. Figure 62. Figure 63. Figure 64. Figure 65. Figure 66. Figure 67. Figure 68. Figure 69. Figure 70. Figure 71. Figure 72. Figure 73. Figure 74. Figure 75. Figure 76. Figure 77. Figure 78. Figure 79. Figure 80.

Camshaft Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-37 V-C18 Engine Harness Ether Relay Connector. . . . . . . . . . . . . . .0018-38 X-C6 Parking Brake Switch Connector. . . . . . . . . . . . . . . . . . . . . .0018-38 Parking Brake Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-39 V-C8 Transmission Oil Temperature Sensor Connector. . . . . . . .0018-39 E-C23 Instrument Panel Harness Brake Switch Connector. . . . . .0018-40 KK-C1 Service Brake Switch Harness Connector. . . . . . . . . . . . .0018-41 X-C8 FORWARD/NEUTRAL/REVERSE (FNR) Sensor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-41 E-C11 Bi-directional Mode Switch Connector. . . . . . . . . . . . . . . . .0018-42 A-C3 Fuse Panel Harness Start Relay Connector. . . . . . . . . . . . .0018-42 E-C27 Dash Harness Brake Position Sensor. . . . . . . . . . . . . . . . .0018-43 MA-C7 Platform Harness Connector to Transmission Jumper Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-44 MP-C2 Transmission Jumper Harness Connector to Platform Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-45 MP-C1 Transmission Jumper Harness Connector to P-C1 Transmission Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-46 P-C1 Transmission Harness Connector to Connector MP-C1. . . .0018-47 P-C2 Transmission Harness Speed Sensor #1 Connector. . . . . . .0018-47 X-C4 Steering Harness Downshift/Upshift Switch Connector. . . . .0018-48 Downshift/Upshift Switch Connector. . . . . . . . . . . . . . . . . . . . . . . .0018-48 X-C9 Harness Code Plug Connector to Steering Harness. . . . . . .0018-49 PW-C1 Harness Code Receptacle Connector to Steering Harness Connector X-C9. . . . . . . . . . . . . . . . . . . . . . . . .0018-50 V-C10 Engine Harness Torque Converter Output Speed Sensor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-50 Torque Converter Output Speed Sensor. . . . . . . . . . . . . . . . . . . .0018-51 P-C8 Transmission Harness Speed Sensor #2 Connector. . . . . . .0018-51 MA-C4 Platform Harness Parking Brake Dump Solenoid Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-52 Parking Brake Dump Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-53 MA-C12 Platform Harness Left Brake Solenoid Connector. . . . . .0018-54 Left Brake Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-55 MA-C6 Secondary Brake Dump Solenoid Connector. . . . . . . . . . .0018-56 Secondary Brake Dump Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . .0018-57 P-C4 Transmission Solenoid Valve #1 Connector. . . . . . . . . . . . .0018-58 P-C3 Transmission Solenoid Valve #2 Connector. . . . . . . . . . . . .0018-59 P-C7 Transmission Solenoid Valve #3 Connector. . . . . . . . . . . . .0018-60 P-C6 Transmission Solenoid Valve #4 Connector. . . . . . . . . . . . .0018-61 P-C5 Transmission Solenoid Valve #5 Connector. . . . . . . . . . . . .0018-62 X-C5 Steering Harness Reverse Switch Connector. . . . . . . . . . . .0018-63 RT-C1 Reverse Switch Connector (Pigtail). . . . . . . . . . . . . . . . . . .0018-63 TW-C2 Fuel Tank Harness Fuel Level Sender Connector. . . . . . .0018-64 MA-C23 Platform Harness to Fuel Tank Harness Connector. . . . .0018-64 TW-C7 Fuel Tank Harness to Platform Harness Connector. . . . . .0018-64 vii

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Figure 81. E-C3 Instrument Panel Harness Action Alarm Connector. . . . . . . 0018-65 Figure 82. E-C25 Instrument Panel Harness Action Lamp Connector. . . . . . 0018-65 Figure 83. L-C2 Chassis Harness Hydraulic Oil Temperature Sensor Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-66 Figure 84. L-C1 Chassis Harness to Platform Harness Connector. . . . . . . . . 0018-67 Figure 85. MA-C17 Platform Harness to Chassis Harness Connector. . . . . . 0018-68 Figure 86. E-C9 Instrument Panel Harness Gauge Cluster Connector. . . . . . 0018-68 Figure 87. E-C10 Instrument Panel Harness Lamp Gear Module Connector. 0018-69 Figure 88. V-C9 Engine Harness Torque Converter Outlet Temperature Sensor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-69 Figure 89. RW-C7 RH Console Harness Hydraulic Lockout Switch Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-70 Figure 90. L-C4 Chassis Harness Implement Lockout Solenoid Connector. . 0018-71 Figure 91. Hydraulic Lockout Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-72 Figure 92. GA-C2 Left Front Cylinder Mounted Flood Lamp Harness Connector to Left Front Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . 0018-72 Figure 93. GC-C2 Right Front Cylinder Mounted Flood Lamp Harness Connector to Right Front Flood Lamp. . . . . . . . . . . . . . . . . . . . . . 0018-73 Figure 94. GA-C1 Left Front Flood Lamp Harness to Radiator Guard Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-73 Figure 95. G-C2 Front Lighting Harness to Left Front Flood Lamp Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-73 Figure 96. GC-C1 Right Front Flood Lamp Harness to Radiator Guard Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-74 Figure 97. G-C3 Front Lighting Harness to Right Flood Lamp Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-74 Figure 98. G-C1 Front Lighting Harness to Engine Harness Connector. . . . . 0018-75 Figure 99. V-C15 Engine Harness to Radiator Guard Harness Connector. . . 0018-75 Figure 100. E-C5 Instrument Panel Harness Connector to Main Light Switch. 0018-75 Figure 101. TK-C2 Left Rear Flood Lamp Harness Connector to Left ROPS Mounted Forward Facing Flood Lamp. . . . . . . . . . . . . 0018-76 Figure 102. TJ-C2 Right Rear Flood Lamp Harness Connector to Right ROPS Mounted Forward Facing Flood Lamp. . . . . . . . . . . . 0018-76 Figure 103. TK-C3 Left Rear Flood Lamp Harness Connector to Fuel Tank Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-76 Figure 104. TJ-C3 Right Rear Flood Lamp Harness to Fuel Tank Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-77 Figure 105. TW-C3 Fuel Tank Harness to Left ROPS Flood Lamp Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-77 Figure 106. TW-C5 Fuel Tank Harness to Right ROPS Flood Lamp Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-78 Figure 107. TK-C1 Left Rear Flood Lamp Harness Connector to Left Rearward Facing Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . 0018-78 Figure 108. TJ-C1 Right Rear Flood Lamp Harness Connector to Right Rearward Facing Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . 0018-78 Figure 109. E-C22 Instrument Panel Harness Connector to Rearward Facing Flood Lamp Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-79 viii

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Figure 110. V-C16 Engine Harness Under Hoodlight Connector. . . . . . . . . . .0018-79 Figure 111. V-C17 Engine Harness Under Hoodlight Switch Connector. . . . .0018-80 Figure 112. E-C16 Instrument Panel Harness Connector to Cab Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-80 Figure 113. H-C2 Cab Harness to Instrument Panel Harness Connector. . . .0018-81 Figure 114. H-C6 Cab Harness to Headliner Harness Connector. . . . . . . . . .0018-82 Figure 115. HA-C2 Cab Harness to Headliner Harness Connector. . . . . . . . .0018-83 Figure 116. Arctic Kit Heater Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-83 Figure 117. YY-C3 Arctic Kit Heater Harness to Arctic Kit Heater Fuel Pump. 0018-84 Figure 118. YY-C2 Arctic Kit Heater Diagnostic Connector. . . . . . . . . . . . . . .0018-84 Figure 119. Arctic Kit Heater Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-85 Figure 120. XX-C2 Arctic Kit Heater Harness Connector to Arctic Kit Heater Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-86 Figure 121. 108 Blue Rear Wiper Power Supply Connector to Rear Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-86 Figure 122. 108 Blue Front Wiper Power Supply Connector to Front Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-87 Figure 123. H-C1 Cab Harness Front Wiper Motor Connector. . . . . . . . . . . . .0018-87 Figure 124. H-C5 Cab Harness Left Door Wiper Motor Connector. . . . . . . . . .0018-88 Figure 125. H-C4 Cab Harness Right Door Wiper Motor Connector. . . . . . . .0018-88 Figure 126. HA-C4 Headliner Harness to Rear Wiper Motor Connector. . . . .0018-89 Figure 127. YY-C1 Arctic Kit Heater Harness to Arctic Kit Heater Main Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-89 Figure 128. XY-C4 Arctic Kit Heater Main Harness to Arctic Kit Heater Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-90 Figure 129. XX-C1 Arctic Kit Heater Switch Harness to Arctic Kit Heater Main Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-90 Figure 130. XY-C3 Arctic Kit Heater Main Harness to Arctic Kit Heater Switch Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-91 Figure 131. XY-C1 Arctic Kit Heater Main Harness to Platform Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-91 Figure 132. MA-C21 Platform Harness to Arctic Kit Heater Main Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-92 Figure 133. H-C7 Cab Harness to Headliner Harness Connector. . . . . . . . . .0018-93 Figure 134. HA-C1 Headliner Harness to Cab Harness Connector. . . . . . . . .0018-94 Figure 135. 500 Brown Front Wiper Park Supply Connector to Front Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-94 Figure 136. 501 Green Front Wiper Low Supply Connector to Front Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-95 Figure 137. 502 Orange Front Wiper High Supply Connector to Front Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-95 Figure 138. 523 Brown Left Door Wiper Park Supply Connector to Left Door Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-96 Figure 139. 524 Blue Left Door Wiper Low Supply Connector to Left Door Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-96 Figure 140. 525 Gray Left Door Wiper High Supply Connector to Left DoorWiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-97 ix

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Figure 141. 526 Yellow Right Door Wiper Park Supply Connector to Right Door Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-97 Figure 142. 527 Green Right Door Wiper Low Supply Connector to Right Door Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-98 Figure 143. 528 Pink Right Door Wiper High Supply Connector to Right Door Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-98 Figure 144. 503 Brown Rear Wiper Park Supply Connector to Rear Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-99 Figure 145. 504 Yellow Rear Wiper Low Supply Connector to Rear Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-99 Figure 146. 505 Blue Rear Wiper High Supply Connector to Rear Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-100 Figure 147. 108 Blue Right Wiper Power Supply Connector to Right Door Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . 0018-100 Figure 148. 108 Blue Left Wiper Power Supply Connector to Left Door Wiper Motor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-101 Figure 149. 108 Blue Rear Wiper Power Supply Connector to Rear Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-101 Figure 150. 506 Purple Front Washer Supply Connector to Front Washer Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-102 Figure 151. 507 White Rear Washer Supply Connector to Rear Washer Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-102 Figure 152. 503 Orange Right Washer Supply Connector to Right Washer Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-103 Figure 153. 529 White Left Washer Supply Connector to Left Washer Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-103 Figure 154. H-C8 Cab Harness Washer Bottle Connector. . . . . . . . . . . . . . . 0018-104 Figure 155. HH-C1 Washer Bottle to Cab Harness Connector. . . . . . . . . . . 0018-104 Figure 156. G-C4 Front Lighting Harness Top Horn Connector. . . . . . . . . . . 0018-105 Figure 157. G-C5 Front Lighting Harness Bottom Horn Connector. . . . . . . . 0018-105 Figure 158. MA-C13 Platform Harness to RH Console Harness Connector (Green). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-106 Figure 159. RW-C3 RH Console Harness to Platform Harness Connector (Green). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-107 Figure 160. R-C5 RH Console Harness Connector to Horn Switch. . . . . . . . 0018-108 Figure 161. CH-C3 A/C Compressor Harness Connector to Compressor Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-108 Figure 162. CH-C2 A/C Compressor Harness Connector to Compressor Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-109 Figure 163. E-C6 Instrument Panel Harness Ignition Switch Connector. . . . 0018-109 Figure 164. CH-C1 A/C Compressor Harness Connector to Engine Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-110 Figure 165. V-C13 Engine Harness Connector to A/C Compressor Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-110 Figure 166. E-C14 Instrument Panel Harness Connector to Blower Motor Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . 0018-111 Figure 167. EE-C8 Blower Motor Harness Connector to Instrument x

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Panel Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-112 Figure 168. 522 White Thermostat Switch Connector. . . . . . . . . . . . . . . . . .0018-113 Figure 169. 200 Black Thermostat Switch Connector. . . . . . . . . . . . . . . . . . .0018-114 Figure 170. E-C21 Instrument Panel Harness Connector to A/C Switch. . . .0018-114 Figure 171. E-C2 Instrument Panel Harness Connector to Blower Motor Speed Switch Connector. . . . . . . . . . . . . . . . . . . . . . . . . .0018-115 Figure 172. 124 Green Fuse Panel Wiring Harness Blower Motor Circuit Breaker Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-115 Figure 173. 112 Purple Blower Motor Circuit Breaker Supply Power Wire Point AE1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-116 Figure 174. EE-C3 Blower Motor Harness to Resistor Connector. . . . . . . . .0018-117 Figure 175. EE-C4 Blower Motor Harness to Blower Motor Connector. . . . .0018-117 Figure 176. Blower Motor Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-118 Figure 177. A-C2 Fuse Panel Harness Main Power Relay Connector. . . . . .0018-118 Figure 178. Main Power Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-119 Figure 179. V-C2 Engine Harness Ether Injection Solenoid Connector. . . . .0018-120 Figure 180. Flood Lamp Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-120 Figure 181. Engine Flood Lamp Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-121 Figure 182. Front Wiper Switch Terminal B. . . . . . . . . . . . . . . . . . . . . . . . . .0018-121 Figure 183. Left Wiper Switch Terminal B. . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-122 Figure 184. Right Wiper Switch Terminal B. . . . . . . . . . . . . . . . . . . . . . . . . .0018-122 Figure 185. Rear Wiper Switch Terminal B. . . . . . . . . . . . . . . . . . . . . . . . . . .0018-123 Figure 186. Front Wiper Motor Pigtail Connector. . . . . . . . . . . . . . . . . . . . . .0018-123 Figure 187. Left Wiper Motor Pigtail Connector. . . . . . . . . . . . . . . . . . . . . . .0018-124 Figure 188. Right Wiper Motor Pigtail Connector. . . . . . . . . . . . . . . . . . . . . .0018-124 Figure 189. Rear Wiper Motor Pigtail Connector. . . . . . . . . . . . . . . . . . . . . .0018-125 Figure 190. HH-C2 Front Washer Pump Connector. . . . . . . . . . . . . . . . . . . .0018-125 Figure 191. HH-C3 Left Washer Pump Connector. . . . . . . . . . . . . . . . . . . . .0018-126 Figure 192. HH-C4 Right Washer Pump Connector. . . . . . . . . . . . . . . . . . . .0018-126 Figure 193. HH-C5 Rear Washer Pump Connector. . . . . . . . . . . . . . . . . . . .0018-127 Figure 194. Wiper Washer Headliner Ground Stud. . . . . . . . . . . . . . . . . . . .0018-127 Engine Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0019 Table 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Engine Troubleshooting Procedures .. . . . . . . . . . . . . . . . . . . . . . . .0019-2 Radiator Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0019-4 Cylinder #1 Injector Fault Code. . . . . . . . . . . . . . . . . . . . . . . . . . . .0019-8 Cylinder #2 Injector Fault Code. . . . . . . . . . . . . . . . . . . . . . . . . . .0019-12 Cylinder #3 Injector Fault Code. . . . . . . . . . . . . . . . . . . . . . . . . . .0019-16 Cylinder #4 Injector Fault Code. . . . . . . . . . . . . . . . . . . . . . . . . . .0019-18 Cylinder #5 Injector Fault Code. . . . . . . . . . . . . . . . . . . . . . . . . . .0019-22 Cylinder # 6 Injector Fault Code. . . . . . . . . . . . . . . . . . . . . . . . . . .0019-26 Throttle Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0019-30 Throttle Switch Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0019-31 Fuse Panel Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0019-44 Fuse #21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0019-45 Fuse Panel Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0019-48

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Figure 13. Figure 14. Figure 15. Figure 16. Figure 17.

Fuse #21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-49 Ether Override Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-89 Select Ether Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-89 Selection Box and Yes Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-90 Override in Progress and Active Code Box. . . . . . . . . . . . . . . . . . 0019-91

Powertrain Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0020 Table 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38.

Powertrain Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . 0020-2 Fuse Panel Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-10 ECM Fuse #19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-11 ECM Fuse #19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-15 Fuse Panel Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-33 Fuse #15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-34 Brake Switch Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-36 Fuse Panel Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-40 Fuse #5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-41 Fuse #5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-42 Fuse #5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-45 Calibration Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-48 Calibration Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-49 Calibrating Forward Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-50 Calibrating Neutral Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-51 Calibrating Reverse Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-52 Calibrating Neutral Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-53 Calibration Finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-54 Diagnostic Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-55 Fuse Panel Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-60 Fuse Panel Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-64 Fuse Panel Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-68 Fuse Panel Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-72 Fuse #5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-73 Fuse #5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-76 Fuse #5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-78 Fuse Panel Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-84 Fuse #5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-85 Fuse #5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-87 Downshift Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-109 Upshift button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-112 Upshift Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-114 Calibration Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-141 Test Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-142 Calibration Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-143 Calibration Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-145 Calibration Finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-146 Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . 0020-156 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . 0020-157

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Figure 39. Figure 40. Figure 41. Figure 42. Figure 43. Figure 44. Figure 45. Figure 46. Figure 47. Figure 48. Figure 49. Figure 50. Figure 51. Figure 52. Figure 53. Figure 54. Figure 55. Figure 56. Figure 57. Figure 58. Figure 59. Figure 60. Figure 61. Figure 62. Figure 63. Figure 64. Figure 65. Figure 66. Figure 67. Figure 68. Figure 69. Figure 70. Figure 71. Figure 72. Figure 73. Figure 74. Figure 75. Figure 76. Figure 77. Figure 78. Figure 79. Figure 80. Figure 81.

Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0020-158 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . .0020-159 Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0020-162 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . .0020-163 ECM Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-167 Select Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-168 Calibration Finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-168 Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0020-171 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . .0020-172 Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0020-173 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . .0020-174 Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0020-177 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . .0020-178 ECM Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-182 Select Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-183 Calibration Finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-183 Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0020-185 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . .0020-187 Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0020-188 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . .0020-189 Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0020-193 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . .0020-194 ECM Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-198 Select Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-199 Calibration Finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-199 Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0020-202 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . .0020-203 Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0020-204 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . .0020-205 Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0020-208 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . .0020-209 ECM Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-213 Select Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-214 Calibration Finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-214 Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0020-217 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . .0020-218 Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0020-219 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . .0020-220 Guard and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0020-223 Guard, Plate, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . .0020-224 ECM Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-228 Select Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-229 Calibration Finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020-229

Chassis and Implement Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0021 Table 1.

Chassis and Implement Troubleshooting Procedures. . . . . . . . . . . .0021-2

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Table 2. Figure 1. Figure 2. Figure 3.

Chassis Troubleshooting Procedures .. . . . . . . . . . . . . . . . . . . . . . . 0021-6 Hydraulic Lockout Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-15 Hydraulic Lockout Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-16 Hydraulic Lockout Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-21

Cab Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0022 Table 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24.

Cab Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-2 Fuse #8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-9 Fuse #8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-10 Fuse #16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-21 Fuse #16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-23 Fuse #9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-34 Fuse #9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-35 Fuse #16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-41 Fuse #16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-42 Fuse #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-45 Fuse #13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-104 Fuse #13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-105 Fuse #13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-110 A/C Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-118 Fuse #14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-132 Fuse #14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-133 Ether Override Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-140 Select Ether Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-141 Selection Box and Yes Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-142 Fuse #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-143 Ether Override Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-144 Select Ether Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-145 Selection Box and Yes Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-146 Fuse #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-147 Fuse #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-149

Engine Mechanical Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0023 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Engine Turning Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023-2 Timing Pin Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023-3 Timing Top Center Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023-4 Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023-5 Drive Belt Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023-7 Cylinder Head Flatness Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023-8

Engine Lubrication Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0024 Figure 1. Figure 2. Figure 3. Figure 4.

Engine Oil Pressure Test Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024-2 Right Side Engine Oil Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024-4 Left Side Engine Oil Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024-5 Bottom Engine Oil Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024-6

Fuel System Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0025 Figure 1.

Fuel Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0025-2

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Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32.

Fuel Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-3 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-3 Fuel Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-4 Fuel Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-4 Fuel Tank Drain Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-5 Fuel Prime Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-6 ECM Selection 3176C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-7 Cylinder Cutout Test Select. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-7 Cylinder Cutout Test Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-8 Cylinder Cutout in Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-8 Cylinder Cutout Complete. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-9 ECM Selection 3176C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-10 Injector Solenoid Test Selection. . . . . . . . . . . . . . . . . . . . . . . . . . .0025-11 Injector Solenoid Test Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-12 Injector Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-13 Injector Solenoid Test Complete. . . . . . . . . . . . . . . . . . . . . . . . . . .0025-14 Fuel Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-17 Rotate Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-18 Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-19 Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-20 Transducer Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-21 Transducer Cable to Engine Harness. . . . . . . . . . . . . . . . . . . . . . .0025-22 ECM Selection 3176C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-23 Timing Sensor Calibration Select. . . . . . . . . . . . . . . . . . . . . . . . . .0025-24 Timing Sensor Calibration Start. . . . . . . . . . . . . . . . . . . . . . . . . . .0025-24 Timing Sensor Calibration in Process. . . . . . . . . . . . . . . . . . . . . . .0025-25 Timing Sensor Calibration Complete. . . . . . . . . . . . . . . . . . . . . . .0025-26 Transducer Cable to Engine Harness. . . . . . . . . . . . . . . . . . . . . . .0025-27 Transducer Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-28 Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-29 Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025-30

Cooling System Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0026 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13.

Coolant Tank and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0026-2 Coolant Tank and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0026-3 Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0026-4 Lower Radiator Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0026-5 Lower Radiator Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0026-6 Right Side Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0026-7 Right Side Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0026-9 Left Side Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0026-11 Heater Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0026-12 Coolant Tank and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0026-13 Aftercooler Water Pump Inspection. . . . . . . . . . . . . . . . . . . . . . . .0026-14 Water Pump Vent Hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0026-15 Coolant Tank and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0026-16

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Air Inlet and Exhaust Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0027 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Air Hoses and Charge Air Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . 0027-3 Air Cleaner Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027-4 Air Cleaner Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027-5 Exhaust Manifold, Elbow, and Muffler. . . . . . . . . . . . . . . . . . . . . . . 0027-6 Turbocharger Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027-9 Turbocharger Turbine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027-10 Turbocharger Oil Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027-11

Alternator and Charging System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0028 Figure 1. Figure 2. Figure 3.

Ammeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0028-2 Ammeter Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0028-3 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0028-4

Battery Cables And Alternator Cables Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0029 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15.

Positive and Negative Battery Voltage Test. . . . . . . . . . . . . . . . . . . 0029-3 Starter Ground Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029-4 Battery Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029-5 Engine Ground Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029-6 Alternator Ground Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029-6 Negative Contact of NATO Slave Receptacle. . . . . . . . . . . . . . . . . 0029-7 Arctic Kit Negative Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 0029-8 Positive and Negative Battery Voltage Test. . . . . . . . . . . . . . . . . . . 0029-9 Starter Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029-9 Left Side Positive Battery Cable Junction. . . . . . . . . . . . . . . . . . . . 0029-10 Positive Contact of NATO Slave Receptacle. . . . . . . . . . . . . . . . . 0029-11 Breaker Panel Positive Junction Point. . . . . . . . . . . . . . . . . . . . . . 0029-12 Alternator Positive Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029-13 Arctic Kit Positive Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 0029-14 Arctic Kit Battery Cable Junction Block. . . . . . . . . . . . . . . . . . . . . . 0029-15

Battery Tests and Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0030 Starting System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0031 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Battery Test Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031-2 Starter Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031-4 Measuring Voltage at Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031-5 Harness Connector VC-19 and MA-C8. . . . . . . . . . . . . . . . . . . . . . 0031-6 Harness Connector A-C1 and MA-C3. . . . . . . . . . . . . . . . . . . . . . . 0031-7 Harness Connector A-C1 and Starter Relay. . . . . . . . . . . . . . . . . . . 0031-8

Implement Cylinder Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0032 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032-2 Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032-3 Front Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032-4 Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032-5 Front Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032-6 Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032-7 Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032-8 xvi

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Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18.

Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0032-9 Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0032-10 Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0032-11 Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0032-12 Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0032-13 Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0032-14 Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0032-15 Blade Lift Cylinder Drift Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0032-18 Blade Tilt Cylinder Drift Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0032-19 Ripper Lift Cylinder Drift Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0032-20 Ripper Tilt Cylinder Drift Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0032-21

Implement Pump Discharge Tests and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0033 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9.

Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0033-2 Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0033-3 Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0033-4 Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0033-5 Flow Compensator Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0033-6 Differential Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0033-7 Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0033-8 Pressure Compensator Adjustment. . . . . . . . . . . . . . . . . . . . . . . . .0033-9 Pressure Cutoff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0033-10

Pilot Pressure Tests and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0034 Figure 1.

Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0034-3

Steering Hydraulic Circuit Tests and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0035 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9.

Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0035-2 Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0035-3 Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0035-4 Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0035-5 Flow Compensator Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0035-6 Differential Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0035-7 Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0035-8 Pressure Compensator Adjustment. . . . . . . . . . . . . . . . . . . . . . . . .0035-9 Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0035-11

A/C and Heating Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0036 Table 1.

Pressure Range Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0036-3

Service Brake Pedal Limit Switch Tests and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0037 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Powertrain ECM Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0037-1 Select Status Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0037-2 Select Status Group #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0037-2 Service Brake Pedal Released. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0037-3 Service Brake Pedal Depressed. . . . . . . . . . . . . . . . . . . . . . . . . . . .0037-3 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0037-4

Chapter 3 - PMCS Maintenance Instructions

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Preventive Maintenance Checks and Services (PMCS) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0038 Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0039 Table 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Table 2.

Preventive Maintenance Checks and Services (PMCS). . . . . . . . . . 0039-2 Radiator Grill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039-3 Equalizer Bar Oil Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039-5 Final Drive Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039-7 Drive Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039-9 Engine Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039-11 Recoil Spring Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039-14 Torque Converter Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039-17 Transmission Magnetic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . 0039-19 Final Drive Oil Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039-22 D7R Dozer with Ripper and D7R Dozer with Winch PMCS Mandatory Replacement Parts List. . . . . . . . . . . . . . . . . . . . . . . . . 0039-25

Chapter 4 - Maintenance Instructions Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0040 Hydraulic Oil Cooler Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0041 Figure 1. Figure 2. Figure 3.

Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041-2 O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041-3 Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041-4

Transmission Oil Cooler Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0042 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Hose and Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042-2 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042-3 Transmission Oil Cooler Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042-4 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042-5 Hose and Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042-6

Upper Coolant Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0043 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15.

Upper Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-1 Radiator Guard Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-2 Radiator Core Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-3 Radiator Core Lower Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-4 Upper Coolant Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-5 Sight Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-6 Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-7 Baffles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-8 Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-9 Sight Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-9 Upper Coolant Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-10 Radiator Core Lower Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-11 Radiator Core Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-12 Radiator Guard Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-12 Upper Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043-13

A/C Condenser Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0044

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Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.

Lower A/C Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0044-2 Right Side Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0044-3 Upper A/C Line Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0044-4 Cooler Angle Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0044-4 Left Side Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0044-5 Left Side Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0044-6 Cooler Angle Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0044-7 Upper A/C Line Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0044-7 Upper A/C Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0044-8 Lower A/C Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0044-9

Muffler Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0045 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.

Hood Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0045-1 Tailpipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0045-2 A/C Compressor Clutch Wiring Harness. . . . . . . . . . . . . . . . . . . . . .0045-3 Muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0045-4 Muffler Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0045-5 Muffler Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0045-6 Muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0045-7 A/C Compressor Clutch Wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0045-8 Tailpipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0045-9 Hood Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0045-9

Engine Mounts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0046 Figure 1. Figure 2. Figure 3.

Engine Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0046-1 Engine Mount Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0046-2 Engine Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0046-3

Engine Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0047 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Brackets and Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0047-1 Engine Support to Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0047-2 Engine Support to Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0047-3 Engine Support Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0047-4 Engine Support to Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0047-5 Engine Support to Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0047-6 Brackets and Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0047-7

Trunnion Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0048 Figure 1. Figure 2. Figure 3.

Trunnion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0048-1 Trunnion Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0048-2 Trunnion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0048-2

Water Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0049 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Receiver/Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0049-1 Mounting Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0049-2 Cooling Pipe Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0049-3 Lower Cooling Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0049-4 Upper Cooling Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0049-5 Upper Cooling Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0049-6 xix

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Figure 7. Figure 8. Figure 9. Figure 10.

Lower Cooling Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049-7 Cooling Pipe Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049-7 Mounting Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049-8 Receiver/Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049-9

Cooling Fan Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0050 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18.

Lower Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-2 Top of Fan Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-3 Upper Left Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-4 Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-4 Upper Right Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-5 Fan Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-6 Fan Spider. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-7 Fan Spider Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-8 Fan Spider Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-9 Fan Spider Adapter Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-9 Fan Spider Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-10 Fan Spider. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-11 Fan Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-12 Upper Right Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-13 Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-14 Upper Left Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-14 Top of Fan Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-15 Lower Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050-16

Radiator Cooling Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0051 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20.

Aftercooler Pump Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051-2 Hose at Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051-3 Water Temperature Regulator Hose at Radiator. . . . . . . . . . . . . . . 0051-4 Water Temperature Regulator Pipe. . . . . . . . . . . . . . . . . . . . . . . . . 0051-5 Hose to Water Temperature Regulator. . . . . . . . . . . . . . . . . . . . . . . 0051-6 Adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051-7 Water Pump Inlet Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051-8 Water Pump Inlet Hose at Radiator. . . . . . . . . . . . . . . . . . . . . . . . . 0051-9 Water Pump Inlet Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051-10 Vent Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051-11 Vent Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051-12 Water Pump Input Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051-13 Water Pump Inlet Hose at Radiator. . . . . . . . . . . . . . . . . . . . . . . . 0051-14 Water Pump Inlet Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051-15 Adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051-16 Hose to Water Temperature Regulator. . . . . . . . . . . . . . . . . . . . . . 0051-17 Water Temperature Regulator Pipe. . . . . . . . . . . . . . . . . . . . . . . . 0051-18 Water Temperature Regulator Hose at Radiator. . . . . . . . . . . . . . 0051-19 Hose at Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051-20 Aftercooler Pump Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051-21

Radiator Drain Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0052 xx

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Radiator Drain Hose and Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . .0052-1 Transmission Cooler Drain Hose and Fitting. . . . . . . . . . . . . . . . . .0052-2 Drain Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0052-3 Drain Line Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0052-4 Drain Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0052-5 Transmission Cooler Drain Hose and Fitting. . . . . . . . . . . . . . . . . .0052-6 Radiator Drain Hose and Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . .0052-6

NATO Slave and Cables Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0053 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9.

NATO Slave Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0053-2 NATO Slave Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0053-3 NATO Slave and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0053-4 NATO Slave Cables and Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . .0053-5 Starter Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0053-6 NATO Slave Cables and Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . .0053-7 NATO Slave and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0053-8 NATO Slave Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0053-9 NATO Slave Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0053-10

Air Inlet Temperature Sensor Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0054 Figure 1. Figure 2.

Fuel Temperature Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . .0054-1 Fuel Temperature Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . .0054-2

Engine Main Wiring Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0055 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22.

Radiator Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-2 Starter Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-2 Starter Solenoid Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-3 ECM Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-4 Underhood Work Light Connection. . . . . . . . . . . . . . . . . . . . . . . . . .0055-5 Platform Harness Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-6 Ether Aid Solenoid Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-7 A/C Compressor Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-8 Alternator Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-9 Transmission Temperature Connections. . . . . . . . . . . . . . . . . . . .0055-10 Torque Converter Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-11 Torque Converter Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-12 Transmission Temperature Connections. . . . . . . . . . . . . . . . . . . .0055-13 Alternator Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-14 A/C Compressor Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-15 Ether Aid Solenoid Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-16 Platform Harness Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-17 Underhood Work Light Connection. . . . . . . . . . . . . . . . . . . . . . . . .0055-18 ECM Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-19 Starter Solenoid Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-20 Starter Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-21 Radiator Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0055-21

Crank Without Injection Wiring Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0056

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Fuel Temperature Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . 0056-1 Fuel Temperature Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . 0056-2

Volume II How To Use This Technical Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxii Engine Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0057 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40.

Torque Converter Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-2 Torque Converter Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-3 Torque Converter Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-4 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-5 Pump Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-6 Pump Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-7 Fuel Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-8 A/C Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-9 Starter Motor Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . 0057-10 Starter Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-11 A/C Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-13 Platform Harness Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-14 Hose Bundle Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-15 Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-16 Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-17 Engine Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-18 Front Engine Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-19 Rear Engine Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-20 Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-21 Secondary Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-22 Starter Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-23 ECM Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-24 Receiver/Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-25 Harness and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-26 Oil Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-27 Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-28 Engine ECM and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . 0057-29 Engine ECM, Ground Strap, and Retaining Hardware. . . . . . . . . . 0057-30 Engine ECM, Spacers, and Isolators. . . . . . . . . . . . . . . . . . . . . . . 0057-31 Oil Dipstick Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-32 Engine Stand Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-33 Engine Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-34 Engine Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-35 Engine Stand Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-36 Oil Dipstick Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-37 Engine ECM, Spacers, and Isolators. . . . . . . . . . . . . . . . . . . . . . . 0057-38 Engine ECM, Ground Strap, and Retaining Hardware. . . . . . . . . . 0057-39 Engine ECM and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . 0057-40 Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-41 Oil Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-42

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Figure 41. Figure 42. Figure 43. Figure 44. Figure 45. Figure 46. Figure 47. Figure 48. Figure 49. Figure 50. Figure 51. Figure 52. Figure 53. Figure 54. Figure 55. Figure 56. Figure 57. Figure 58. Figure 59. Figure 60. Figure 61. Figure 62. Figure 63. Figure 64. Figure 65.

Harness and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-43 Receiver/Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-43 ECM Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-44 Starter Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-45 Secondary Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-46 Engine Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-47 Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-48 Rear Engine Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-49 Front Engine Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-50 Engine Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-51 Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-51 Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-52 Hose Bundle Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-53 Platform Harness Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-54 A/C Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-55 Starter Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-56 Starter Motor Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . .0057-57 A/C Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-58 Fuel Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-59 Pump Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-59 Pump Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-60 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-61 Torque Converter Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-62 Torque Converter Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-63 Torque Converter Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-64

Engine Lift Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0058 Figure 1. Figure 2. Figure 3.

Rear Engine Lifting Bracket Attachments. . . . . . . . . . . . . . . . . . . . .0058-2 Rear Engine Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0058-3 Rear Engine Lifting Bracket Attachments. . . . . . . . . . . . . . . . . . . . .0058-4

Engine Replacement Transfer of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0059 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15.

Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-2 Line O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-3 Torque Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-5 Alternator Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-6 A/C Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-7 Rear Engine Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-8 Water Pump Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-9 Valve and Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-10 Oil Cooler Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-11 Oil Cooler Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-12 Oil Cooler Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-13 Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-14 Upper Compressor Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-15 Fuel Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-16 Filter Drain Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-17 xxiii

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Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41. Figure 42. Figure 43. Figure 44. Figure 45. Figure 46. Figure 47. Figure 48. Figure 49. Figure 50. Figure 51. Figure 52. Figure 53. Figure 54. Figure 55. Figure 56. Figure 57. Figure 58. Figure 59. Figure 60.

Filter and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-18 Heater Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-19 Muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-20 Muffler Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-21 Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-22 Pipe to Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-23 Pipe to Air Cleaner Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-24 Alternator Ground Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-25 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-26 Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-27 Air Cleaner Housing Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-28 NATO Slave and Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-29 Engine Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-30 Coolant Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-31 Turbo Heat Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-32 Transmission Cooler Drain Hose. . . . . . . . . . . . . . . . . . . . . . . . . . 0059-33 Drain Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-34 Transmission Cooler Drain Hose. . . . . . . . . . . . . . . . . . . . . . . . . . 0059-35 Turbo Heat Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-36 Coolant Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-36 Engine Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-37 NATO Slave and Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-37 Air Cleaner Housing Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-38 Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-39 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-40 Alternator Ground Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-41 Pipe to Air Cleaner Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-42 Pipe to Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-43 Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-44 Muffler Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-45 Muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-46 Heater Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-47 Filter and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-48 Filter Drain Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-49 Fuel Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-50 Upper Compressor Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-51 Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-52 Oil Cooler Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-53 Oil Cooler Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-54 Oil Cooler Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-55 Valve and Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-56 Water Pump Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-57 Rear Engine Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-58 A/C Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-59 Alternator Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-60

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Figure 61. Torque Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-61 Figure 62. Line O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-62 Figure 63. Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-63 Ether Bottle, Valve, Bracket, and Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0060 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18.

Ether Bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-2 Ether Bottle Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-3 Ether Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-4 Ether Bottle and Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-5 Ether Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-6 Ether Bottle and Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-7 Ether Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-8 Ether Valve Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-9 Ether Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-10 Ether Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-11 Ether Valve Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-12 Ether Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-13 Ether Bottle and Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-14 Ether Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-15 Ether Bottle and Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-16 Ether Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-17 Ether Bottle Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-18 Ether Bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-19

Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0061 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0061-2 Ground Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0061-2 Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0061-3 Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0061-4 Ground Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0061-5 Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0061-5

Turbocharger Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0062 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13.

Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-1 Guard Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-2 Turbocharger Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-2 Line Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-3 Oil Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-4 Oil Drain Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-5 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-6 Oil Drain Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-7 Oil Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-8 Line Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-9 Turbocharger Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-10 Guard Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-10 Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-11

Air Inlet Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0063

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Figure 1. Figure 2.

Air Inlet Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0063-2 Air Inlet Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0063-3

Coolant Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0064 Figure 1.

Coolant Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0064-2

Fuel Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0065 Figure 1. Figure 2. Figure 3. Figure 4.

Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065-2 Fuel Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065-3 Fuel Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065-4 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065-4

Turbocharger Inlet Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0066 Figure 1.

Turbocharger Inlet Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . 0066-2

Exhaust Manifold Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0067 Figure 1.

Exhaust Manifold and Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0067-2

Aftercooler Housing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0068 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17.

Rear Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-1 Rear Water Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-2 Rear Water Tube Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-2 Front Water Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-3 Front Water Tube Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-3 Aftercooler Housing Upper Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-4 Aftercooler Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-4 Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-5 Lower Aftercooler Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-6 Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-7 Aftercooler Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-8 Aftercooler Housing Upper Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-8 Front Water Tube Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-9 Front Water Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-9 Rear Water Tube Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-10 Rear Water Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-10 Rear Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-11

Fuel Injector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0069 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Fuel Injection Manifold. Fuel Injection Manifold. Fuel Injection Manifold. Fuel Injection Manifold. Fuel Injection Manifold. Fuel Injection Manifold. Fuel Injection Manifold.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069-7

Fuel Manifold Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0070 Figure 1. Figure 2. Figure 3.

Fuel Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0070-2 Fuel Manifold O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0070-3 Fuel Manifold O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0070-4

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Fuel Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0070-5

Primary Fuel Filter, Base and Bracket Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0071 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15.

Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-2 Filter Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-3 Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-4 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-5 Filter Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-6 Filter Drain Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-7 Filter and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-8 Prime Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-9 Prime Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-10 Filter and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-11 Filter Drain Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-12 Filter Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-13 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-13 Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-14 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-15

Secondary Fuel Filter, Base and Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0072 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-2 Filter Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-3 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-4 Engine Enclosure Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-5 Filter Drain Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-6 Filter and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-7 Filter and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-9 Filter Drain Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-10 Engine Enclosure Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-11 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-11 Filter Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-12 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-13

Fuel Transfer Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0073 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0073-2 Fuel Transfer Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0073-3 Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0073-4 Fuel Transfer Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0073-5 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0073-6

Temperature Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0074 Figure 1. Figure 2. Figure 3.

Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0074-1 Temperature Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0074-2 Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0074-3

Cooling Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0075 Figure 1. Figure 2. Figure 3.

Coolant Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0075-2 Coolant Temperature Sensor O-ring. . . . . . . . . . . . . . . . . . . . . . . . .0075-3 Cooling Manifold Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0075-3 xxvii

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Figure 4. Figure 5. Figure 6.

Cooling Manifold Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0075-4 Coolant Temperature Sensor O-ring. . . . . . . . . . . . . . . . . . . . . . . . 0075-4 Coolant Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0075-5

Water Pump Elbow Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0076 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Hoses to Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076-1 Water Pump Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076-2 Fittings to Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076-3 Fittings to Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076-4 Water Pump Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076-5 Hoses to Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076-6

Water Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0077 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Oil Cooler Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077-2 Water Pump Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077-3 Bypass Tube Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077-4 Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077-5 Bypass Tube Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077-6 Water Pump Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077-7 Oil Cooler Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077-8

Aftercooler Water Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0078 Figure 1.

Aftercooler Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0078-2

Front Crankshaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0079 Figure 1. Figure 2. Figure 3. Figure 4.

Crankshaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079-1 Seal O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079-2 Seal O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079-2 Crankshaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079-3

Crankshaft Damper, Pulley, and Adapter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0080 Figure 1. Figure 2. Figure 3.

Front Housing Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080-2 Front Housing Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080-3 Front Housing Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080-4

Front Housing Cover Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0081 Figure 1.

Front Housing Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0081-2

Oil Filter Engine Base Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0082 Figure 1. Figure 2. Figure 3. Figure 4.

Oil Filter Engine Base Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082-1 Adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082-2 Adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082-3 Oil Filter Engine Base Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082-4

Engine Oil Filter, Base and Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0083 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-2 Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-3 Guard Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-3 Filter Base Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-4 Filter Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-5 Filter Base Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-6 xxviii

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Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13.

Filter Base Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0083-7 Filter Base Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0083-8 Filter Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0083-9 Filter Base Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0083-10 Guard Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0083-11 Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0083-11 Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0083-12

Engine Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0084 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13.

Hose to Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-2 Oil Cooler Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-3 Hose Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-4 Oil Cooler Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-4 Oil Cooler Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-5 Cooler Core Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-6 Elbow O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-6 Cooler Core Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-7 Oil Cooler Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-8 Oil Cooler Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-9 Hose Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-9 Oil Cooler Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-10 Hose to Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-11

Rear Gear Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0085 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18.

Cover and Retaining Hardware on Left Side of Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-1 O-ring on Left Side of Flywheel Housing. . . . . . . . . . . . . . . . . . . . .0085-2 Cover and Retaining Hardware on Right Side of Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-2 O-ring on Right Side of Flywheel Housing. . . . . . . . . . . . . . . . . . . .0085-3 Right Pump Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-4 Left Pump Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-5 Crankshaft Drive Gear and Idler Gears. . . . . . . . . . . . . . . . . . . . . .0085-6 Idler Gear and Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-7 Idler Gear and Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-8 Crankshaft Drive Gear and Idler Gears. . . . . . . . . . . . . . . . . . . . . .0085-9 Bearing Installation on Flywheel Housing. . . . . . . . . . . . . . . . . . . .0085-10 Bearing Installation on Hydraulic Pump Adapter. . . . . . . . . . . . . .0085-11 Left Pump Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-12 Right Pump Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-13 O-ring on Right Side of Flywheel Housing. . . . . . . . . . . . . . . . . . .0085-14 Cover and Retaining Hardware on Right Side of Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-14 O-ring on Left Side of Flywheel Housing. . . . . . . . . . . . . . . . . . . .0085-15 Cover and Retaining Hardware on Left Side of Flywheel Housing. 0085-15

Oil Filler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0086 Figure 1.

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Figure 2. Figure 3. Figure 4.

Oil Fill Tube O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0086-3 Oil Tube O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0086-4 Oil Fill Tube and Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0086-5

Dipstick Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0087 Figure 1. Figure 2. Figure 3.

Oil Level Dipstick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0087-2 Oil Level Dipstick Tube and O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . 0087-3 Oil Level Dipstick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0087-4

Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0088 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9.

Oil Pump Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-1 Oil Pump and Elbow - On Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-2 Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-3 Oil Pump and Elbow - Off Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-3 Oil Pump Elbow and Couplings. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-4 Oil Pump and Elbow - Off Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-5 Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-6 Oil Pump and Elbow - On Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-7 Oil Pump Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-8

Oil Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0089 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Hose and Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089-2 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089-3 Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089-4 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089-6 Hose and Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089-7

Atmospheric Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0090 Figure 1. Figure 2.

Atmospheric Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0090-1 Atmospheric Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0090-2

Engine Oil Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0091 Figure 1. Figure 2. Figure 3.

Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091-1 Engine Oil Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091-2 Access Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091-3

Air Inlet Manifold Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0092 Figure 1.

Air Inlet Manifold Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . 0092-2

Camshaft Timing Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0093 Figure 1. Figure 2. Figure 3.

Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093-1 Camshaft Timing Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093-2 Access Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093-3

Engine Crankshaft Position Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0094 Figure 1.

Engine Crankshaft Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . 0094-2

Fan Hub Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0095 Figure 1. Figure 2. Figure 3. Figure 4.

Hub Lower Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095-1 Hub Upper Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095-2 Hub Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095-3 Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095-4 xxx

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Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13.

Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0095-5 Fan Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0095-6 Pulley and Shaft Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0095-7 Fan Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0095-8 Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0095-9 Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0095-10 Hub Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0095-11 Hub Upper Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0095-12 Hub Lower Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0095-13

V-Belt (A/C Compressor) Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0096 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

A/C Compressor V-Belt Inspection. . . . . . . . . . . . . . . . . . . . . . . . . .0096-2 A/C Compressor Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . .0096-3 A/C Compressor V-Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0096-4 A/C Compressor V-Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0096-5 A/C Compressor Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . .0096-6

A/C Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0097 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Compressor Adjusting Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-2 Compressor Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-3 A/C Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-4 A/C Compressor Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-5 Compressor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-6 Upper Compressor Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-7 Compressor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-8 A/C Compressor Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-9 A/C Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-10 Compressor Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-11 Compressor Adjusting Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-12 Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-13

V-Belt Set (Alternator) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0098 Figure 1. Figure 2. Figure 3. Figure 4.

Alternator V-Belt Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0098-2 Alternator Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0098-3 Alternator V-Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0098-4 Alternator Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0098-5

Alternator and Brackets Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0099 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.

Alternator, Wiring, and Retaining Hardware. . . . . . . . . . . . . . . . . . .0099-2 Alternator and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0099-3 Alternator, Brackets, and Retaining Hardware. . . . . . . . . . . . . . . . .0099-4 Alternator, Bracket, and Retaining Hardware. . . . . . . . . . . . . . . . . .0099-5 Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0099-5 Alternator and Bracket Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . .0099-6 Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0099-7 Alternator, Bracket, and Retaining Hardware. . . . . . . . . . . . . . . . . .0099-7 Alternator, Brackets, and Retaining Hardware. . . . . . . . . . . . . . . . .0099-8 Alternator and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0099-9

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Figure 11. Alternator, Wiring, and Retaining Hardware. . . . . . . . . . . . . . . . . . 0099-10 Flywheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0100 Figure 1. Figure 2. Figure 3.

Flywheel and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . 0100-2 Flywheel, Guide Studs, and Retaining Hardware. . . . . . . . . . . . . . . 0100-3 Flywheel, Guide Studs, and Retaining Hardware. . . . . . . . . . . . . . . 0100-5

Engine ECM Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0101 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Engine ECM and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . 0101-2 Engine ECM, Ground Strap, and Retaining Hardware. . . . . . . . . . . 0101-3 Engine ECM, Spacers, and Isolators. . . . . . . . . . . . . . . . . . . . . . . . 0101-4 Engine ECM, Ground Strap, and Retaining Hardware. . . . . . . . . . . 0101-5 Engine ECM and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . 0101-6

Rear Crankshaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0102 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Crankshaft Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102-1 Rear Crankshaft Seal, O-ring Seal, and Retaining Hardware. . . . . 0102-2 Rear Crankshaft Seal, O-ring Seal, Plastic Sleeve, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102-3 Bolt Tightening Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102-4 Crankshaft Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102-4

Flywheel Housing Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0103 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Bracket and Retaining Hardware on Right Side of Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103-2 Flywheel Housing Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103-3 Flywheel Housing and Retaining Hardware. . . . . . . . . . . . . . . . . . . 0103-5 Flywheel Housing and Retaining Hardware. . . . . . . . . . . . . . . . . . . 0103-7 Flywheel Housing Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103-8 Bracket and Retaining Hardware on Right Side of Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103-8

Flange (Flywheel Housing) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0104 Figure 1. Figure 2. Figure 3.

Flange and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0104-1 Flange Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0104-2 Flange and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0104-3

Harness Assembly (ECM) Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0105 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Crankshaft Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-2 Camshaft Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-3 Coolant Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-4 Fuel Temperature Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-5 Fuel Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-6 Oil Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-7 ECM Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-8 ECM Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-9 ECM Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-10 Oil Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-11 Fuel Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-11 Fuel Temperature Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-12 xxxii

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Figure 13. Coolant Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0105-13 Figure 14. Camshaft Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0105-14 Figure 15. Crankshaft Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0105-15 Valve Mechanism Cover, Base and Injector Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0106 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20.

Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-2 Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-3 Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-4 Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-5 Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-5 Atmospheric Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-6 Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-7 Valve Cover Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-8 Injector Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-9 Injector Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-10 Valve Cover Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-11 Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-12 Atmospheric Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-13 Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-14 Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-14 Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-15 Valve Cover Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-16 Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-17 Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-18 Valve Cover Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-19

Rocker Arm Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0107 Figure 1. Figure 2. Figure 3. Figure 4.

Rocker Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0107-2 Valve Bridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0107-2 Rocker Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0107-5 Valve Lash Adjustment No.1 TDC. . . . . . . . . . . . . . . . . . . . . . . . . .0107-7

Cylinder Head Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0108 Figure 1. Figure 2. Figure 3. Figure 4.

Cylinder Head Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0108-2 Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0108-3 Cylinder Head Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0108-4 Cylinder Head Bolts Torque Sequence. . . . . . . . . . . . . . . . . . . . . . .0108-5

Radiator Core Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0109 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9.

Radiator Guard Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0109-3 Center Radiator Core Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0109-4 Center Radiator Core Lower Mount. . . . . . . . . . . . . . . . . . . . . . . . .0109-4 Center Radiator Core Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0109-5 Center Radiator Core Bracket and Isolator. . . . . . . . . . . . . . . . . . . .0109-5 Outer Radiator Core Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0109-6 Outer Radiator Core Lower Mount. . . . . . . . . . . . . . . . . . . . . . . . . .0109-7 Outer Radiator Core Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0109-7 Outer Radiator Core Bracket and Isolator. . . . . . . . . . . . . . . . . . . . .0109-8

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Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17.

Outer Radiator Core Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109-9 Outer Radiator Core Lower Mount. . . . . . . . . . . . . . . . . . . . . . . . . . 0109-9 Outer Radiator Core Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109-10 Outer Radiator Core Bracket and Isolator. . . . . . . . . . . . . . . . . . . 0109-11 Radiator Core Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109-12 Radiator Core Lower Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109-12 Radiator Core Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109-13 Radiator Guard Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109-14

Lower Radiator Tank Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0110 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.

Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-2 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-3 Lower Radiator Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-4 Elbows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-5 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-5 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-6 Elbows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-7 Lower Radiator Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-8 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-9 Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-10

Air Cleaner Assembly Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0111 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15.

Air Cleaner Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-2 Air Filters Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-3 Air Cleaner Outlet Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-4 Air Cleaner Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-5 Air Cleaner Prescreener. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-6 Air Cleaner Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-6 Air Cleaner Housing and Elements. . . . . . . . . . . . . . . . . . . . . . . . . . 0111-7 Air Cleaner Housing Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-8 Air Cleaner Housing and Elements. . . . . . . . . . . . . . . . . . . . . . . . . . 0111-9 Air Cleaner Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-10 Air Cleaner Prescreener. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-10 Air Cleaner Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-11 Air Cleaner Outlet Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-12 Air Filters Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-12 Air Cleaner Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-13

Implement Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0112 Figure 1. Figure 2.

Implement Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112-3 Implement Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112-5

Cooling System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0113 Figure 1. Figure 2. Figure 3.

Radiator Filler Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113-2 Coolant Drain Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113-3 Sight Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113-5

Engine Oil Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0114 Figure 1.

Oil Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0114-2 xxxiv

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Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0114-3 Oil Filler and Dipstick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0114-4

Adapter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0115 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0115-1 Forcing Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0115-2 O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0115-2 O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0115-3 Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0115-3

Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0116 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Axle Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-1 Thrust Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-2 Outer Axle Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-3 Inner Axle Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-3 Inner Axle Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-4 Outer Axle Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-5 Thrust Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-5 Axle Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-6

Main Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0117 Figure 1. Figure 2. Figure 3.

Main Drive Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0117-1 U-Joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0117-2 Main Drive Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0117-3

Powertrain Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0118 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Flange Type Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0118-3 Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0118-5 Threaded Fitting Type Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . .0118-7 Threaded Fitting Type Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . .0118-9 Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0118-11 Flange Type Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0118-12

Powertrain Manifold Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0119 Figure 1. Figure 2. Figure 3. Figure 4.

Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0119-2 Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0119-3 Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0119-4 Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0119-5

Coupling Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0120 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-1 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-2 Guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-2 Couplings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-3 Couplings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-4 Guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-4 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-5 Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-5

Transmission Mounting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0121

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Transmission Mounting Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0121-2

Torque Converter Output Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0122 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122-2 Converter Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122-3 Sensor Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122-3 Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122-4 Sensor Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122-5 Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122-6

Torque Converter Relief Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0123 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Pressure Check Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123-1 Torque Converter Output Relief Valve. . . . . . . . . . . . . . . . . . . . . . . 0123-2 Pressure Check Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123-3 Test Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123-4 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123-5 Test Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123-6

Torque Converter Relief Valve Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0124 Figure 1.

Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0124-2

Equalizer Bar Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0125 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125-1 Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125-2 Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125-3 Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125-4 Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125-5 Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125-6

Accumulator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0126 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Accumulator Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126-1 Threaded Fitting Type Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . 0126-2 Accumulator Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126-3 Accumulator Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126-4 Testing with Nitrogen Charging Kit. . . . . . . . . . . . . . . . . . . . . . . . . . 0126-5 Charging Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126-7

Track Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0127 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Adjuster Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-2 Adjuster Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-3 Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-3 Track Blocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-4 Track Separation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-5 Track Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-6 Track Blocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-7 Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-8 Track Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-8 Track Tension Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-9 Adjuster Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-9 Track Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-10 xxxvi

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Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19.

Loose Track. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0127-10 Adjuster Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0127-11 Adjuster Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0127-11 Track Tension Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0127-12 Adjuster Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0127-12 Track Tension Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0127-13 Adjuster Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0127-13

Track Shoe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0128 Figure 1.

Track Shoe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0128-2

Track Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0129 Figure 1.

Track Shoe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0129-2

Trunnion Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0130 Figure 1.

Trunnion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0130-2

Strip Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0131 Figure 1. Figure 2. Figure 3.

Rear Strip Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0131-1 Front Strip Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0131-2 Rear Strip Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0131-3

Double Flange Track Roller Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0132 Figure 1. Figure 2. Figure 3. Figure 4.

Front and Rear Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0132-2 Track Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0132-3 Track Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0132-4 Front and Rear Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0132-5

Single Flange Track Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0133 Figure 1. Figure 2. Figure 3. Figure 4.

Front and Rear Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0133-2 Track Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0133-3 Track Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0133-4 Front and Rear Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0133-5

Track Adjuster and Recoil Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0134 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13.

Track Frame Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-2 Forcing Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-3 Front Idler and Adjuster Separation. . . . . . . . . . . . . . . . . . . . . . . . .0134-4 Front Idler and Adjuster Removal. . . . . . . . . . . . . . . . . . . . . . . . . . .0134-5 Track Frame Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-6 Track Adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-7 Track Adjuster Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-8 Track Adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-9 Track Frame Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-10 Seals Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-11 Front Idler and Adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-12 Guide Sealing Compound. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-13 Track Frame Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-13

Idler Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0135 Figure 1.

Idler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0135-2 xxxvii

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Final Drive Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0136 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Cap and Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-2 Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-3 Final Drive Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-4 Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-5 Final Drive Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-5 Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-6 Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-7 Final Drive Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-8 Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-9 Final Drive Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-10 Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-11 Cap and Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-12

Sprocket Segment Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0137 Figure 1.

Sprocket Segment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0137-2

Brake and Planetary Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0138 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14.

Cap and Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-2 Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-3 Final Drive Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-4 Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-5 Final Drive Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-5 Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-6 Brake Planetary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-7 Brake Planetary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-8 Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-9 Final Drive Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-10 Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-11 Final Drive Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-12 Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-13 Cap and Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-14

Brake and Differential Drive Assembly Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0139 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Sliding Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-2 Cap and Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-3 Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-4 Final Drive Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-5 Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-6 Brake Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-7 Housing O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-8 Brake Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-9 Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-10 Final Drive Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-11 Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-12 Cap and Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-13

Hydrostatic Drive Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0140

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Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0140-2 Hydrostatic Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0140-3 Forcing Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0140-4 Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0140-5 Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0140-6 Hydrostatic Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0140-7 Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0140-8

Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0141 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16.

Bell and Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-2 Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-3 Headliner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-3 Cab Lifting Device Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-4 Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-5 O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-5 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-6 Pump O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-7 Pump O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-8 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-9 O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-10 Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-10 Cab Lifting Device Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-11 Headliner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-11 Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-12 Bell and Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-13

Transmission Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0142 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20.

Sliding Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-2 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-3 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-4 Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-5 Transmission Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-6 Transmission Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-7 Transmission Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-8 Transmission Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-9 Transmission Stand Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-10 Transmission Roller and Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . .0142-11 Case O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-12 Case O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-13 Transmission Roller and Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . .0142-13 Transmission Stand Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-14 Transmission Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-15 Transmission Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-16 Transmission Adapter Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-17 Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-18 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-19 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-20 xxxix

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Transmission Intermediate Speed Sensor One Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0143 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143-1 Transmission Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143-2 Transmission Solenoid O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143-3 Transmission Solenoid O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143-4 Transmission Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143-4 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143-5

Transmission Intermediate Speed Sensor Two Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0144 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144-1 Transmission Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144-2 Transmission Solenoid O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144-3 Transmission Solenoid O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144-4 Transmission Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144-5 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144-6

Transmission Clutch Solenoid Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0145 Figure 1. Figure 2. Figure 3.

Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145-1 Transmission Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145-2 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145-3

Transmission Temperature Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0146 Figure 1.

Transmission Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . 0146-2

Control Valve (Steering and Brake) Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0147 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Control Valve Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147-2 Control Valve Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147-3 Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147-3 Secondary Brake Parking Valve and First Coil. . . . . . . . . . . . . . . . . 0147-4 Secondary Brake Parking Valve and First Coil. . . . . . . . . . . . . . . . . 0147-5 Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147-6 Control Valve Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147-6 Control Valve Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147-7

Torque Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0148 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14.

Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-2 Transmission Cooler Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-3 Tube to Torque Converter Housing. . . . . . . . . . . . . . . . . . . . . . . . . 0148-4 Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-4 Tube Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-5 Hose Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-6 Outlet Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-7 Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-8 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-9 Headliner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-9 Cab Tool Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-10 Torque Converter Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-11 Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-11 Torque Converter Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-12 xl

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Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36.

Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-12 Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-13 Torque Converter and Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-14 Cab Tool Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-15 Torque Converter and Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-16 Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-17 Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-18 Sensor Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-18 Torque Converter Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-19 Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-19 Torque Converter Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-20 Cab Tool Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-21 Headliner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-21 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-22 Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-23 Outlet Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-23 Hose Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-24 Tube Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-25 Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-26 Tube to Torque Converter Housing. . . . . . . . . . . . . . . . . . . . . . . .0148-26 Transmission Cooler Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-27 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-27

Final Drive Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0149 Figure 1.

Final Drive Oil Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0149-2

Recoil Spring Compartment Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0150 Figure 1.

Recoil Spring Compartment Oil Change. . . . . . . . . . . . . . . . . . . . . .0150-2

Transmission System Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0151 Figure 1. Figure 2. Figure 3.

Transmission Drain Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0151-2 Transmission Scavenge Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . .0151-3 Transmission System Oil Level Check. . . . . . . . . . . . . . . . . . . . . . .0151-4

Transmission System Oil Filter Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0152 Figure 1. Figure 2.

Transmission Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0152-2 Transmission System Oil Level Check. . . . . . . . . . . . . . . . . . . . . . .0152-3

Transmission System Oil Filter Base Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0153 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Transmission Filter Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0153-2 Transmission Filter Base Isolators. . . . . . . . . . . . . . . . . . . . . . . . . .0153-3 Transmission Filter Base Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . .0153-3 Transmission Filter Base Bypass Switch. . . . . . . . . . . . . . . . . . . . .0153-4 Transmission Filter Base Bypass Switch. . . . . . . . . . . . . . . . . . . . .0153-5 Transmission Filter Base Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . .0153-5 Transmission Filter Base Isolators. . . . . . . . . . . . . . . . . . . . . . . . . .0153-6 Transmission Filter Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0153-7

Flood Lamp Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0154 Figure 1.

Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0154-1 xli

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Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11.

Front Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-2 Front Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-3 Front Flood Lamp Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-4 Rear Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-5 Rear Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-6 Rear Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-7 Front Flood Lamp Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-8 Front Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-9 Front Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-10 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-11

Battery Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0155 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9.

Arctic Kit Battery Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-2 Arctic Kit Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-3 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-4 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-5 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-6 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-8 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-9 Arctic Kit Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-10 Arctic Kit Battery Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-11

Battery Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0156 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17.

Battery Box Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-2 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-3 Battery Disconnect Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-4 Inside Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-5 Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-5 Battery Disconnect Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-6 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-6 Pivot Shaft Tank Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-7 Information Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-8 Pivot Shaft Tank Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-9 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-10 Battery Disconnect Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-10 Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-11 Inside Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-11 Battery Disconnect Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-12 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-13 Battery Door Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-14

Fuel Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0157 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Fuel Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157-2 Fuel Return Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157-3 Tank Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157-4 Tank Return Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157-5 Fuel Line Retaining Straps and Spacers. . . . . . . . . . . . . . . . . . . . . 0157-6 Fuel Line Retaining Straps and Spacers. . . . . . . . . . . . . . . . . . . . . 0157-7 xlii

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Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16.

Tank Return Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0157-8 Fuel Drain Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0157-9 Fuel Drain Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0157-10 Tank Return Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0157-11 Fuel Line Retaining Straps and Spacers. . . . . . . . . . . . . . . . . . . .0157-12 Fuel Line Retaining Straps and Spacers. . . . . . . . . . . . . . . . . . . .0157-13 Tank Return Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0157-14 Tank Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0157-15 Fuel Return Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0157-16 Fuel Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0157-17

Pivot Shaft Lubrication Line Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0158 Figure 1. Figure 2. Figure 3. Figure 4.

Pivot Shaft Oil Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0158-2 Pivot Shaft Lubrication Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0158-3 Pivot Shaft Lubrication Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0158-4 Pivot Shaft Lubrication Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0158-6

Battery Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0159 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13.

Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-2 Battery Positive Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-3 Battery Positive Cable to Junction Box. . . . . . . . . . . . . . . . . . . . . . .0159-4 Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-5 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-6 Fuse Panel Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-7 Fuse Panel Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-8 Fuse Panel Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-9 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-10 Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-11 Battery Positive Cable to Junction Box. . . . . . . . . . . . . . . . . . . . . .0159-12 Battery Positive Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-13 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-14

Battery Ground Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0160 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Arctic Kit Battery Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-2 Arctic Kit Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-3 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-4 Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-5 Switch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-6 Ground Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-7 Ground Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-8 Switch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-9 Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-10 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-11 Arctic Kit Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-12 Arctic Kit Battery Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-13

Battery Crossover Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0161 Figure 1.

Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0161-2

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Figure 2. Figure 3. Figure 4.

Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0161-3 Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0161-4 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0161-5

Battery Disconnect Switch, Receptacle and Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0162 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Battery Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0162-2 Receptacle and Battery Disconnect Switch Connections. . . . . . . . . 0162-3 Receptacle Cable at Junction Block. . . . . . . . . . . . . . . . . . . . . . . . . 0162-4 Receptacle and Battery Disconnect Switch Connections. . . . . . . . . 0162-6 Battery Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0162-7

Alternator Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0163 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.

Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-1 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-2 Fuse Panel Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-3 Alternator Cable to Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-4 Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-5 Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-6 Alternator Cable to Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-7 Fuse Panel Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-8 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-9 Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-10

Starter Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0164 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Starter Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164-2 Starter Cable to Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164-3 Starter Cable to Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164-4 Starter Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164-5 Starter Cable to Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164-6 Starter Cable to Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164-7 Starter Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164-8

Junction Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0165 Figure 1.

Junction Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0165-2

Junction Block Replacement (With Arctic Kit Heater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0166 Figure 1.

Junction Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0166-2

Front Lighting Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0167 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Frame Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167-1 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167-2 Light Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167-3 Horn Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167-4 Light Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167-5 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167-6 Frame Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167-7

Backup Alarm Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0168 Figure 1. Figure 2.

Frame Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168-1 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168-2

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Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Alarm Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0168-2 Alarm Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0168-3 Alarm Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0168-4 Alarm Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0168-4 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0168-5 Frame Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0168-5

Transmission Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0169 Figure 1. Figure 2. Figure 3.

Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0169-1 Transmission Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0169-2 Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0169-3

Fuel Tank Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0170 Figure 1.

Fuel Tank Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0170-2

Fuel Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0171 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27.

Fuel Tank Supply Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-2 Fuel Tank Return Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-3 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-4 Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-5 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-5 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-6 Sending Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-7 Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-8 Supply Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-9 Drain Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-10 Fuel Tank Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-11 Fuel Tank Return Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-12 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-13 Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-14 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-15 Fuel Tank Return Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-16 Fuel Tank Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-17 Drain Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-18 Supply Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-19 Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-20 Sending Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-21 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-22 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-23 Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-23 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-24 Fuel Tank Return Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-25 Fuel Tank Supply Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-26

Chassis Harness Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0172 Figure 1. Figure 2. Figure 3.

Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0172-1 Chassis Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0172-2 Harness to Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0172-3

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Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Temp Sensor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172-3 Temp Sensor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172-4 Harness To Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172-5 Chassis Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172-6 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172-7

Transmission Sensor Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0173 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-2 Transmission Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-3 Speed Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-4 Control Solenoids Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-5 Transmission Harness Main Connector. . . . . . . . . . . . . . . . . . . . . . 0173-6 Transmission Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-7 Transmission Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-8 Transmission Harness Main Connector. . . . . . . . . . . . . . . . . . . . . . 0173-9 Control Solenoids Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-10 Speed Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-11 Transmission Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-12 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-13

Switch and Harness Assembly (Service Brake) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0174 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14.

Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-1 Brake Switch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-2 Brake Switch Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-3 Instrument Panel Lower Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-4 Instrument Panel Upper Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-5 Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-6 Brake Switch Harness Grommet. . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-7 Brake Switch Harness Grommet. . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-8 Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-9 Instrument Panel Upper Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-10 Instrument Panel Lower Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-11 Brake Switch Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-12 Brake Switch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-13 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-14

ECM (Powertrain) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0175 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175-1 Left Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175-2 ECM (Powertrain). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175-3 ECM (Powertrain). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175-4 Left Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175-5 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175-5

Fuse Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0176 Figure 1. Figure 2. Figure 3.

Fuse Box Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176-2 Starter and Main Relay Straps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176-3 Main Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176-4

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Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17.

Starter Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-5 Junction Block Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-6 Blower Motor Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-7 Fuse Block Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-8 Junction Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-9 Alternator Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-10 Junction Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-11 Fuse Block Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-12 Blower Motor Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-13 Junction Block Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-14 Starter Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-15 Main Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-16 Starter and Main Relay Straps. . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-17 Fuse Box Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-18

Power Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0177 Figure 1. Figure 2.

Power Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0177-1 Power Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0177-2

Wiring Harness Assembly (Steering Control) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0178 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0178-1 Left Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0178-2 Powertrain Control Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . .0178-3 Powertrain Control Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . .0178-4 Left Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0178-5 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0178-6

Right Cab Switch Panel Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0179 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Upper Right Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-1 Switch Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-2 Switch Pod Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-2 Pod Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-3 Switch Panel Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-4 Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-5 Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-6 Switch Panel Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-7 Pod Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-8 Switch Pod Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-9 Switch Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-10 Upper Right Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-11

Winch Solenoid Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0180 Figure 1. Figure 2.

Winch Solenoid Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0180-2 Winch Solenoid Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0180-3

Hydraulic Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0181 Figure 1. Figure 2. Figure 3.

Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0181-1 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0181-2 Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0181-2 xlvii

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Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0181-3

Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0182 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Left Hand Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182-1 Horn Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182-2 Horn and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182-3 Horn and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182-4 Horn Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182-5 Left Hand Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182-6

Backup Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0183 Figure 1. Figure 2. Figure 3.

Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183-1 Backup Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183-2 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183-3

Hydraulic Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0184 Figure 1. Figure 2.

Hydraulic System Oil Fill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184-2 Hydraulic System Oil Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184-3

Hydraulic Oil Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0185 Figure 1. Figure 2. Figure 3.

Hydraulic System Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185-3 Hydraulic Filter Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185-5 Hydraulic System Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185-6

Hydraulic System Pressure Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0186 Figure 1. Figure 2.

Cab Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0186-1 Hydraulic System Fill Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0186-2

Hydraulic Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0187 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21.

Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-2 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-3 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-4 Hydraulic Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-5 Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-6 Hydraulic Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-6 Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-7 Hydraulic Tank Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-8 Hydraulic Tank Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-8 Hydraulic Tank Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-9 Hydraulic Tank Filler Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-9 Hydraulic Tank Rear Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . 0187-10 Hydraulic Tank Valve Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-11 Hydraulic Tank Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . 0187-12 Hydraulic Tank T Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-13 Hydraulic Tank Front Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . 0187-14 Hydraulic Tank Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-15 Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-15 Hydraulic Tank Safety Drain Valve. . . . . . . . . . . . . . . . . . . . . . . . . 0187-16 Hydraulic Tank Pick-up Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-17 Hydraulic Tank Internal Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-18 xlviii

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Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41. Figure 42. Figure 43. Figure 44.

Hydraulic Tank Internal Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-19 Hydraulic Tank Internal Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-20 Hydraulic Tank Internal Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-21 Hydraulic Tank Pick-up Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-22 Hydraulic Tank Safety Drain Valve. . . . . . . . . . . . . . . . . . . . . . . . .0187-23 Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-24 Hydraulic Tank Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-24 Hydraulic Tank Front Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . .0187-25 Hydraulic Tank T Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-26 Hydraulic Tank Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . .0187-27 Hydraulic Tank Valve Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-28 Hydraulic Tank Rear Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . .0187-29 Hydraulic Tank Filler Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-30 Hydraulic Tank Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-30 Hydraulic Tank Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-31 Hydraulic Tank Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-31 Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-32 Hydraulic Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-32 Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-33 Hydraulic Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-34 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-35 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-36 Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-37

Hydraulic Tank Enclosure Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0188 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Enclosure Bracket and Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0188-2 Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0188-3 Information Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0188-4 Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0188-5 Enclosure Bracket and Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0188-6

Hydraulic Oil Cooler Lines Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0189 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14.

Upper Hydraulic Oil Cooler Line Elbow. . . . . . . . . . . . . . . . . . . . . . .0189-3 Upper Hydraulic Oil Cooler Line. . . . . . . . . . . . . . . . . . . . . . . . . . . .0189-4 Upper Hydraulic Oil Cooler Line at Counterbalance Valve. . . . . . . .0189-5 Lower Hydraulic Oil Cooler Line Connector. . . . . . . . . . . . . . . . . . .0189-6 Clamps Under Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0189-7 Clamps Under Foot Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0189-8 Lower Hydraulic Oil Cooler Line at Hydraulic Tank. . . . . . . . . . . . .0189-9 Lower Hydraulic Oil Cooler Line at Hydraulic Tank. . . . . . . . . . . .0189-10 Clamps Under Foot Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0189-11 Clamps Under Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0189-12 Lower Hydraulic Oil Cooler Line Connector. . . . . . . . . . . . . . . . . .0189-13 Upper Hydraulic Oil Cooler Line at Counterbalance Valve. . . . . . .0189-14 Upper Hydraulic Oil Cooler Line. . . . . . . . . . . . . . . . . . . . . . . . . . .0189-15 Upper Hydraulic Oil Cooler Line Elbow. . . . . . . . . . . . . . . . . . . . . .0189-16

Hydraulic Suction Line Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0190 xlix

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Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11.

Upper Hydraulic Suction Line at Right Front Panel. . . . . . . . . . . . . 0190-3 Lower Hydraulic Suction Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190-4 Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190-5 Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190-6 Right Front Panel Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190-7 Upper Hydraulic Suction Line at Hydraulic Tank. . . . . . . . . . . . . . . 0190-8 Right Front Panel Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190-9 Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190-10 Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190-11 Lower Hydraulic Suction Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190-12 Upper Hydraulic Suction Line at Right Front Panel. . . . . . . . . . . . 0190-13

Hydraulic Implement Pump Tank Hose Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0191 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9.

Implement Pump to Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . 0191-3 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191-3 Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191-4 Clamps at Filler Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191-4 Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191-5 Clamps at Filler Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191-6 Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191-7 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191-7 Implement Pump to Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . 0191-8

Hydraulic Implement Pump Steering Motor Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0192 Figure 1. Figure 2. Figure 3.

Implement Pump to Steering Motor Tee. . . . . . . . . . . . . . . . . . . . . . 0192-3 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192-4 Implement Pump to Steering Motor Tee. . . . . . . . . . . . . . . . . . . . . . 0192-5

Hydraulic Implement Pump Main Control Valve Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0193 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Implement Pump to Main Hydraulic Control Valve. . . . . . . . . . . . . . 0193-3 Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193-3 Main Hydraulic Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193-4 Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193-5 Implement Pump to Main Hydraulic Control Valve. . . . . . . . . . . . . . 0193-6

Hydraulic Implement Pump Pilot Accumulator Hose Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0194 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Implement Pump to Pilot Accumulator. . . . . . . . . . . . . . . . . . . . . . . 0194-3 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194-3 Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194-4 Pilot Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194-5 Pilot Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194-6 Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194-7 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194-8 Implement Pump to Pilot Accumulator. . . . . . . . . . . . . . . . . . . . . . . 0194-8

Hydraulic Steering Motor/Tank Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0195 Figure 1. Figure 2. Figure 3.

Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195-3 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195-3 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195-4 l

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Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.

Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0195-4 Steering Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0195-5 Steering Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0195-6 Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0195-7 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0195-7 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0195-8 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0195-8

Hydraulic Counterbalance Valve Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0196 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0196-3 Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0196-4 Implement Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0196-4 Implement Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0196-6 Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0196-7 Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0196-7

Volume III How To Use This Technical Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxx Lift Cylinder Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0197 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22.

Tube to Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-2 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-3 Hose Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-3 Tube Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-4 Quick Drop Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-5 Front Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-6 Upper Rear Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-7 Lower Rear Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-8 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-9 Right Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-10 Implement Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-11 Implement Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-12 Right Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-13 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-14 Lower Rear Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-15 Rear Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-16 Front Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-17 Quick Drop Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-18 Tube Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-19 Hose Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-20 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-20 Tube to Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197-21

Tilt Cylinder Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0198 Figure 1. Figure 2. Figure 3. Figure 4.

Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0198-2 Tilt Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0198-2 Radiator Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0198-3 Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0198-4

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Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19.

Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-5 Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-6 Rear Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-7 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-8 Right Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-9 Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-10 Right Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-11 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-12 Rear Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-13 Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-14 Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-15 Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-16 Radiator Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-17 Tilt Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-17 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-18

Bottom Guards Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0199 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Front Bottom Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199-3 Middle Bottom Guard Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199-4 Middle Bottom Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199-5 Rear Bottom Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199-6 Rear Bottom Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199-7 Middle Bottom Guard Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199-8 Middle Bottom Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199-9 Front Bottom Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199-10

Hood Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0200 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19.

Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-1 Fresh Air Intake Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-2 Muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-2 Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-3 Pre-Cleaner Body Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-4 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-4 Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-5 Hood Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-6 Slides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-6 Grommets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-7 Slides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-8 Hood Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-8 Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-9 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-10 Pre-Cleaner Body Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-10 Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-11 Muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-12 Fresh Air Intake Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-12 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200-13

Engine Enclosure Left Door Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0201 lii

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Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13.

Left Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-2 Hinge Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-3 Striker Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-4 Latch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-5 Latch Pawl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-6 Door Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-7 Door Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-8 Door Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-9 Latch Pawl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-9 Latch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-10 Striker Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-11 Hinge Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-12 Left Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-13

Engine Enclosure Left Door Guard Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0202 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9.

Left Engine Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0202-1 Left Engine Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0202-2 Mounting Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0202-3 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0202-4 Arctic Heater Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0202-5 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0202-6 Mounting Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0202-7 Left Engine Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0202-7 Left Engine Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0202-8

Engine Enclosure Right Door Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0203 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13.

Right Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0203-2 Hinge Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0203-3 Striker Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0203-4 Latch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0203-5 Latch Pawl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0203-6 Door Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0203-7 Door Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0203-8 Door Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0203-9 Latch Pawl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0203-9 Latch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0203-10 Striker Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0203-11 Hinge Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0203-12 Right Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0203-13

Engine Enclosure Right Door Guard Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0204 Figure 1. Figure 2. Figure 3.

Right Engine Plate and Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0204-1 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0204-2 Right Engine Plate and Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0204-3

Radiator Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0205 Figure 1. Figure 2.

Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0205-2 Cylinder Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0205-3

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Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22.

Cylinder Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-4 Radiator Drain Hose and Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-5 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-5 Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-6 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-6 Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-7 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-7 Bracket Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-8 Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-9 Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-10 Bracket Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-11 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-11 Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-12 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-13 Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-13 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-14 Radiator Drain Hose and Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-14 Cylinder Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-15 Cylinder Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-16 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-17

Platform Enclosure Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0206 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24.

Steering Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-2 Engine Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-3 Heater Core Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-4 Heater and A/C Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-5 A/C Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-6 Light Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-7 Fuse Box Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-8 Fuse Box Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-9 Brake Solenoid Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-10 Brake Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-11 Transmission Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . . 0206-12 Chassis Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-13 Arctic Heater Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . . 0206-14 Bracket Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-15 Rear Cab Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-16 Front Cab Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-17 Lower Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-18 Bracket Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-19 Lower Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-20 Front Cab Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-21 Rear Cab Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-22 Bracket Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-22 Arctic Heater Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . . 0206-23 Chassis Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206-24

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Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35.

Transmission Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . .0206-25 Brake Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-26 Brake Solenoid Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-27 Fuse Box Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-28 Fuse Box Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-29 Light Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-30 A/C Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-31 Heater and A/C Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-32 Heater Core Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-33 Engine Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-34 Steering Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-35

Left Platform Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0207 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0207-1 Lower Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0207-2 Upper Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0207-3 Upper Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0207-4 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0207-5

Right Platform Access Panels Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0208 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16.

Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0208-2 Right Armrest Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0208-3 Lower Right Access Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . .0208-4 Upper Right Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0208-5 Switch Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0208-6 Switch Pod Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0208-7 Pod Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0208-8 Switch Panel Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0208-9 Switch Panel Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0208-10 Pod Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0208-11 Switch Pod Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0208-12 Switch Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0208-12 Upper Right Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0208-13 Lower Right Access Panels Installation. . . . . . . . . . . . . . . . . . . . .0208-14 Right Armrest Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0208-15 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0208-16

Platform Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0209 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.

Right Rear Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0209-2 Right Side Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0209-3 Harness Connector, Plate, and Clip. . . . . . . . . . . . . . . . . . . . . . . . .0209-4 Right Front Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0209-5 Platform Harness to Instrument Panel Harness Connector. . . . . . .0209-6 Platform Harness to Platform Floor. . . . . . . . . . . . . . . . . . . . . . . . . .0209-7 Fuse Panel Access Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0209-7 Platform Rear Harness Connections. . . . . . . . . . . . . . . . . . . . . . . .0209-8 Platform Rear Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . .0209-9 Platform Rear Harness Connector Plate. . . . . . . . . . . . . . . . . . . . .0209-10 lv

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Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30.

Power Outlets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-10 Platform Rear Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-11 Machine ECM Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-12 Harness Ground Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-13 Left Side Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-14 Left Side Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-15 Harness Ground Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-16 Machine ECM Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-17 Platform Rear Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-17 Power Outlets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-18 Platform Rear Harness Connector Plate. . . . . . . . . . . . . . . . . . . . 0209-18 Platform Rear Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . 0209-19 Platform Rear Harness Connections. . . . . . . . . . . . . . . . . . . . . . . 0209-20 Fuse Panel Access Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-21 Platform Harness to Platform Floor. . . . . . . . . . . . . . . . . . . . . . . . 0209-21 Platform Harness to Instrument Panel Harness Connector. . . . . . 0209-22 Right Front Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-23 Harness Connector, Plate, and Clip. . . . . . . . . . . . . . . . . . . . . . . . 0209-24 Right Side Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-25 Right Rear Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-26

Cylinder Flood Lamp and Bracket Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0210 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11.

Flood Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210-1 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210-2 Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210-3 Flood Lamp Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210-4 Disconnecting Lamp Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . 0210-5 Bulb Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210-6 Connecting Lamp Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210-7 Flood Lamp Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210-8 Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210-9 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210-10 Flood Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210-11

Valve Bank GP - Test 5 ServiceWith Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0211 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Top Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211-2 Control Valve Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211-3 Hoses and Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211-4 Control Lever Linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211-5 Front Side Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211-6 Control Valve Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211-7 Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211-8 Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211-9 Steering Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . 0211-10 Bulldozer Lift Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . 0211-11 Bulldozer Tilt Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . 0211-12 Ripper Tilt Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . . 0211-13 lvi

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Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26.

Ripper Lift Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . .0211-14 Valve Cap Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-14 Ripper Tilt Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . .0211-16 Bulldozer Tilt Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . .0211-17 Bulldozer Lift Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . .0211-18 Steering Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . .0211-19 Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-20 Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-21 Control Valve Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-22 Front Side Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-23 Control Lever Linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-24 Hoses and Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-25 Control Valve Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-26 Top Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-27

Valve Bank GP - Test 4 Service With Winch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0212 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29.

Hose Removal from Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-2 Hose Connections at Front of Valve Bank. . . . . . . . . . . . . . . . . . . .0212-3 Hose Connections at Rear of Valve Bank. . . . . . . . . . . . . . . . . . . . .0212-3 Disconnecting Steering Control Link. . . . . . . . . . . . . . . . . . . . . . . . .0212-4 Valve Bank Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-5 Hose Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-6 Valve Bank Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-7 Valve Bank Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-8 Cover O-ring Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-9 Winch Valve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-10 O-ring Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-11 Bulldozer Tilt Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . .0212-12 Bulldozer Lift Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . .0212-13 Steering Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . .0212-14 Valve Cap Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-14 O-ring Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-16 Steering Control Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . .0212-17 Bulldozer Lift Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . .0212-17 Bulldozer Tilt Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . .0212-18 Winch Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-19 O-ring Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-20 Valve Bank Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-21 Bracket Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-22 Hose Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-23 Control Valve Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-24 Connecting Steering Control Link. . . . . . . . . . . . . . . . . . . . . . . . . .0212-24 Hose Connections at Rear of Valve Bank. . . . . . . . . . . . . . . . . . . .0212-25 Hose Connections at Front of Valve Bank. . . . . . . . . . . . . . . . . . .0212-25 Hose Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-26

Ripper Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0213 lvii

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Ripper Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0213-2

Winch Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0214 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Winch Manifold Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214-2 Winch Manifold Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214-3 Winch Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214-4 Winch Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214-5 Winch Manifold Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214-6 Winch Manifold Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214-7

Quick Drop Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0215 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215-2 Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215-3 Upper Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215-4 Quick Drop Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215-5 Upper Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215-7 Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215-7 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215-8

Control Manifold Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28.

Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-2 Control Valve Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-3 Control Valve Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-4 Control Manifold Assembly Sampling Valve and Fitting. . . . . . . . . . 0216-5 Sampling Valve and Fittings Disassembly. . . . . . . . . . . . . . . . . . . . 0216-6 Control Manifold Assembly Diagnostic Port Fitting. . . . . . . . . . . . . . 0216-7 Diagnostic Port Fitting Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . 0216-8 Pressure Reducing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-9 Front Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-9 Control Manifold Assembly Elbow Fitting. . . . . . . . . . . . . . . . . . . . 0216-10 Elbow Fitting Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-10 Control Manifold Assembly T Fitting. . . . . . . . . . . . . . . . . . . . . . . . 0216-11 Fitting Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-12 Rear Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-13 Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-14 Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-14 Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-15 Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-16 Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-17 Rear Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-18 Fitting Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-19 Control Manifold Assembly T Fitting. . . . . . . . . . . . . . . . . . . . . . . . 0216-20 Elbow Fitting Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-21 Control Manifold Assembly Elbow Fitting. . . . . . . . . . . . . . . . . . . . 0216-21 Front Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-22 Pressure Reducing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216-22 Diagnostic Port Fitting Disassembly. . . . . . . . . . . . . . . . . . . . . . . . 0216-23 Control Manifold Assembly Diagnostic Port Fitting. . . . . . . . . . . . . 0216-24 lviii

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Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35.

Sampling Valve and Fittings Assembly. . . . . . . . . . . . . . . . . . . . . .0216-25 Control Manifold Assembly Sampling Valve and Fitting. . . . . . . . .0216-26 Control Valve Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-27 Control Valve Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-28 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-29 Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-30 Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-31

Counterbalance Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0217 Figure 1. Figure 2. Figure 3. Figure 4.

Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0217-2 Counterbalance Valve Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . .0217-3 Counterbalance Valve Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . .0217-4 Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0217-5

Lowering Equipment with Engine Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0218 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Fire Extinguisher and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0218-1 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0218-2 Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0218-3 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0218-4 Fire Extinguisher and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0218-5

Blower Fan Case Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0219 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15.

Cab Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-1 Temperature Switch Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-2 Temperature Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-3 Blower Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-4 Resistor Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-5 Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-5 Blower Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-6 Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-7 Blower Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-8 Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-9 Resistor Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-9 Blower Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-10 Temperature Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-11 Temperature Switch Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-12 Cab Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0219-12

Air Conditioner Evaporator Coil Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0220 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0220-2 Cab Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0220-3 Temperature Switch Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0220-3 Hose Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0220-4 AC Evaporator Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0220-5 Temperature Switch Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0220-6 Cab Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0220-6 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0220-7

Heater Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0221

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

Heater Hose Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221-1 Heater Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221-2 Heater Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221-3 Heater Coil Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221-4 Heater Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221-5 Heater Hose Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221-6

Front Wiper Motor, Wiper Arm and Wiper Blade Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0222 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11.

Cab Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-1 Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-2 Wiper Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-2 Spray Nozzle, Hose, and Wiper Arm. . . . . . . . . . . . . . . . . . . . . . . . 0222-3 Wiper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-4 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-4 Wiper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-5 Spray Nozzle, Hose, and Wiper Arm. . . . . . . . . . . . . . . . . . . . . . . . 0222-6 Wiper Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-7 Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-7 Cab Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-8

Rear Wiper Motor, Wiper Arm, and Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0223 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11.

Wiper Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0223-1 Spray Nozzle, Hose, and Wiper Arm. . . . . . . . . . . . . . . . . . . . . . . . 0223-2 Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0223-3 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0223-3 Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0223-4 Bolt and Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0223-4 Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0223-5 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0223-5 Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0223-6 Spray Nozzle, Hose, and Wiper Arm. . . . . . . . . . . . . . . . . . . . . . . . 0223-7 Wiper Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0223-8

Washer Bottle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0224 Figure 1.

Washer Bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0224-2

ROPS Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0225 Figure 1. Figure 2. Figure 3. Figure 4.

Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0225-2 ROPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0225-3 ROPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0225-4 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0225-5

Front Washer Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0226 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Front Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0226-1 Front Washer Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0226-2 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . . . 0226-3 Hose and Harness Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0226-4 Left Column Access Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0226-4 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . . . 0226-5 lx

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Figure 7. Figure 8.

Front Washer Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0226-6 Front Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0226-7

Rear Washer Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0227 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9.

Rear Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0227-1 Rear Washer Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0227-2 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . . .0227-3 Hose and Harness Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0227-4 Left Column Access Hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0227-5 Hose and Harness Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0227-6 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . . .0227-7 Rear Washer Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0227-8 Rear Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0227-9

Door Washer Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0228 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0228-2 Door Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0228-3 Door Washer Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0228-4 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . . .0228-5 Hose and Harness Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0228-6 Left Column Access Hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0228-7 Left Column Access Hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0228-8 Hose and Harness Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0228-9 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . .0228-10 Door Washer Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0228-11 Door Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0228-12 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0228-13

Headliner and Interior Trim Panels Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0229 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19.

Rearview Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-1 Front Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-2 Headliner and Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-2 Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-3 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-4 Rear Wiper Motor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-4 Rear Headliner Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-5 Headliner Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-6 Speaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-7 Wiper Control Plate Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-7 Cab Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-8 Cab Lamp Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-8 Right-hand Pillar Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-9 Left-hand Pillar Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-10 Right-hand Pillar Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-11 Cab Lamp Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-11 Cab Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-12 Wiper Control Plate Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-12 Speaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0229-13 lxi

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Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27.

Headliner Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-14 Rear Headliner Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-15 Rear Wiper Motor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-16 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-16 Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-17 Headliner and Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-18 Front Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-18 Rearview Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-19

Front Floor Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0230 Figure 1. Figure 2. Figure 3.

Floor Mat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0230-1 Front Floor Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0230-2 Floor Mat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0230-3

Rear Floor Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0231 Figure 1. Figure 2. Figure 3.

Floor Mat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0231-1 Rear Floor Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0231-2 Rear Floor Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0231-3

Headliner Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0232 Figure 1.

Headliner Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0232-2

Cab Overhead Interior Lamp Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0233 Figure 1. Figure 2. Figure 3. Figure 4.

Cab Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0233-1 Cab Lamp Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0233-2 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0233-2 Cab Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0233-3

Wiper Control Plate and Switches Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0234 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Wiper Control Plate Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0234-1 Wiper Control Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0234-2 Wiper Control Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0234-3 Wiper Control Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0234-4 Wiper Control Plate Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0234-5

Rearview Mirror Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0235 Figure 1. Figure 2. Figure 3.

Rearview Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0235-1 Rearview Mirror Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0235-2 Rearview Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0235-3

Messenger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0236 Figure 1.

Messenger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0236-2

Steering, Transmission Control and Parking Brake Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . WP 0237 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Steering Control Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-2 Steering Control Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-3 Control Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-4 Shaft and Collar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-5 Main Control Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-6 Parking Brake Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-7 Parking Brake Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-7 lxii

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Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38.

Parking Brake Switch Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-8 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-8 Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-9 Handle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-10 Backup Alarm Switch Connections. . . . . . . . . . . . . . . . . . . . . . . . .0237-11 Backup Alarm Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-12 Sensor Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-12 Forward/Neutral/Reverse Sensor. . . . . . . . . . . . . . . . . . . . . . . . . .0237-13 Detent Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-13 Handle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-14 Main Control Housing Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-14 Lock Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-15 Lock Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-16 Main Control Housing Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-17 Handle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-17 Detent Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-18 Forward/Neutral/Reverse Sensor. . . . . . . . . . . . . . . . . . . . . . . . . .0237-18 Sensor Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-19 Backup Alarm Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-19 Backup Alarm Switch Connections. . . . . . . . . . . . . . . . . . . . . . . . .0237-20 Handle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-21 Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-22 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-23 Parking Brake Switch Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-23 Parking Brake Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-24 Parking Brake Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-24 Main Control Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-25 Shaft and Collar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-26 Control Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-27 Steering Control Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-28 Steering Control Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-29

Steering Control Rod Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0238 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Steering Control Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0238-1 Bracket. (Hydraulic lines removed for clarity). . . . . . . . . . . . . . . . . .0238-2 Steering Control Rod Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . .0238-3 Bracket. (Hydraulic lines removed for clarity). . . . . . . . . . . . . . . . . .0238-4 Steering Control Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0238-5

Accumulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0239 Figure 1.

Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0239-2

Receiver Dryer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0240 Figure 1.

Receiver Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0240-2

Air Conditioning High Pressure Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0241 Figure 1. Figure 2.

Compressor Hose to Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . .0241-2 Receiver Dryer Hose to Evaporator Coil. . . . . . . . . . . . . . . . . . . . . .0241-3

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Figure 3. Figure 4. Figure 5. Figure 6.

Receiver Dryer Hose to Condenser Coil. . . . . . . . . . . . . . . . . . . . . . 0241-4 Receiver Dryer Hose to Condenser Coil. . . . . . . . . . . . . . . . . . . . . . 0241-5 Receiver Dryer Hose to Evaporator Coil. . . . . . . . . . . . . . . . . . . . . . 0241-6 Compressor Hose to Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . 0241-7

Air Conditioning Low Pressure Hoses Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0242 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Compressor Hose to Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . 0242-2 Accumulator Hose to Evaporator Coil. . . . . . . . . . . . . . . . . . . . . . . . 0242-3 Accumulator Hose Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0242-4 Evaporator Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0242-5 Evaporator Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0242-6 Accumulator Hose to Evaporator Coil. . . . . . . . . . . . . . . . . . . . . . . . 0242-7 Accumulator Hose Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0242-8 Compressor Hose to Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . 0242-9

Heater Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0243 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.

Heater Hose Shutoff Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0243-2 Right Side Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0243-3 Transmission Cooler Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0243-3 Rear Engine Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0243-4 Heater Coil and Water Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0243-5 Heater Coil and Water Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0243-6 Rear Engine Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0243-7 Transmission Cooler Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0243-8 Right Side Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0243-8 Heater Hose Shutoff Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0243-9

Water Valve and Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0244 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13.

Water Valve Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0244-1 Water Valve Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0244-2 Water Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0244-3 Heater Control Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0244-4 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0244-5 Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0244-6 Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0244-7 Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0244-8 Heater Control Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0244-8 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0244-9 Water Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0244-10 Water Valve Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0244-11 Water Valve Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0244-12

Cab Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0245 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Electrical Harness and Washer Hoses. . . . . . . . . . . . . . . . . . . . . . . 0245-2 Messenger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0245-3 Rifle Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0245-4 Cab Bolts at Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0245-5 Cab Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0245-6

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Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19.

Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-7 Surround. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-8 Harness Connector and Angle Bracket. . . . . . . . . . . . . . . . . . . . . . .0245-8 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-9 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-10 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-11 Harness Connector and Angle Bracket. . . . . . . . . . . . . . . . . . . . . .0245-12 Surround. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-12 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-13 Cab Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-13 Cab Bolts at Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-14 Rifle Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-15 Messenger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-16 Electrical Harness and Washer Hoses. . . . . . . . . . . . . . . . . . . . . .0245-17

Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0246 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Front Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0246-2 Rear Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0246-3 Right Side Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0246-4 Left Side Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0246-5 Left Side Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0246-6 Right Side Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0246-7 Rear Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0246-8 Front Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0246-9

Seat Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0247 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21.

Headrest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-1 Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-2 Seat Belt Retractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-3 Seat Belt Buckle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-3 Seat Back Cushion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-4 Seat Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-4 Seat Cushion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-5 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-6 Mark Latch and Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-6 Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-7 Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-7 Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-8 Seat Recliner Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-8 Recliner Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-9 Lumbar Support Adjustment Knob. . . . . . . . . . . . . . . . . . . . . . . . .0247-10 Seat Adjuster Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-10 Seat Adjuster Release Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-11 Lumbar Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-11 Seat Back Bag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-12 Lumbar Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-13 Seat Adjuster Release Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0247-13 lxv

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Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37.

Seat Adjuster Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-14 Lumbar Support Adjustment Knob. . . . . . . . . . . . . . . . . . . . . . . . . 0247-14 Recliner Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-15 Seat Recliner Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-16 Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-16 Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-17 Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-17 Mark Latch and Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-18 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-18 Seat Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-19 Seat Cushion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-19 Seat Back Cushion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-20 Seat Belt Buckle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-20 Seat Belt Retractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-21 Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-22 Headrest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-23

Seat Suspension Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0248 Figure 1. Figure 2.

Seat Suspension Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0248-2 Seat Suspension Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0248-3

Door Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0249 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25.

Door Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-1 Interior Door Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-2 Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-2 Cap and Grip Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-3 Grip Handle Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-3 Interior Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-4 Door Striker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-5 Hose and Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-6 Exterior Door Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-7 Door and Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-8 Window and Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-9 Retaining Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-10 Exterior Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-11 Linkage Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-11 Door Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-12 Linkage Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-13 Exterior Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-13 Retaining Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-14 Window and Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-15 Door and Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-16 Exterior Door Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-17 Hose and Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-18 Door Striker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-19 Interior Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-20 Grip Handle Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0249-20 lxvi

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Figure 26. Figure 27. Figure 28. Figure 29.

Cap and Grip Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-21 Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-21 Interior Door Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-22 Door Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-22

Door Wiper Motor, Wiper Arm and Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0250 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14.

Wiper Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-1 Spray Nozzle and Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-2 Washer Hose Nut and Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-2 Wiper Arm Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-3 Wiper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-4 Spray Nozzle and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-5 Wiper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-5 Wiper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-6 Spray Nozzle and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-7 Wiper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-8 Wiper Arm Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-9 Washer Hose Nut and Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-9 Spray Nozzle and Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-10 Wiper Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-11

Outside Cab Door Latch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0251 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Door Latch Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0251-1 Door Striker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0251-2 Latch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0251-3 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0251-3 Latch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0251-4 Latch Striker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0251-5 Door Latch Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0251-6

Cab Flood Lamp and Bracket Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0252 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Flood Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0252-3 Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0252-4 Lamp Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0252-5 Bulb Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0252-6 Bulb Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0252-7 Lamp Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0252-8 Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0252-9 Flood Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0252-10

Engine Flood Lamp and Bracket Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0253 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0253-1 Flood Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0253-2 Flood Lamp and Adjusting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . .0253-3 Adjusting Bracket Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0253-4 Flood Lamp Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0253-5 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0253-5 Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0253-6

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Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20.

Flood Lamp Screws and Trim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-6 Flood Lamp Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-7 Bulb Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-7 Bulb Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-8 Flood Lamp Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-9 Flood Lamp Screws and Trim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-9 Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-10 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-10 Flood Lamp Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-11 Adjusting Bracket Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-12 Flood Lamp and Adjusting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . 0253-13 Flood Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-14 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-14

Cab Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0254 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22.

Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-2 Electrical Harness and Washer Hoses. . . . . . . . . . . . . . . . . . . . . . . 0254-3 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-4 Surround. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-5 Instrument Panel Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-6 Front Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-7 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . . . 0254-8 Hose and Harness Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-9 Left Column Access Hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-10 Ground Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-10 Cab Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-11 Cab Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-12 Ground Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-13 Left Column Access Hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-13 Hose and Harness Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-14 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . . 0254-15 Front Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-16 Instrument Panel Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-17 Surround. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-18 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-19 Electrical Harness and Washer Hoses. . . . . . . . . . . . . . . . . . . . . . 0254-20 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-21

Fire Extinguisher and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0255 Figure 1. Figure 2. Figure 3.

Fire Extinguisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0255-1 Fire Extinguisher Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0255-2 Fire Extinguisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0255-3

Pilot Valve Service (With Ripper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0256 Figure 1. Figure 2. Figure 3. Figure 4.

Hoses and Pilot Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0256-1 Pilot Valve and Hand Control Assembly. . . . . . . . . . . . . . . . . . . . . . 0256-2 Knob, Base Plate and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0256-3 Knob, Base Plate and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0256-4 lxviii

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Pilot Valve and Hand Control Assembly. . . . . . . . . . . . . . . . . . . . . .0256-5 Hoses and Pilot Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0256-5

Pilot Valve Service (With Winch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0257 Figure 1. Figure 2. Figure 3.

Winch Pilot Valve Hoses and Connectors. . . . . . . . . . . . . . . . . . . .0257-1 Winch Pilot Valve and Plate Assembly. . . . . . . . . . . . . . . . . . . . . . .0257-2 Hoses and Pilot Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0257-3

Governor and Brake Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0258 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20.

Dash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-2 Tiedown Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-2 Instrument Panel Electrical Connectors. . . . . . . . . . . . . . . . . . . . . .0258-3 Grommet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-3 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-4 Wiring Harnesses and Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-5 Brake Pedal, Foot Pad, and Sensor. . . . . . . . . . . . . . . . . . . . . . . . .0258-6 Brake Pedal, Foot Pad, and Sensor. . . . . . . . . . . . . . . . . . . . . . . . .0258-7 Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-7 Decelerator Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-8 Decelerator Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-9 Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-9 Brake Pedal, Foot Pad, and Sensor. . . . . . . . . . . . . . . . . . . . . . . .0258-10 Brake Pedal, Foot Pad, and Sensor. . . . . . . . . . . . . . . . . . . . . . . .0258-10 Wiring Harnesses and Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . .0258-11 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-12 Grommet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-12 Dash Electrical Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-13 Tiedown Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-13 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-14

Pilot Valve Bulldozer Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0259 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Hoses and Pilot Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0259-2 Retainer Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0259-3 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0259-3 Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0259-4 Retainer Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0259-5 Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0259-6 Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0259-6 Retainer Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0259-7 Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0259-8 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0259-9 Hoses and Pilot Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0259-9 Retainer Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0259-10

Instrument Panel Harness Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0260 Figure 1. Figure 2. Figure 3.

Back of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0260-2 Instrument Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0260-3 Platform Harness to Instrument Panel Harness Connector. . . . . . .0260-4

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Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Instrument Panel Main Harness Connector. . . . . . . . . . . . . . . . . . . 0260-5 Platform Harness to Harness Connector. . . . . . . . . . . . . . . . . . . . . 0260-5 Instrument Panel Main Harness Connector. . . . . . . . . . . . . . . . . . . 0260-6 Instrument Panel Main Harness Connector. . . . . . . . . . . . . . . . . . . 0260-7 Platform Harness to Instrument Panel Harness Connector. . . . . . . 0260-7 Instrument Panel Main Harness Connector. . . . . . . . . . . . . . . . . . . 0260-8 Platform Harness to Instrument Panel Harness Connector. . . . . . . 0260-8 Instrument Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0260-9 Back of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0260-10

Air Conditioning Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0261 Figure 1.

Air Conditioning Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 0261-2

Instrument Panel Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0262 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24.

Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-2 Back of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-3 Heater Control Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-4 Instrument Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-4 Support Cable and Gauge Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-5 Heater Control Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-6 Connector Clamps and Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-7 Indicator Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-8 Upper Half of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-9 Lower Half of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-10 Light Socket Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-11 Level and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-11 Level and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-12 Light Socket Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-13 Lower Half of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-14 Upper Half of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-15 Indicator Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-16 Connector Clamps and Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . 0262-17 Heater Control Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-18 Support Cable and Gauge Lights. . . . . . . . . . . . . . . . . . . . . . . . . . 0262-19 Instrument Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-20 Heater Control Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-20 Back of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-21 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-22

Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0263 Figure 1. Figure 2. Figure 3. Figure 4.

Recovery Hook-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0263-3 Evacuation Hook-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0263-5 Low Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0263-6 Charging Hook-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0263-8

Yoke Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0264 Figure 1. Figure 2.

Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0264-2 Pin and Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0264-3

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Figure 3. Figure 4. Figure 5. Figure 6.

Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0264-3 Bearing and Bearing Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0264-4 Pin and Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0264-5 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0264-6

Lift Cylinder Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0265 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Lower Hose Connection Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-2 Upper Hose Connection Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-3 Upper Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-4 Lower Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-5 Lower Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-6 Upper Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-7 Upper Hose Connection Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-8 Lower Hose Connection Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-8

Lift Cylinder (Bulldozer) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0266 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.

Upper Hose Connection Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0266-3 Upper Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0266-4 Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0266-5 Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0266-6 Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0266-7 Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0266-9 Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0266-9 Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0266-10 Upper Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0266-11 Upper Hose Connection Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . .0266-12

Tilt Cylinder (Bulldozer) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0267 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11.

Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0267-2 Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0267-3 Sling and Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0267-4 Retainer and Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0267-4 Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0267-5 Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0267-6 Sling and Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0267-7 Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0267-8 Retainer and Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0267-8 Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0267-9 Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0267-10

Blade Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0268 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Hoses and Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0268-2 Manifold Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0268-3 Lift Cylinder Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0268-4 Retaining Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0268-5 Push Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0268-6 Push Arm Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0268-7 Support Stabilizer Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0268-8

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Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24.

Blade Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-9 Left Stabilizer Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-11 Pin and Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-12 Knuckle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-13 Stabilizer Bar Yoke on Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-14 Stabilizer Bar Yoke on Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-15 Knuckle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-16 Pin and Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-17 Left Stabilizer Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-18 Blade Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-19 Push Arm Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-20 Push Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-20 Retaining Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-21 Lift Cylinder Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-22 Support Stabilizer Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-23 Manifold Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-24 Hoses and Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-25

Blade Cutting Edge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0269 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Blade Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0269-2 Blade Cutting Edges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0269-3 Blade Cutting Edge Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0269-4 Blade Cutting Edges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0269-5 Blade Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0269-6 Cutting Edge Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0269-7

Blade Tilt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0270 Figure 1.

Tilt Cylinder and Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0270-3

Blade Pitch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0271 Figure 1.

Left Hand Stabilizer Bar and Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0271-2

Winch Assembly Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0272 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

Winch Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0272-3 Winch Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0272-4 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0272-5 Lifting Device Attached to Winch. . . . . . . . . . . . . . . . . . . . . . . . . . . 0272-6 Winch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0272-7 Winch Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0272-8 Winch Adapter Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0272-9 Installing Winch on Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0272-10 Winch Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0272-11 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0272-11 Winch Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0272-12 Winch Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0272-13

Winch Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0273 Figure 1. Figure 2.

Winch Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0273-3 Hose Connections at Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0273-4 lxxii

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Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14.

Retainer Clip Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-5 Hose Retainer Clip Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-5 Hose Retainer Clip Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-6 Hose Connections at Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . .0273-6 Pump Hose and Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-7 Pump Hose and Retainer Clips. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-8 Hose Connections at Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . .0273-9 Hose Retainer Clip Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-9 Hose Retainer Clip Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-10 Retainer Clip Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-10 Hose Connections at Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-11 Winch Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-12

Winch Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0274 Figure 1.

Winch Plug Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0274-2

Winch Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0275 Figure 1. Figure 2. Figure 3.

Winch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0275-2 Removing Cable from Drum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0275-3 Installing Cable on Winch Drum. . . . . . . . . . . . . . . . . . . . . . . . . . . .0275-4

Cylinder Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0276 Figure 1. Figure 2.

Ripper Cylinder Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0276-3 Ripper Cylinder Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0276-4

Cylinder, Ripper Lift Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0277 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Ripper Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0277-3 Ripper Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0277-3 Ripper Lift Cylinder Rod End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0277-4 Ripper Lift Cylinder Head End. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0277-4 Ripper Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0277-5 Ripper Lift Cylinder Head End. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0277-6 Ripper Lift Cylinder Rod End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0277-6 Ripper Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0277-7

Cylinder, Ripper Tilt Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0278 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Ripper Tilt Cylinder Hose Assemblies. . . . . . . . . . . . . . . . . . . . . . . .0278-2 Ripper Tilt Cylinder Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0278-3 Ripper Tilt Cylinder Head End. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0278-4 Ripper Tilt Cylinder Rod End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0278-4 Ripper Tilt Cylinder Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0278-5 Ripper Tilt Cylinder Rod End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0278-6 Ripper Tilt Cylinder Head End. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0278-6 Ripper Tilt Cylinder Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . .0278-7

Ripper Frame Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0279 Figure 1. Figure 2. Figure 3. Figure 4.

Ripper Frame Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0279-2 Ripper Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0279-3 Tiedown Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0279-4 Tiedown Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0279-5 lxxiii

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Figure 5. Figure 6.

Ripper Frame Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0279-6 Ripper Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0279-7

Ripper Tooth Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0280 Figure 1.

Ripper Tooth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0280-2

Ripper Shank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0281 Figure 1.

Shank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0281-2

Ripper Carriage Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0282 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Ripper Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-2 Ripper Tilt Cylinder Rod End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-2 Ripper Tilt Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-3 Ripper Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-5 Ripper Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-7 Ripper Tilt Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-8 Ripper Tilt Cylinder Rod End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-9 Ripper Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-10

Arctic Kit Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0283 Arctic Kit Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0284 Arctic Kit Heater Fuel Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0285 Figure 1.

Measuring Fuel Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0285-3

Arctic Kit Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0286 Figure 1. Figure 2.

Intake and Exhaust Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0286-1 Intake and Exhaust Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0286-2

Arctic Kit Battery Cables and Junction Block Power Cable Replacement. . . . . . . . . . . . . . . . . . . . . . . WP 0287 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18.

Arctic Kit Battery Box Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0287-2 Crossover Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0287-3 Cable Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0287-4 Positive and Negative Arctic Kit Battery Cables. . . . . . . . . . . . . . . . 0287-5 Positive Battery Cables at Terminal. . . . . . . . . . . . . . . . . . . . . . . . . 0287-6 Negative Battery Cables at Disconnect Switch. . . . . . . . . . . . . . . . . 0287-7 Negative Battery Cable and Grommets. . . . . . . . . . . . . . . . . . . . . . 0287-8 Arctic Kit Positive Battery Cable at Terminal. . . . . . . . . . . . . . . . . . 0287-9 Arctic Kit Positive Battery Cables at Junction Block. . . . . . . . . . . . 0287-10 Arctic Kit Positive Battery Cables at Junction Block. . . . . . . . . . . . 0287-11 Arctic Kit Positive Battery Cable at Terminal. . . . . . . . . . . . . . . . . 0287-12 Negative Battery Cable and Grommets. . . . . . . . . . . . . . . . . . . . . 0287-13 Negative Battery Cables at Disconnect Switch. . . . . . . . . . . . . . . . 0287-14 Positive Battery Cables at Terminal. . . . . . . . . . . . . . . . . . . . . . . . 0287-15 Positive and Negative Arctic Kit Battery Cables. . . . . . . . . . . . . . . 0287-16 Cable Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0287-17 Crossover Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0287-18 Arctic Kit Battery Box Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0287-19

Arctic Kit Batteries Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0288 Figure 1.

Arctic Kit Battery Box Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0288-2 lxxiv

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Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9.

Crossover Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0288-3 Cable Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0288-4 Positive and Negative Arctic Kit Battery Cables. . . . . . . . . . . . . . . .0288-5 Arctic Kit Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0288-6 Positive and Negative Arctic Kit Battery Cables. . . . . . . . . . . . . . . .0288-8 Cable Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0288-9 Crossover Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0288-10 Arctic Kit Battery Box Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0288-11

Arctic Kit Battery Box Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0289 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.

Battery Box Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-1 Arctic Kit Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-2 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-2 Mounting Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-3 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-3 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-4 Mounting Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-4 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-5 Arctic Kit Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-5 Battery Box Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-6

Arctic Kit Heater Switch and Heater Harness Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0290 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14.

Upper Right Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0290-1 Switch Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0290-2 Arctic Kit Heater Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0290-2 Arctic Kit Heater Switch Harness. . . . . . . . . . . . . . . . . . . . . . . . . . .0290-3 Engine Compartment Arctic Kit Heater Harness at Heater. . . . . . . .0290-3 Engine Compartment Arctic Kit Heater Harness. . . . . . . . . . . . . . . .0290-4 Platform Arctic Kit Heater Harness. . . . . . . . . . . . . . . . . . . . . . . . . .0290-5 Platform Arctic Kit Heater Harness. . . . . . . . . . . . . . . . . . . . . . . . . .0290-6 Engine Compartment Arctic Kit Heater Harness. . . . . . . . . . . . . . . .0290-7 Engine Compartment Arctic Kit Heater Harness at Heater. . . . . . . .0290-8 Arctic Kit Heater Switch Harness. . . . . . . . . . . . . . . . . . . . . . . . . . .0290-8 Arctic Kit Heater Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0290-9 Switch Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0290-9 Upper Right Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0290-10

Arctic Kit Heater and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0291 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.

Arctic Kit Heater Fuel Shutoff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0291-1 Arctic Kit Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0291-2 Arctic Bracket from Below. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0291-3 Arctic Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0291-3 Coolant Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0291-4 Fuel Metering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0291-5 Fuel Metering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0291-6 Coolant Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0291-7 Arctic Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0291-8 Arctic Bracket from Below. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0291-8 lxxv

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Figure 11. Arctic Kit Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0291-9 Figure 12. Arctic Kit Heater Fuel Shutoff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0291-10 Arctic Kit Heater Hoses and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0292 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9.

Arctic Kit Heater Lower Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . 0292-2 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0292-3 Arctic Kit Heater Upper Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . 0292-4 Arctic Kit Heater Upper Coolant Routing. . . . . . . . . . . . . . . . . . . . . 0292-5 Arctic Kit Heater Upper Coolant Fitting. . . . . . . . . . . . . . . . . . . . . . . 0292-6 Arctic Kit Heater Upper Coolant Routing. . . . . . . . . . . . . . . . . . . . . 0292-7 Arctic Heater Upper Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . . . . 0292-7 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0292-8 Arctic Kit Heater Lower Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . 0292-9

Arctic Kit Fuel Metering Pump, Hose, and Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0293 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Arctic Kit Heater Fuel Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . 0293-3 Arctic Kit Heater Fuel Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . 0293-4 Arctic Kit Heater Fuel Metering Pump. . . . . . . . . . . . . . . . . . . . . . . 0293-5 Arctic Kit Heater Fuel Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0293-6 Arctic Kit Heater Fuel Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0293-7 Arctic Kit Heater Fuel Metering Pump. . . . . . . . . . . . . . . . . . . . . . . 0293-8 Arctic Kit Heater Fuel Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . 0293-9 Arctic Kit Heater Fuel Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . 0293-10

Using Jack Stands to Support Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0294 Figure 1. Figure 2. Figure 3. Figure 4.

Rear Support. Front Support. Rear Support. Front Support.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0294-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0294-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0294-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0294-5

Mechanical General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0295 Electrical General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0296 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.

Connector Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0296-2 Splicing Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0296-3 Ring Terminal Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0296-4 Military Connector Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0296-5 Weatherproof Connector - Female. . . . . . . . . . . . . . . . . . . . . . . . . . 0296-6 Female Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0296-7 Weatherproof Connector - Female. . . . . . . . . . . . . . . . . . . . . . . . . . 0296-7 Weatherproof Connector - Male. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0296-8 Male Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0296-8 Weatherproof Connector - Male. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0296-9

Preparation for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0297 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Tiedown Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-3 Floodlamp Wiring Harness and Connector. . . . . . . . . . . . . . . . . . . . 0297-6 Footlight Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-7 Quick Drop Valve Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-8 Lift Cylinder Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-9 lxxvi

TM 5-2410-241-23-1

TABLE OF CONTENTS - CONTINUED

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WP Sequence No.

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Page No.

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Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41. Figure 42. Figure 43. Figure 44. Figure 45.

Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-10 Lift Cylinder Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-11 Exhaust Pipe Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-12 Exhaust Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-12 Battery Cable Connections at Junction Block and Stud. . . . . . . . .0297-14 Arctic Kit Heater Battery Box Cover. . . . . . . . . . . . . . . . . . . . . . . .0297-15 Arctic Kit Heater Battery Connections. . . . . . . . . . . . . . . . . . . . . . .0297-16 Arctic Kit Heater Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-17 Wiring Harness and Washer Hoses. . . . . . . . . . . . . . . . . . . . . . . .0297-18 Headrest Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-18 Messenger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-19 Rifle Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-19 Cab Bolts at Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-20 Cab Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-20 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-21 Surround. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-21 Wiring Harness Connector and Angle Bracket. . . . . . . . . . . . . . . .0297-22 Cab Lift Eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-23 Cab Lift Eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-25 Wiring Harness Connector and Angle Bracket. . . . . . . . . . . . . . . .0297-26 Surround. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-26 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-27 Cab Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-28 Cab Bolts at Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-28 Rifle Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-29 Messenger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-29 Headrest Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-30 Wiring Harness and Washer Hoses. . . . . . . . . . . . . . . . . . . . . . . .0297-30 Arctic Kit Heater Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-32 Arctic Kit Heater Battery Connections. . . . . . . . . . . . . . . . . . . . . . .0297-33 Battery Cable Connections at Junction Block and Stud. . . . . . . . .0297-34 Arctic Kit Heater Battery Box Cover. . . . . . . . . . . . . . . . . . . . . . . .0297-35 Exhaust Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-36 Exhaust Pipe Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-37 Lift Cylinder Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-38 Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-39 Lift Cylinder Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-39 Quick Drop Valve Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-40 Floodlamp Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-40 Floodlamp Wiring Harness Connector. . . . . . . . . . . . . . . . . . . . . .0297-41

Torque Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0298 Figure 1. Figure 2. Figure 3. Figure 4.

Extension Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0298-2 Torque Wrench Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0298-2 Torque Calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0298-2 Measuring a Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0298-3

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TM 5-2410-241-23-1

Table 1. Table 2. Table 3. Table 4. Table 5. Table 6. Table 7. Table 8.

Torque Limits - SAE Standard Fasteners. . . . . . . . . . . . . . . . . . . . .0298-4 Torque Limits - Metric Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . .0298-5 37 Degree Flare Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0298-6 Straight Thread with O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0298-7 Split Flange Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0298-7 O-ring Face Seal End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0298-8 O-ring Boss End Fitting or Locknut. . . . . . . . . . . . . . . . . . . . . . . . . .0298-8 Pipe Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0298-9

Schematics Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0299 Chapter 5 - Supporting Information References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0300 Maintenance Allocation Chart (MAC) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0301 Maintenance Allocation Chart (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0302 Table 1. Table 2. Table 3.

Maintenance Allocation Chart (MAC) for D7R Series II Dozer, Type I with Winch and D7R Series II Dozer, Type II with Ripper.. . .0302-1 Tools and Test Equipment for the D7R Series II Dozer, Type I with Winch and D7R Series II Dozer, Type II with Ripper.. .0302-15 Remarks for the D7R Series II Dozer, Type I with Winch and D7R Series II Dozer, Type II with Ripper. . . . . . . . . . . . . . . . .0302-18

Expendable and Durable Items List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0303 Table 1.

Expendable and Durable Items for the D7R Series II Dozer, Type I with Winch and D7R Series II Dozer, Type II with Ripper . . .0303-2

Special Fabricated Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0304 Figure 1.

Pressure Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0304-1

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HOW TO USE THIS TECHNICAL MANUAL

-

This manual is designed to help you operate and maintain the D7R Dozer, Type I with Winch and Type II with Ripper. FEATURES OF THIS MANUAL 1. A Table of Contents is provided at the beginning of this manual. 2. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted in BOLD print as a visual aid.

WARNING A WARNING indicates a hazard which can result in death or serious injury to personnel.

CAUTION A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment.

NOTE A NOTE is a statement containing information that will make the procedure easier to perform. 3. Statements and words of particular importance are printed in CAPITAL LETTERS to create emphasis. 4. Instructions are located with illustrations that show the specific task on which the operator or mechanic is working. 5. Dashed leader lines used in illustrations indicate that called out items are not visible (i.e., they are located within the structure). Dashed leader lines in the Lubrication Chart indicate that lubrication is required on BOTH sides of the equipment. 6. Technical instructions include metric units in addition to standard units. A metric conversion chart is provided on the inside back cover. 7. An alphabetical index is provided at the end of the manual to assist in locating information not readily found in the Table of Contents. FOLLOW THESE GUIDELINES WHEN YOU USE THIS MANUAL 1. Read through this manual and become familiar with its contents before attempting to operate or maintain the dozer. 2. A Warning Summary is provided at the beginning of this manual and should be read before attempting to operate or maintain the dozer. 3. Within a chapter or work package, headings are used to help group the material to assist in quickly finding tasks. Read all preliminary information found at the beginning of each task.

lxxix/(lxxx-blank)

2 TM 5-2410-241-23-1

CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION

4

TM 5-2410-241-23-1

0001

FIELD MAINTENANCE 0 0 0 1

-

GENERAL INFORMATION

SCOPE

0001

1. Type of Manual. This manual is for use in field maintenance and troubleshooting on the Caterpillar D7R Series II Dozer, Type I with Winch and Type II with Ripper. 2. Model Numbers and Equipment Names. Tractor-Dozer, Self-Propelled Crawler, Diesel Engine Driven (DED), Model D7R Series II Type I with Winch or Model D7R Series II Type II with Ripper. 3. Purpose of Equipment. The D7R Series II Dozer is an earth-moving machine with a bulldozing attachment that cuts, moves, and grades material through forward motion of the machine. Additional attachments include a ripper and a towing winch, which are used to exert a push or pull force. Mission support role includes construction and maintenance of roads, airfields, hardstands, drainage, and site preparation for pipeline and river crossing.

MAINTENANCE FORMS, RECORDS, AND REPORTS

0001

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual; DA PAM 738751, Functional Users Manual for the Army Maintenance Management Systems - Aviation (TAMMS-A); or AR 700138, Army Logistics Readiness and Sustainability.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

0001

If your D7R Dozer needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don’t like about your equipment. Let us know why you don’t like the design or performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to go to http:// www.nslcptsmh.csd.disa.mil/webpqdr.htm. The Internet form lets you submit a Product Quality “Deficiency Report (PQDR). You may also submit your information using an SF 368, Product Quality Deficiency Report. You can send your SF 368 via e-mail, regular mail, or facsimile directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: RDTA-EN, MS 268, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is [email protected].

CORROSION PREVENTION AND CONTROL (CPC)

0001

1. CPC of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. 2. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking. 3. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking. 4. SF Form 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, TAMMS Users Manual.

0001-1

TM 5-2410-241-23-1

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

0001

0001

For destruction of Army materiel to prevent enemy use, refer to TM 750-244-3. PREPARATION FOR STORAGE AND SHIPMENT

0001

Refer to TM 5-2410-241-10 for information on preparation for storage and shipment, and preparation for transport. WARRANTY INFORMATION

0001

The D7R Dozer is warranted for six months. The warranty starts on the date found in block 23 of DA Form 2408-9, Equipment Control Record. Report all defects to your supervisor, who will take appropriate action. LIST OF ABBREVIATIONS/ACRONYMS

0001

NOTE Refer to ASME Y14.38-1999, Abbreviations and Acronyms, for standard abbreviations. ABBREVIATION/ACRONYM

DEFINITION

A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ampere AAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Association of American Railroads A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning BII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Issue Item B.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blackout C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Celsius CAGEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial and Government Entity Code CARC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chemical Agent Resistant Coating CBRN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chemical, Biological, Radiological, and Nuclear CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterclockwise CID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cubic Inch Displacement cm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Centimeter COEI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component of End Item CONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continental United States CPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosion Prevention and Control CPK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crew Protection Kit CPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cardiopulmonary Resuscitation CSF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Structural Frame CW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Current DED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diesel Engine Driven ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Module ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electronic Control Unit EIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Improvement Recommendation EMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electromagnetic Pulse EMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Monitoring System F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fahrenheit

0001-2

TM 5-2410-241-23-1

0001

FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Falling Object Protective Structure ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foot gal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gallon GIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gabarit International de Chargement HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heating, Ventilation, and Air Conditioning I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inch kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilogram km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometer kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilopascal km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers per Hour kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilowatt L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liter LASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lighter Aboard Ship lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound lb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound-Foot lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound-Inch LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Crystal Display LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Emitting Diode m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minute mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Millimeter MOPP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mission Oriented Protective Posture mph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Miles per Hour NATO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . North Atlantic Treaty Organization NBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuclear, Biological, and Chemical Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Newton-meter NSN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . National Stock Number OCONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside Continental United States PMCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive Maintenance Checks and Services PQDR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Quality Deficiency Report psi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pounds per Square Inch pt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pint ROC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rated Operating Capacity ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollover Protective Structure RO/RO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roll-on/Roll-off RPSTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair Parts and Special Tools List RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revolutions Per Minute SAHR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring Applied Hydraulically Released SAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supplemental Armor Set

0001-3

TM 5-2410-241-23-1

0001

ABBREVIATION/ACRONYM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DEFINITION SDDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surface Deployment and Distribution Command SEABEE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naval Construction Engineer, Sea Barge SPK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Purpose Kit TAMMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Army Maintenance Management System TOE/MTOE . . . . . . . . . . . . . Table of Organization and Equipment/Modified Table of Organization and Equipment U/M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unit of Measure UV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ultra Violet V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volt WCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty Claim Action WP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Work Package ELECTROMAGNETIC PULSE (EMP) EXPOSURE

0001

Components listed and designated as EMP susceptible may be damaged by EMP exposure. If the machine is exposed to an EMP incident, verify proper operation and repair as necessary THREAT OF CHEMICAL, BIOLOGICAL, RADIOLOGICAL, AND NUCLEAR (CBRN) CONTAMINATION

0001

1. The D7R Dozer incorporates a CARC painted exterior. Materials used in the machine are metal, rubber, plastic, fabric, and glass. 2. In the event of CBRN contamination of these surfaces, refer to FM 3-11.3, Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Contamination Avoidance and FM 3-11.5, Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination. COMMON TOOLS AND EQUIPMENT

0001

For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE), CTA 50-970, Expendable/Durable Items (Except: Medical, Class V, Repair Parts, and Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment, or CTA 8-100, Army Medical Department Expendable/Durable Items, as applicable to your unit. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

0001

Refer to the Repair Parts and Special Tools List (RPSTL) (TM 5-2410-241-24P) and to the Maintenance Allocation Chart (MAC) (WP 0302). REPAIR PARTS

0001

Repair parts are listed and illustrated in the Repair Parts and Special Tools List (RPSTL) (TM 5-2410-241-24P). SUPPLEMENTAL ARMOR SET (SAS)

0001

If equipped with an armor kit, it may be necessary to remove armor components during maintenance procedures. Refer to Supplemental Armor Set Technical Bulletin (TB 5-2410-241-13) for armor removal/install procedures and parts information. END OF WORK PACKAGE

0001-4

10 TM 5-2410-241-23-1

0002

FIELD MAINTENANCE 0 0 0

2

-

EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

0002

1. The D7R Dozer, classified as a tractor-dozer, is a self-propelled, fully tracked machine used for high production earth-moving. The D7R Dozer provides the Army with the capability of performing such tasks as land clearing, low and high bank sloping, backfilling, and rough and final grade work. The D7R Dozers are equipped with either a rear-mounted ripper or a rear-mounted winch. The ripper is designed for breaking up materials such as compacted soil. The winch is designed for pulling loads. Mission support role includes construction and maintenance of roads, airfields, hardstands, drainage, and site preparation for pipeline and river crossing. 2. The D7R Dozer has excellent maneuverability; fast, precise blade control without drift; superior visibility, convenience, and safety; as well as an advanced cab design featuring joysticks for control.

0002-1

TM 5-2410-241-23-1

0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

0002

Figure 1. D7R Dozer Left Side 1 of 2. KEY

COMPONENT

DESCRIPTION

1

Left Engine Access Door

Provides access to engine air filters, engine cooling system reservoir, engine oil dipstick, engine oil filler cap, ether starting aid cylinder, fuel system pump priming, fuel system water separator element, NATO Slave, and primary and secondary fuel filters, and arctic heater.

2

Grab Handle

Provides hand-hold for climbing onto and down from machine.

3

Door Handle

Used for opening and closing cab door.

4

Window Wiper

Provides means to improve operator visibility when view through glass is obscured by moisture, dust, or other substance.

5

Left Door Latch

Used to hold door in open position.

6

Left Rear Flood Light

Provides illumination of work area behind machine.

7

Left Fender Access Door

Provides access to pivot shaft oil reservoir and window washer fluid reservoir.

8

Battery Access Door

Provides access to batteries.

9

Grab Handle

Provides hand-hold for climbing onto and down from machine.

10

Step

Provides safe means of climbing up to and down from cab.

11

Left Engine Access Cover

Provides access to engine.

0002-2

0002

TM 5-2410-241-23-1

0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 2. D7R Dozer Left Side 2 of 2.

KEY

COMPONENT

DESCRIPTION

1

Left Front Flood Lights

Provides illumination of bulldozer work area.

2

Top Access Door

Provides access to radiator pressure cap.

3

Window Wiper

Provides means to improve operator visibility when view through glass is obscured by moisture, dust, or other substance.

4

Fuse Box Access Door

Provides access to fuse box.

5

Filler Tank Cap Filter and Strainer

Provides means to fill fuel tank.

6

Final Drive Oil Fill Plug

Provides means to check final drive oil level and to fill final drive with oil.

7

Battery Disconnect Switch Access Door

Provides access to battery disconnect switch.

8

Track

Used to propel machine.

9

Cab Door

Provides entry/exit point for operator.

10

Bulldozer Stabilizer

Hydraulic stabilizer for bulldozer.

0002-3

0002

TM 5-2410-241-23-1

0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 3. D7R Dozer Right Side 1 of 2.

KEY

COMPONENT

DESCRIPTION

1

Right Rear Flood Light

Provides illumination of work area behind machine.

2

Hydraulic Filler Neck and Cap

Provides means to fill hydraulic tank.

3

Right Fender Access Doors

Provides access to Hydraulic System Oil Sample, Transmission System Oil Level, Transmission System Oil Sample, and Transmission System Oil Filter.

4

Cab Door

Provides entry/exit point for operator.

5

Door Handle

Used for opening and closing cab door.

6

Exhaust Pipe

Directs exhaust fumes away from machine.

7

Right Front Flood Light

Provides illumination of bulldozer work area.

8

Right Engine Access Door

Provides access to engine oil filter, and engine oil sampling port.

9

Right Engine Access Cover

Provides access to engine and alternator belt.

10

Step

Provides safe means of climbing up to and down from cab.

11

Grab Handle

Provides hand-hold for climbing onto and down from machine.

0002-4

0002

TM 5-2410-241-23-1

0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 4. D7R Dozer Right Side 2 of 2.

KEY

COMPONENT

DESCRIPTION

1

Window Wiper

Provides means to improve operator visibility when view through glass is obscured by moisture, dust, or other substance.

2

Windshield Wiper

Provides means to improve operator visibility when view through glass is obscured by moisture, dust, or other substance.

3

Cabin Air Filter Cover

Provides means to change cabin air filter.

4

Bulldozer Lift Cylinders

Hydraulic cylinders used for raising and lowering bulldozer.

5

Bulldozer Blade

Hydraulically controlled attachment. Provides means for cutting, moving, and grading materials such as earth. Equipped with replaceable cutting edges.

6

Bulldozer Tilt Cylinder

Hydraulic cylinder used for tilting bulldozer.

7

Bulldozer C-Frame

Provides support and stability to bulldozer attachment.

8

Track

Used to propel machine.

9

Final Drive Oil Fill Plug

Provides means to check final drive oil level and to fill final drive with oil.

10

Right Door Latch

Used to hold door in open position.

0002-5

0002

TM 5-2410-241-23-1

0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 5. D7R Dozer with Ripper.

KEY

COMPONENT

0002

DESCRIPTION

1

Ripper Tilt Cylinders

Hydraulic cylinders used for adjusting ripper tilt.

2

Ripper Carriage

Provides support and stability to ripper attachment.

3

Ripper Tooth

Used for breaking up materials such as earth.

4

Ripper Shank

Provides support and stability to ripper tooth.

5

Ripper

Hydraulically controlled attachment. Provides means for breaking up materials such as earth.

6

Ripper Lift Cylinders

Hydraulic cylinders used for raising and lowering ripper.

0002-6

TM 5-2410-241-23-1

0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 6. D7R Dozer with Winch.

KEY

COMPONENT

DESCRIPTION

1

Winch

Hydraulically controlled attachment. Provides means for pulling loads.

2

Winch Cable

Used for attaching load to winch.

3

Winch Cable Drum

Used for reeling in and reeling out winch cable.

0002-7

0002

TM 5-2410-241-23-1

EQUIPMENT DATA

0002

0002

Weight With Blade and Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,000 lb (30,391 kg) With Blade, Ripper, and SAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71,500 lb (32,432 kg) Transport with Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57,500 lb (26,082 kg) With Blade and Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63,500 lb (28,803 kg) With Blade, Winch, and SAS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68,000 lb (30,844 kg) Transport with Winch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54,000 lb (24,494 kg) Length With Blade and Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 in. (7,239 mm) Without Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 in. (6,781 mm) With Blade and Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 in. (6,121 mm) Without Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 in. (5,817 mm) Width With Blade and Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 in. (3,683 mm) With Blade and Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 in. (3,683 mm) Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 in. (2,540 mm) Height With Blade and Ripper or Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 in. (3,404 mm) With Blade and Ripper or Winch and SAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 in. (3,531 mm) Transport (exhaust pipe, cab upper, and cab doors removed) . . . . . . . . . . . . . . . . . . . . . . . 112 in. (2,845 mm) Military Load Classification Without Armor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 With Armor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Grade Ascending Ability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60% Grade Descending Ability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60% Tilt Dozing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 degrees Drawbar Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105,820 lb (48,000 kg) Fording Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 in. (76 cm) Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4 in. (417 mm) Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 psi (75.84 kPa) Maximum Speed Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.55 mph (10.5 km/h) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.44 mph (13.5 km/h)

0002-8

TM 5-2410-241-23-1

0002

Engine Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caterpillar Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cat 3176C with Electronic Unit Injection Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 HP Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629 cu. in. (10.3 L) Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Injection Cooling System (thermostat opening temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 to 180°F (69 to 82°C) Cooling System (thermostat completely open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197°F (92°C) Powertrain Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caterpillar Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronically Controlled Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Forward / 3 Reverse Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multiple disc, oil bathed, spring applied/hydraulically released Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrically activated, spring applied/hydraulically released Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pivot Capacities Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126.5 gal. (479 L) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.8 gal. (75 L) Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 gal. (31 L) Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 gal. (178 L) Final Drive (each) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 gal. (12.8 L) Roller Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 gal. (24.6 L) Pivot Shaft Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 gal. (1.9 L) Attachment Hydraulic System (tank only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3 gal. (54.1 L) Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 gal. (15 L) Electrical System Batteries Quantity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V dc System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V dc Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 MT Alternator Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 amps Arctic Heater Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V dc System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V dc Bulldozer (Blade) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7SU Digging Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.7 in. (527 mm)

0002-9

TM 5-2410-241-23-1

0002

Ripper Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caterpillar Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,431 lb (3,370 kg) Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic cylinders Number of Shanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Winch Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PACCAR Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H110 Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cable Capacity (1 in./25 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 ft (53.3 m) END OF WORK PACKAGE

0002-10

2 TM 5-2410-241-23-1

0003

FIELD MAINTENANCE 0 0 0 3

-

THEORY OF OPERATION: INTRODUCTION

INTRODUCTION

0003

This work package provides a brief functional description of the major systems and components found on the D7R Dozer. The D7R Dozer is an earth-moving machine with a bulldozing attachment that cuts, moves, and grades material through forward motion of the machine. A 10.3L diesel engine powers the D7R Dozer. Additional implements for the machine include a hydraulically operated ripper and a towing winch. A dozer will have only one implement, not both. Refer to the Theory of Operation work packages for information about the following systems: ENGINE AND FUEL •

The 3176C engine has an in-line six cylinder arrangement with a bore of 4.92 inch (125.0 mm) and a stroke of 5.51 inch (140.0 mm). The displacement is 629 cu. in. (10.3 L). The engine has a firing order sequence of: 1, 5, 3, 6, 2, and 4. The rotation of the engine is counterclockwise when the engine is viewed from the flywheel end. The engine utilizes a turbocharger and a water jacket aftercooler. The following engine components are described: Cylinder block, Pistons, Rings, Connecting Rods, Crankshaft, Camshaft, Vibration damper, and Rear power take-off (RPTO). The 3176C engine incorporates a high pressure electronic unit injector system and an electronic control system. The features enhance engine speed control, cold starting capabilities, and lower the smoke level for emissions under all operating conditions. The Electronic Unit Injector system eliminates many of the mechanical components that are traditionally used in the fuel injector assembly. The Electronic Unit Injector (EUI) provides increased control of the timing and the fuel air mixture. The timing advance is achieved by precise control of the fuel injection timing. Engine rpm is controlled by adjusting the injection duration. A special pulse wheel provides information to the engine Electronic Control Module (ECM) for detection of cylinder position and engine rpm. The engine has built-in diagnostics in order to ensure that all of the components are operating properly. In the event of a system component failure, the operator will be alerted to the condition by a check engine light, located on the dashboard. An electronic service tool can be used to read the numerical code of the faulty component or condition. Intermittent faults are logged and stored in memory. The fuel system is subdivided into the following systems: electronic unit injector, low pressure fuel, electronic controls, and injector actuation.

AIR INLET AND EXHAUST •

The components of the air inlet and exhaust system control the quality of air and the amount of air that is available for combustion. The major components of the air inlet and exhaust system are: Air cleaner, Turbocharger, Aftercooler, Cylinder head, Valves and valve system components, Piston and cylinder, and Exhaust manifold.

LUBRICATION •

The lubrication system supplies 230 °F (110 °C) filtered oil at approximately 40 psi (275 kPa) at rated engine operating conditions. The engine oil pump is mounted to the back of the front gear train on the lower right hand side of the engine.

0003-1

TM 5-2410-241-23-1

0003

INTRODUCTION – CONTINUED COOLING •

The water pump is driven by a gear and is located on the right hand side of the engine. The water pump supplies the coolant for the engine cooling system. The coolant is supplied to the following components: Engine oil cooler, Cylinder head, Cylinder liner, and Aftercooler. The aftercooler has its own water pump.

ELECTRICAL •

This work package addresses the following systems: Engine Electrical, Powertrain Control ECM, and Engine Electronic Control.

•

The engine electrical system addresses the following topics: Grounding practices, Charging, and Starting.

•

The powertrain control system addresses the following controls and operations: Electronic Clutch Pressure control, Transmission Shifting operation, Electronic Brake control, Auto shift operation, and Electronic Hydraulic Implement Control.

•

The engine electronic control system is integrally designed into the engine’s fuel system and engine’s air inlet and exhaust system in order to electronically control the fuel delivery and the injection timing.

PRIMARY POWERTRAIN •

The engine is the source of the mechanical power. Power flows from the engine to tracks through the powertrain: torque divider, drive shaft, power shift transmission, bevel and transfer gears, steering differential and brake, planetary gears and brake, and final drives.

•

This work package addresses the following systems: Powertrain Hydraulics, Powertrain Electronic Controls, Transmission, and Transmission Hydraulic Controls.

FINAL DRIVE AND UNDERCARRIAGE •

The final drives take power from the outer axle shafts and sends the power to the tracks. The final drives give a double reduction through the planetary gears.

•

The undercarriage of the machine is not suspended. Pivot shafts connect the roller frames at the rear of the machine.

•

This work package addresses the following: Standard undercarriage arrangements, Pivot shaft, Equalizer bar, Track roller frame, and Track.

IMPLEMENT AND STEERING HYDRAULIC •

The machine is equipped with an implement system that is controlled by the operator and hydraulically actuated. The hydraulic system includes a bulldozer and a ripper or a winch.

•

This work package addresses the following: Hydraulic Tank, Oil Cooler, Piston Pumps, and Control Valves for both Implements and Steering systems.

AIR CONDITIONING AND HEATING •

The six components of the manual orifice tube system are the following: orifice tube, accumulator, compressor, condenser coil, evaporator coil, and in-line dryer.

•

The heating system uses the coolant from the engine cooling system to heat the operator compartment.

END OF WORK PACKAGE

0003-2

14 TM 5-2410-241-23-1

0004

FIELD MAINTENANCE 0 0 0 4

-

THEORY OF OPERATION: ENGINE AND FUEL

ENGINE

0004

Cylinder Block

0004

The cylinder block is a unique design with a deep counterbore that supports the cylinder liner. The cylinder block also forms the coolant jacket. Two oil manifolds are provided in the cylinder block for engine lubrication. The manifold on the lower right side of the cylinder block provides oil to the following components: •

Piston cooling jets

•

Crankshaft bearings

•

Oil filter base

The manifold on the upper left side of the cylinder block provides oil to the following components: •

Camshaft bearings

•

Valve mechanism

The manifold on the right supplies oil to the manifold on the left. The oil travels through the cut above the number one main bearing and the cut above the number four main bearing. Cylinder liners (Figure 1, Item 1) are seated on a ridge (Figure 1, Item 4) in the middle of the cylinder wall between the crankcase and the coolant jacket. The ridge is created by a counterbore in the cylinder block. The cylinder liners have a lip (Figure 1, Item 2), which rests on the ridge. The seals of the coolant jacket are located in the upper regions and middle regions of the cylinder liners. The lower barrier uses a D-ring seal (Figure 1, Item 3) that is located above the seating surface of the cylinder liner. The upper barrier is the head gasket, which is above the coolant jacket. The cylinder block has seven main bearings in order to support the crankshaft. The main bearing caps are fastened to the cylinder block with two bolts per cap.

Figure 1. Cylinder Block.

0004-1

0004

TM 5-2410-241-23-1

0004

ENGINE – CONTINUED Pistons, Rings, and Connecting Rods

0004

The piston is a two-piece articulated assembly. The piston has a forged steel crown (Figure 2, Item 2) and a forged aluminum skirt (Figure 2, Item 6). Both parts are retained by the piston pin to the small end of the connecting rod. Each piston has three rings: •

Compression ring

•

Intermediate ring

•

Oil ring

Rings (Figure 2, Item 1, 7, and 8) are located in grooves in steel crown (Figure 2, Item 2). The rings seal the crankcase from the combustion gases and provide control of the engine oil. The design of compression ring (Figure 2, Item 1) is a barrel face with a plasma face coating. The design of intermediate ring (Figure 2, Item 8) is a tapered shape and a chrome finish. Oil ring (Figure 2, Item 7) is double railed with a coil spring expander and has a ground profile and a chrome finish. Connecting rod (Figure 2, Item 5) is a conventional design. The cap is fastened to the rod by two bolts (Figure 2, Item 4) that are threaded into the rod. Each side of the small end of the connecting rod (Figure 2, Item 3) is machined at an angle of 12 degrees in order to fit within the piston cavity. This allows a larger surface area on the piston, and connecting rod in order to minimize bearing load.

Figure 2. Piston, Rings, Connecting Rods.

0004-2

0004

TM 5-2410-241-23-1

0004

ENGINE – CONTINUED Crankshaft

0004

The crankshaft converts the linear motion of the pistons into rotational motion. The crankshaft drives a group of gears (front gear train) on the front of the engine. The front gear train provides power for the following components: •

Camshaft

•

Water pump

•

Engine oil pump

•

Fuel transfer pump

•

Accessory drive

The crankshaft is held in place by seven main bearings. The oil holes and the oil grooves in the shell of the upper bearing supply oil to the connecting rod bearings. The oil holes for the connecting rod bearings are located at the following main bearing journals: 2, 3, 5, and 6. Hydrodynamic seals are used at both ends of the crankshaft to control oil leakage. The hydrodynamic grooves in the seal lip move lubrication oil back into the crankcase as the crankshaft turns. The front seal is located in the front housing. The rear seal is installed in the flywheel housing. Camshaft

0004

The camshaft (Figure 3, Item 1) has three lobes at each cylinder in order to operate the unit injector, the exhaust valves, and the inlet valves. Seven bearings support the camshaft. The camshaft is driven by an idler gear that is turned by the crankshaft in the front gear train. Each bearing journal is lubricated from the oil manifold in the cylinder block. A thrust pin that is located at the rear of the block positions the camshaft through a circumferential groove. The groove is machined at the rear of the camshaft. Timing of the camshaft is accomplished by aligning marks on the crankshaft gear, idler gear, and camshaft gear with each other.

Figure 3. Camshaft.

0004-3

0004

TM 5-2410-241-23-1

0004

ENGINE – CONTINUED Vibration Damper

0004

The force from combustion in the cylinders and from driveline components will cause the crankshaft to twist. This is called torsional vibration. If the vibration is too great, the crankshaft will be damaged. Driveline components can excite torsional stress, which could cause damage to components. The vibration damper limits the torsional vibrations to an acceptable amount in order to prevent damage to the crankshaft. The viscous vibration damper is installed on the front of the crankshaft and consists of a weight in a case. The space between the weight and the case is filled with a viscous fluid. The movement of the weight in the case limits the torsional vibration. Rear Power Take-Off (RPTO)

0004

The Rear Power Take-Off (RPTO) is an integral part of the flywheel housing. The RPTO provides continuous live power through the following direct drive gears: •

Crankshaft gear

•

Idler gear

•

Output shaft gear

These gears are driven off the rear of the crankshaft. FUEL SYSTEM

0004

There are five major components of the Electronic Unit Injector (EUI) fuel system: •

Electronic Unit Injectors

•

Fuel Transfer Pump

•

Engine Electronic Control Module (ECM)

•

Sensors

•

Actuators

The electronic unit injectors produce fuel injection pressures up to 30,000 psi (207,000 kPa) and fire up to 19 times per second at rated speed. The fuel transfer pump supplies the injectors by drawing fuel from the tank and by pressurizing the fuel between 60 and 125 psi (414 and 862 kPa). The engine ECM is a powerful computer, which controls all major engine functions. Sensors are electronic devices, which monitor engine performance parameters, which include measurement of pressure, temperature, and speed. This information is sent to the engine ECM via a signal voltage. Actuators are electronic devices, which use electronic currents from the engine ECM to change engine performance. An example of an actuator is an injector solenoid.

0004-4

TM 5-2410-241-23-1

Figure 4. Fuel System.

0004-5

0004

0004

TM 5-2410-241-23-1

0004

FUEL SYSTEM – CONTINUED Low Pressure Fuel System

0004

The low pressure fuel system supplies fuel from the fuel tank to the injectors and has three basic functions. It supplies fuel to: •

The injectors for combustion

•

The injectors for cooling

•

The fuel system in order to remove air

The major parts of the low pressure fuel system are: •

Fuel tank

•

Fuel transfer lines

•

Primary fuel filter or water separator

•

Fuel transfer pump

•

Secondary fuel filter

•

Fuel priming pump

•

Fuel pressure regulator valve

The electronic unit injectors, the engine ECM, sensors, and actuators are also part of the low pressure fuel system. In the low pressure fuel system, the fuel is pulled from the fuel tank to the primary fuel filter water separator. The primary fuel filter removes large debris from the fuel before the fuel flows into the transfer pump. The fuel transfer pump is a gear pump that contains a pressure relief valve. Fuel flows from the outlet port of the transfer pump to the secondary fuel filter. The 2 micron secondary fuel filter removes small abrasive contaminants from the fuel system, which can cause damage to the unit injectors. The primary fuel filter base contains a hand-operated fuel priming pump, which removes air from the system when a fuel filter has been changed or a unit injector has been changed. The priming pump pulls fuel from the tank to the transfer pump. The transfer pump pushes fuel through the secondary fuel filter to the supply passage in the cylinder head and back to the tank. The fuel pressure regulator consists of a check valve that is spring loaded. The pressure relief valve opens at approximately 60 to 125 psi (414 to 862 kPa). When the engine is off and the fuel pressure drops below 60 psi, the check valve closes in order to prevent the fuel in the cylinder head from draining back into the fuel tank. Retaining the fuel in the head maintains a supply of fuel for the injectors during start-up. The engine ECM controls major engine functions. Sensors are electronic devices that monitor engine performance parameters. The pressure sensor, the temperature sensor, and the speed sensor provide information to the engine ECM by a signal voltage. Actuators are electronic devices, which use electrical currents from the engine ECM to change engine performance. An example of an actuator is an injector solenoid.

0004-6

TM 5-2410-241-23-1

0004

FUEL SYSTEM – CONTINUED

Figure 5. Low Fuel Pressure.

0004-7

0004

TM 5-2410-241-23-1

0004

FUEL SYSTEM – CONTINUED Engine Electronic Control System

0004

The engine electronic control system provides complete electronic control of all engine functions. The engine electronic control system consists of the following three types of components: input, control, and output. Sensors monitor engine operating conditions. This information is sent to the engine Electronic Control Module (ECM), which has three main functions. The engine ECM provides power for the engine electronics and monitors input signals from the engine sensors. The engine ECM also acts as a governor to control engine rpm. The engine ECM stores active faults, logged faults, and logged events. The Personality Module is the software in the engine ECM, which contains the specific maps that define power, torque, and rpm of the engine. The engine ECM sends electrical current to the output components in order to control engine operation. The engine ECM has the following connectors: two 70-pin harness connectors, one engine harness connector, and one vehicle harness connector. The vehicle harness connects the engine ECM to the engine control portion of the vehicle harness. The following features are part of the engine electronic control system: •

Cold start strategy

•

Oil pressure

•

Coolant temperature warning indicator

•

Automatic altitude compensation

•

Variable injection timing

•

Electronic engine speed governing

These features result in: precise engine speed control, very little smoke, faster cold starting, and built-in engine protection. The engine ECM consists of the following two main components: the electronic control module and the personality module. The engine ECM is a computer and the personality module is the software for the computer. The personality module contains the operating maps, which define the following characteristics of the engine: •

Horsepower

•

Torque curves

•

RPM

•

Other characteristics

The engine ECM, the personality module, the sensors, and the unit injectors work together in order to control the engine, but can not control the engine alone. The engine ECM determines a desired rpm based on the following criteria: •

Throttle signal

•

Certain diagnostic codes

•

Vehicle speed signal

The engine ECM maintains the desired engine rpm by sensing the actual engine rpm and then calculates the amount of fuel needed to be injected in order to achieve the desired rpm.

0004-8

TM 5-2410-241-23-1

0004

FUEL SYSTEM – CONTINUED Fuel Timing and Delivery

0004

The engine ECM controls the injected fuel by varying the signals to the unit injectors. The unit injectors inject fuel ONLY if the unit injector solenoid is energized. The engine ECM sends a 90-volt signal to the solenoid to energize it. By controlling the timing of the 90-volt signal, the engine ECM controls injection timing. By controlling the duration of the 90-volt signal, the engine ECM controls the amount of injected fuel. Injection timing is determined by engine rpm and other engine data. The engine ECM senses the top center position of cylinder number 1 from the signal that is provided by the engine timing sensor. The engine ECM decides when the injection should occur relative to the top center position and provides the signal to the unit injector at the desired time. Injector Actuation System

0004

The unit injector pressurizes the fuel. The correct amount of fuel is then injected into the cylinder block at precise times. The engine ECM determines the injection timing and the amount of fuel that is delivered. The unit injector is operated by a camshaft lobe and a rocker arm. The camshaft has three camshaft lobes for each cylinder. Two lobes operate the inlet and exhaust valves, and the other lobe operates the unit injector mechanism. Force is transferred from the unit injector lobe on the camshaft through the lifter to the pushrod (Figure 6, Item 4). The force of the pushrod is transferred through rocker arm assembly (Figure 6, Item 3) and to the top of the unit injector (Figure 6, Item 1). The adjusting nut (Figure 6, Item 2) allows adjustment of the unit injector.

Figure 6. Unit Injector Mechanism.

0004-9

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TM 5-2410-241-23-1

0004

FUEL SYSTEM – CONTINUED Operation of the Electronic Unit Injector

0004

The operation of the Electronic Unit Injector (EUI) consists of the following four stages: pre-injection, injection, end of injection, and fill. Unit injectors use a plunger and barrel to pump high pressure fuel into the combustion chamber. Components of the injector include the tappet (Figure 7, Item 2), the plunger (Figure 7, Item 3), the barrel (Figure 7, Item 4) and nozzle assembly (Figure 7, Item 5). Components of the nozzle assembly include the spring, the nozzle check, and a nozzle tip. The cartridge valve is made up of the following components: solenoid (Figure 7, Item 1), armature, poppet valve, and poppet spring. The injector is mounted in an injector bore in the cylinder head, which has an integral fuel supply passage. The injector sleeve separates the injector from the engine coolant in the water jacket. The engine uses a stainless steel sleeve, which fits into the cylinder head with a light press fit.

Figure 7. Unit Injector.

0004-10

0004

TM 5-2410-241-23-1

0004

FUEL SYSTEM – CONTINUED Pre-injection

0004

Pre-injection metering starts with the injector plunger and the injector tappet at the top of the fuel injection stroke. When the plunger cavity is full of fuel, the poppet valve is in the open position and the nozzle check is in the open position. Fuel leaves the plunger cavity when the rocker arm pushes down on the tappet and the plunger. Fuel flow that is blocked by the closed nozzle check valve flows past the open poppet valve to the fuel supply passage in the cylinder head. If the solenoid is energized, the poppet valve remains open and the fuel from the plunger cavity continues flowing into the fuel supply passage.

Figure 8. Pre-Injection.

0004-11

0004

TM 5-2410-241-23-1

0004

FUEL SYSTEM – CONTINUED Injection

0004

To start injection, the engine ECM sends a current to the solenoid on the cartridge valve. The solenoid creates a magnetic field, which attracts the armature. When the solenoid is energized, the armature assembly will lift the poppet valve so the poppet valve contacts the poppet seat. This is the closed position. Once the poppet valve closes, the flow path for the fuel that is leaving the plunger cavity is blocked. The plunger continues to push fuel from the plunger cavity and the fuel pressure builds up. When the fuel pressure reaches approximately 5,000 psi (34,474 kPa), the force of the high pressure fuel overcomes the spring force. This holds the nozzle check in the closed position. The nozzle check moves off the nozzle seat and the fuel flows out of the injector tip. This is the start of injection.

Figure 9. Injection.

0004-12

0004

TM 5-2410-241-23-1

0004

FUEL SYSTEM – CONTINUED End of Injection

0004

Injection is continuous while the injector plunger moves in a downward motion and the energized solenoid holds the poppet valve closed. When injection pressure is no longer required, the engine ECM stops current flow to the solenoid. When the current flow to the solenoid stops, the poppet valve opens. The poppet valve is opened by the fuel injector spring and the fuel pressure. High pressure fuel can now flow around the open poppet valve and into the fuel supply passage. This results in a rapid drop in injection pressure. When the injection pressure drops to approximately 3,500 psi (24,132 kPa), the nozzle check closes and injection stops. This is the end of injection.

Figure 10. End of Injection.

0004-13

0004

TM 5-2410-241-23-1

0004

FUEL SYSTEM – CONTINUED Fill

0004

When the plunger reaches the bottom of the barrel, fuel is no longer forced from the plunger cavity. The plunger is pulled up by the tappet and the tappet spring. The upward movement of the plunger causes the pressure in the plunger cavity to drop below fuel supply pressure. Fuel flows from the fuel supply passage around the open poppet and into the plunger cavity as the plunger travels upward. When the plunger reaches the top of the stroke, the plunger cavity is full of fuel and fuel flow into the plunger cavity stops. This is the beginning of pre-injection.

Figure 11. Fill. END OF WORK PACKAGE

0004-14

0004

6 TM 5-2410-241-23-1

FIELD MAINTENANCE 0 0 0 5

THEORY OF OPERATION: AIR INLET AND EXHAUST

0005-1

0005

-

TM 5-2410-241-23-1

AIR INLET AND EXHAUST SYSTEM

0005

0005

The components of the air inlet and exhaust system control the quality of air and the amount of air that is available for combustion. The components of the air inlet and exhaust system are: •

Air cleaner

•

Turbocharger

•

Aftercooler

•

Cylinder head

•

Valves and valve system components

•

Piston and cylinder

•

Exhaust manifold

Inlet air is pulled through the air cleaner into the air inlet (Figure 1, Item 2) by the turbocharger compressor wheel (Figure 1, Item 3). The air is compressed and heated to about 300°F (150°C) before the air is forced to the aftercooler (Figure 1, Item 1). As the air flows through the aftercooler the temperature of the compressed air lowers to about 180°F (82°C). Cooling of the inlet air increases combustion efficiency. Increased combustion efficiency helps achieve the following benefits: •

Lower fuel consumption

•

Increased horsepower output

The aftercooler (Figure 1, Item 1) is a water jacket aftercooler. This cools the turbocharged inlet air with the engine coolant. From the aftercooler, air is forced into the inlet manifold (Figure 1, Item 7). Air flow from the inlet chambers into the cylinders is controlled by inlet valves (Figure 1, Item 9). There are two inlet valves and two exhaust valves (Figure 1, Item 8) for each cylinder. The inlet valves open when the piston moves down on the intake stroke. When the inlet valves open, cooled compressed air from the inlet port is pulled into the cylinder. The inlet valves close and the piston begins to move up on the compression stroke. The air in the cylinder is compressed. When the piston is near the top of the compression stroke, fuel is injected into the cylinder. The fuel mixes with the air and combustion starts. During the power stroke, the combustion force pushes the piston downward. The exhaust valves open and the exhaust gases are pushed through the exhaust port into the exhaust manifold (Figure 1, Item 6) as the piston rises on the exhaust stroke. After the exhaust stroke, the exhaust valves close and the cycle starts again. The complete cycle consists of four strokes: •

Inlet

•

Compression

•

Power

•

Exhaust

Exhaust gases from exhaust manifold (Figure 1, Item 6) enter the turbine side of the turbocharger in order to turn turbocharger turbine wheel (Figure 1, Item 4). The turbine wheel is connected to the shaft that drives the compressor wheel. Exhaust gases from the turbocharger pass through exhaust outlet (Figure 1, Item 5), a muffler and an exhaust stack.

0005-2

TM 5-2410-241-23-1

0005

AIR INLET AND EXHAUST SYSTEM – CONTINUED

Figure 1. Air Inlet and Exhaust System.

0005-3

0005

TM 5-2410-241-23-1

0005

AIR INLET AND EXHAUST SYSTEM – CONTINUED Turbocharger

0005

The turbocharger is installed on the center section of the exhaust manifold. All the exhaust gases from the engine go through the turbocharger. The compressor side of the turbocharger is connected to the aftercooler by a pipe. The exhaust gases enter turbine housing (Figure 2, Item 6) through exhaust inlet (Figure 2, Item 9). The exhaust gases then push the blades of turbine wheel (Figure 2, Item 7) and exit the exhaust outlet (Figure 2, Item 8). The turbine wheel is connected by a shaft to compressor wheel (Figure 2, Item 2). Clean air from the air cleaner is pulled through the compressor housing air inlet (Figure 2, Item 1) by the rotation of compressor wheel (Figure 2, Item 2). The action of the compressor wheel blades causes a compression of the inlet air. This compression gives the engine more power by allowing the engine to burn more air and more fuel during combustion. When the load on the engine increases, more fuel is injected into the cylinders. The combustion of this additional fuel produces more exhaust gases. The additional exhaust gases cause the turbine and the compressor wheels of the turbocharger to turn faster. As the compressor wheel turns faster, more air is forced into the cylinders. The increased flow of air gives the engine more power by allowing the engine to burn the additional fuel with greater efficiency. Bearings (Figure 2, Items 3 and 5) for the turbocharger use engine oil under pressure for lubrication. The oil comes in through the oil inlet port (Figure 2, Item 4). The oil then goes through passages in the center section in order to lubricate the bearings. Oil from the turbocharger goes out through the oil outlet port (Figure 2, Item 10) in the bottom of the center section. The oil then goes back to the engine lubrication system.

Figure 2. Turbocharger.

0005-4

0005

TM 5-2410-241-23-1

0005

AIR INLET AND EXHAUST SYSTEM – CONTINUED Valves and Valve System Components

0005

The valve system components control the flow of inlet air into the cylinders and exhaust gases out of the cylinders during engine operation. The crankshaft gear drives the camshaft gear through an idler gear. Camshaft (Figure 3, Item 6) must be timed to the crankshaft in order to get the correct relation between the piston movement and the valve movement. The camshaft has three camshaft lobes for each cylinder. Two lobes operate the inlet and exhaust valves, and one operates the unit injector mechanism. As the camshaft turns, the camshaft lobes cause a lifter (Figure 3, Item 5) to move a pushrod (Figure 3, Item 4) up and down. Upward movement of the pushrod against the rocker arm (Figure 3, Item 3) results in downward movement of bridge (Figure 3, Item 1) and opening of the valves (Figure 3, Item 8). Each cylinder has two inlet valves, two exhaust valves, and four valve guides (Figure 3, Item 7). Valve springs (Figure 3, Item 9) close the valves when the lifters move downward. Valve rotators (Figure 3, Item 2) cause the valves to rotate while the engine is running. The rotation of the valves keeps the carbon deposits on the valves to a minimum. Also, the rotation gives the valves longer service life.

Figure 3. Valve System Components. END OF WORK PACKAGE

0005-5/(6 blank)

0005

6 TM 5-2410-241-23-1

FIELD MAINTENANCE 0 0 0 6

THEORY OF OPERATION: LUBRICATION

0006-1

0006

-

TM 5-2410-241-23-1

0006

LUBRICATION SYSTEM

0006

Oil Flow Through Lubrication System

0006

Refer to Table 1.

0006

The lubrication system (Figure 1) supplies 230°F (110°C) filtered oil at approximately 40 psi (276 kPa) at rated engine operating conditions. Oil pump bypass valve is controlled by the engine oil manifold pressure, rather than the oil pump pressure. The engine oil manifold pressure is independent of the pressure drop that is caused by the engine oil filter and the engine oil cooler. Oil cooler bypass valve maintains the engine oil temperature at 230°F (110°C). High pressure relief valve, which is located in the filter base, protects the filters and other components during cold starts. The opening pressure of the high pressure relief valve is 100 psi (690 kPa). The bypass housing diverts five percent of the oil to the oil sump through the bypass valve. The remaining oil continues through the filter and oil filter bypass valve. The opening pressure of the oil filter bypass valve is 25 psi (172 kPa). Engine oil pressure sensor is part of the engine protection system. The turbocharger cartridge bearings are lubricated by an oil supply line from the main oil gallery, and oil drain line returns the oil flow to the sump.

0006-2

TM 5-2410-241-23-1

0006

LUBRICATION SYSTEM – CONTINUED

Figure 1. Lubrication System Schematic. Table 1. Lubrication System. Key Component 1

Piston cooling jets

9

Oil pump bypass valve

2

Main oil gallery in cylinder block

10

High pressure relief valve

3

Engine oil pressure sensor

11

Oil pan sump

4

Oil flow to valve mechanism

12

Engine oil cooler

5

Camshaft journals

13

Oil cooler bypass valve

6

Main bearings

14

Bypass housing

7

Signal line

15

Engine oil filter

8

Engine oil pump

16

Oil filter bypass valve

0006-3

0006

0006

TM 5-2410-241-23-1

0006

LUBRICATION SYSTEM – CONTINUED Oil Flow Through Filter Housing to Engine

0006

Refer to Table 2.

0006

The engine oil pump is mounted to the back of the front gear train on the lower right hand side of the engine. The engine oil pump is driven by an idler gear from the crankshaft gear. Oil is pulled from the sump to the oil pump and pushed from the oil pump through the bypass valve on the way to the engine oil cooler. The bypass valve controls the oil pressure from the engine oil pump. The engine oil pump can supply excess oil for the lubricating system. When this situation is present, the oil pressure increases, and the bypass valve opens allowing the excess oil to return to the sump. High pressure relief valve regulates high pressure in the system by allowing the oil to return to the sump when the oil pressure reaches 100 psi (690 kPa). The oil then flows through the engine oil cooler. The engine oil cooler uses engine coolant in order to cool the oil. The oil cooler bypass valve directs the oil flow through the engine oil cooler by two different methods. Oil cooler bypass valve will close partially when the oil temperature exceeds 212°F to 217°F (100°C to 103°C). This will direct some of the oil through the engine oil cooler. If the oil reaches a temperature of 260°F (127°C), the bypass valve will close fully. This will direct all of the oil flow through the engine oil cooler.

0006-4

TM 5-2410-241-23-1

0006

LUBRICATION SYSTEM – CONTINUED

Figure 2. Oil Flow through Filter Housing to Engine. Table 2. Oil Flow through Filter Housing to Engine. Key Component/Flow 1

Oil flow to the piston, piston cooling jets, valve mechanism, camshaft journals, crankshaft main bearings, and the turbocharger

10

Oil pump bypass valve

2

Main oil gallery in cylinder block

11

Oil cooler bypass valve

3

Oil drains to sump

12

Passage to engine oil filter

4

Cylinder block

13

Oil filter bypass valve

5

High pressure relief valve

14

Bypassed oil

6

Oil from engine oil pump

15

Filtered oil

7

Oil to engine oil cooler

16

Passage to engine oil filter

8

Passages to bypass housing

17

Oil from engine oil cooler

9

Oil bypass drain

0006-5

0006

0006

TM 5-2410-241-23-1

0006

LUBRICATION SYSTEM – CONTINUED The oil bypass valve is normally closed if the pressure across the engine oil cooler is less than 22 ± 3 psi (155 ± 21 kPa). This will direct the oil through the engine oil cooler. Approximately five percent of the oil flow is directed through the orifice of a passage that leads to bypass housing. The oil flows through the bypass housing and to the engine oil sump. The main oil flow flows toward the engine oil filter. When the oil pressure differential across oil filter bypass valve reaches 25 psi (172 kPa), the valve allows the oil to bypass the engine oil filter in order to lubricate the engine parts. The bypass valve provides immediate lubrication to the engine components when there is a restriction in the engine oil filter due to the following conditions: •

Cold oil with high viscosity

•

Plugged engine oil filter

Filtered oil flows through the main oil gallery in the cylinder block to the following components: •

Piston cooling jets

•

Valve mechanism

•

Camshaft bearings

•

Crankshaft main bearings

•

Turbocharger

An oil cooling chamber is formed by the following pieces: the lip forge at the top of the skirt of the piston and the cavity behind the ring grooves in the crown. Oil flow from the piston cooling jet enters the cooling chamber through a drilled passage in the skirt. The oil returns to the sump through the clearance gap between the crown and the skirt. Four holes that are drilled in the piston oil ring groove to the interior of the piston drain excess oil from the oil ring. The breather assembly allows engine blowby to escape from the crankcase. The engine blowby is discharged into the atmosphere through a hose. This prevents pressure from building up that could cause seals or gaskets to leak. END OF WORK PACKAGE

0006-6

4 TM 5-2410-241-23-1

FIELD MAINTENANCE 0 0 0 7

THEORY OF OPERATION: COOLING

0007-1

0007

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TM 5-2410-241-23-1

0007

COOLING SYSTEM

0007

Engine Cooling System

0007

The engine cooling system consists of the following components: •

Transmission oil cooler

•

Engine oil cooler

•

Cylinder head

•

Cylinder liner

•

Temperature regulator (thermostat)

The gear driven water pump (Figure 1, Item 7) is located on the right hand side of the front timing gear housing. The water pump pulls the antifreeze coolant solution from the bottom of radiator (Figure 1, Item 5). The rotation of the water pump’s impeller creates coolant flow within the cooling system. The water pump impeller is rotated at 1.17 times the engine speed by an idler gear, which is turned by the crankshaft gear. The water pump shaft is supported by two ball bearings. One ball bearing is located in the water pump housing; the other ball bearing is located in the front timing gear housing. The water pump impeller face is open. The impeller vane is radial. The impeller is made out of cast iron. The rear cover is made out of die cast aluminum. The water pump uses a cartridge seal located on the inlet side of the pump in order to provide good water flow around the seal for cooling. The antifreeze coolant solution is pumped through the engine oil cooler (Figure 1, Item 1) to the transmission cooler (Figure 1, Item 8) and into the supply manifold (Figure 1, Item 9), which is located in the cylinder block. The supply manifold distributes the antifreeze coolant solution at each cylinder. The antifreeze coolant solution then flows around the upper portion of the cylinder liner (Figure 1, Item 10), which cools the upper portion of the cylinder liner. At each cylinder, the antifreeze coolant solution flows from the cylinder liner to the cylinder head (Figure 1, Item 2). The cylinder head is divided into single cylinder cooling sections. In the cylinder head, the antifreeze coolant solution flows across the center of the cylinder and across the injector seat boss. At the center of the cylinder, the antifreeze coolant solution flows around the injector sleeve over the exhaust port. The antifreeze coolant solution then exits into the return manifold (Figure 1, Item 4), which collects the antifreeze coolant solution from each cylinder and directs the flow to the temperature regulator housing (Figure 1, Item 3). When the temperature regulator is in the closed position, the antifreeze coolant solution flows through the regulator, allowing it to flow through the bypass tube (Figure 1, Item 6) directly back to the water pump. The water pump then recirculates the antifreeze coolant solution. With the temperature regulator in the open position, the antifreeze coolant solution is directed through the radiator and then back to the water pump inlet.

0007-2

TM 5-2410-241-23-1

0007

COOLING SYSTEM – CONTINUED

Figure 1. Cooling System Components and Flow Schematic. Coolant Temperature Regulator

0007

0007

The coolant temperature regulator is located inside the temperature regulator housing (Figure 1, Item 3). The coolant temperature regulator is a full flow bypass type regulator, which is used to control the outlet temperature of the coolant. When the engine is cold, the regulator is in the closed position. This allows the coolant to flow from the return manifold (Figure 1, Item 4), through the regulator, through the bypass tube (Figure 1, Item 6), which bypasses the radiator (Figure 1, Item 5), and flow directly to the water pump (Figure 1, Item 7) for recirculation. As the coolant temperature increases, the temperature regulator begins to open directing some of the coolant to the radiator and bypassing the remainder to the water pump inlet. At the full operating temperature of the engine, the regulator moves to the open position. This allows all the coolant flow to be directed to the radiator and then to the water pump. This route provides the maximum heat release from the coolant. A vent line is provided from the manifold to the radiator overflow tank in order to provide venting for the cooling system.

0007-3

TM 5-2410-241-23-1

0007

COOLING SYSTEM – CONTINUED Supply Manifold

0007

Cooling is provided for only the portion of the cylinder liner above the seal in the block. The antifreeze coolant solution enters the block at each cylinder through the slits in the supply manifold. The supply manifold is an integral casting in the block. The coolant flows around the circumference of the cylinder liner and into the cylinder head through a single drilled passage for each liner. The coolant flow is split at each liner so that 60 percent flows around the liner and the remainder bypasses the liner and flows directly to the cylinder head. Aftercooler Flow

0007

The gear driven aftercooler water pump (Figure 2, Item 5) is located on the left side of the engine. Coolant flows from the aftercooler water pump through the cooler line (Figure 2, Item 4) into the aftercooler inlet (Figure 2, Item 3). Coolant passes through the aftercooler (Figure 2, Item 2) to cool the turbocharger inlet air before it enters the engine. Coolant exits the aftercooler outlet (Figure 2, Item 1) and returns to the radiator.

Figure 2. Aftercooler Flow. END OF WORK PACKAGE

0007-4

0007

30 TM 5-2410-241-23-1

0008

FIELD MAINTENANCE 0 0 0

8

-

THEORY OF OPERATION: ELECTRICAL

ELECTRICAL SYSTEM

0008

Grounding Practices

0008

Proper grounding of the machine and engine electrical systems is necessary for proper machine performance and reliability. Improper grounding will result in uncontrolled and unreliable electrical circuit paths. Uncontrolled engine electrical circuit paths can result in damage to main bearings, crankshaft bearing journal surfaces, and aluminum components. To ensure proper functioning of the machine and engine electrical systems, an engine-to-frame ground strap with a direct path to the negative battery post is required.

Figure 1. Grounding Stud To Battery Ground.

0008-1

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED The engine has a wire ground to the battery. Ground wires or ground straps are combined at ground studs that are only for ground use. All of the grounds should be tight and free of corrosion. All of the ground paths must be capable of carrying any likely current faults. An AWG #0 or larger wire is used for the grounding cable to the starter and engine block and grounding strap from the starter to the frame. The engine alternator is grounded to the engine block with a ground strap that is capable of managing the full charging current of the alternator. The engine ECM and powertrain ECM have several input components that require an operating voltage range. Unlike many electronic systems of the past, the electrical system is shielded from common external sources of electrical noise and interference. Engine Electrical System

0008

The electrical system has the following separate circuits: a. Charging b. Starting c. Accessories with low amperage Some of the electrical system components are used in more than one circuit. The following components are common in more than one circuit: •

Batteries

•

Circuit breakers

•

Battery cables

The charging circuit is in operation when the engine is running. An alternator makes electricity for the charging circuit. An internal voltage regulator controls the electrical output in order to keep the battery at full charge. The starting circuit is activated through the engine ECM when the start switch is activated. Charging System Components

0008

Refer to Table 1.

0008

Alternator

0008

The alternator is driven by a belt from the crankshaft pulley, and is a three-phase, self-rectifying charging unit. The regulator is part of the alternator. The alternator design has no need for slip rings and the only moving part is the rotor assembly. All conductors that carry current are stationary. The following conductors are in the circuit: •

Field winding

•

Stator windings

•

Six rectifying diodes

•

Regulator circuit components

0008-2

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED The rotor assembly has many magnetic poles that look like fingers with air space between each of the opposite poles. The poles have residual magnetism, which produces a small magnetic field between the poles. As the rotor assembly begins to turn between the field winding and the stator windings, a small amount of alternating current (AC) is produced. The AC current is produced in the stator windings from the small magnetic field. The AC current is changed to direct current (DC) when the AC current passes through the diodes of the rectifier bridge. The current is used for the following applications: •

Charging the battery

•

Supplying the accessory circuit that has the low amperage

•

Strengthening the magnetic field

The first two applications use the majority of the current. As the DC current increases through the field windings, the strength of the magnetic field is increased. As the magnetic field becomes stronger, more AC current is produced in the stator windings. The increased speed of the rotor assembly also increases the current and voltage output of the alternator. The voltage regulator is a solid-state electronic switch, which senses the voltage in the system. The voltage regulator switches ON and OFF many times per second in order to control the field current for the alternator. The alternator uses the field current in order to generate the required voltage output.

CAUTION Never operate the alternator without the battery in the circuit. Making or breaking an alternator connection with heavy load on the circuit can cause damage to the regulator. Failure to follow this caution may cause damage to equipment.

Figure 2. Alternator Components. Table 1. Alternator Components. Key Components 1

Regulator

5

Fan

2

Roller bearing

6

Rotor assembly

3

Stator winding

7

Field winding

4

Ball bearing

8

Rectifier bridge

0008-3

0008

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Starting System Components

0008

Refer to Table 2.

0008

Starting Solenoid

0008

The starting solenoid is an electromagnetic switch that performs the following basic operations: •

Closes the high current starting motor circuit with a low current start switch circuit.

•

Engages the pinion for the starting motor with the ring gear.

The solenoid has windings around a hollow cylinder. A plunger capable of moving forward or backward with spring pressure (core) is inside of the cylinder. When the start switch is closed and electricity is sent through the windings, a magnetic field is created. The magnetic field pulls the plunger forward in the cylinder. This moves the shift lever in order to engage the pinion drive gear with the ring gear. The front end of the plunger then makes contact across the battery and motor terminals of solenoid. Next, the starting motor begins to turn the flywheel of the engine. When the start switch is opened, current no longer flows through the windings. The spring now pushes the plunger back to the original position. At the same time, the spring moves the pinion gear away from the flywheel. The windings are called the hold-in winding and the pull-in winding. Both sets of windings have the same number of turns around the cylinder, but the pull-in winding uses a wire with a larger diameter. The wire with a larger diameter produces a greater magnetic field. When the start switch is closed, part of the current flows from the battery through the hold-in windings. The remaining current flows through the pull-in windings to the motor terminal. The current then flows through the motor to ground. The solenoid is fully activated when the connection across the battery terminal and the motor terminal is complete. When the solenoid is fully activated, the current is shut off through the pull-in windings. At this point, only the smaller hold-in windings are in operation. The hold-in windings operate for the duration of time that is required in order to start the engine. The solenoid will now draw less current from the battery, and the heat that is generated by the solenoid will be kept at an acceptable level.

0008-4

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED

Figure 3. Starter Motor Components. Table 2. Starter Components. Key Components 1

Solenoid

6

Pinion gear

2

Spring

7

Armature

3

Windings

8

Brush assembly

4

Plunger

9

Commutator

5

Clutch

10

Field

0008-5

0008

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Powertrain ECM Control System

0008

The Powertrain electronic control module (ECM) enables electronic control for the transmission. The ECM electronically controls the operation of the braking system.

Figure 4. Powertrain ECM Control System.

0008-6

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Electronic Clutch Pressure Control (ECPC)

0008

Refer to Table 3.

0008

The ECM uses Electronic Clutch Pressure Control (ECPC) to control the movement of the machine. The ECM uses five transmission clutch solenoid valves to enable shifting of the transmission. The transmission solenoid valves control the hydraulic circuits that engage the transmission clutch pressures. The ECM supplies electrical current to the appropriate transmission solenoid valve to move the machine in one of the three available speeds in forward or reverse. In order to move the machine, the ECM will energize two clutch solenoids, one for the direction and one for speed. The ECM selects the transmission clutches that must be engaged according to the inputs from the operator controls. The clutch pressure is modulated electronically. The ECM controls the modulation of clutch pressure by sending a variable output current to the appropriate proportional clutch solenoids. The ECM uses input from the transmission speed sensors, the torque converter output speed sensor and the transmission temperature sensor in order to determine the correct output current in order to allow for the smooth engagement of the clutches. The ECM will receive a pulse width modulated (PWM) signal in order to vary the current to the solenoid. The current to the solenoid determines the amount of oil pressure that is applied to the clutch. The travel of the plunger is proportional to the electrical current that is supplied to the solenoid. The position of the plunger controls the amount of oil pressure and the amount of clutch engagement. An increase in electrical current will open the solenoid valve further. This will cause an increase in oil pressure and an increase in clutch engagement pressure. Transmission Shifting Operation

0008

The upshift switch, the downshift switch, and the position sensor for the direction lever, informs the ECM of the shifting that is requested from the operator. The requests are “FORWARD,” “NEUTRAL,” “REVERSE,” “UPSHIFT,” or “DOWNSHIFT.” The ECM activates the transmission solenoid valves in order to shift the transmission. Each transmission clutch has a corresponding transmission solenoid valve. The transmission solenoid valves control the hydraulic circuits that engage the transmission clutch pressures. The ECM applies electrical current to the appropriate transmission solenoid valve. For the movement of the machine, two clutch solenoids are activated. One solenoid is activated for the direction and one solenoid is activated for speed. Under normal conditions, the ECM shifts the transmission based on the information from the forward/neutral/reverse (FNR) position sensor and from the upshift and downshift switches. Table 3. Transmission Gear and Solenoid Valve Logic. Gear Engaged

Solenoid Valves On

Clutches Engaged

1F

5 and 2

5 and 2

2F

4 and 2

4 and 2

3F

3 and 2

3 and 2

Neutral

3

3

1F

5 and 1

5 and 1

2F

4 and 1

4 and 1

3F

3 and 1

3 and 1

0008-7

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Electronic Brake Control

0008

The ECM controls the service brakes on the machine. The ECM uses PWM input from a position sensor on the service brake pedal in order to send the appropriate current signal to the proportional brake solenoid. The ECM control of this solenoid determines the amount of braking that is applied to the left hand service brake according to the position of the brake pedal. The ECM also monitors the status of the parking brake system and the secondary brake system. The ECM is not the primary controller of these two systems. The ECM has secondary control over these two systems and it will control the parking brake solenoid and the secondary brake solenoid when certain machine conditions occur. Autoshift Operation

0008

The autoshift function allows the operator to preset the gear speed for directional shifting. The autoshift function allows a directional shift that differs from a normal shift. Normally, the machine shifts from 1F to 1R. With the autoshift switch, the operator can select either 1F to 2R, 2F to 2R, or 2F to 1R. The autoshift indicator displays the status of the autoshift function to the operator. The indicator is on the left side of the dash. The indicator is near the autoshift switch. The operator selects the autoshift operation with the autoshift switch. The autoshift indicator shows the selected mode. The modes are 1F2R or 2F2R or 2F1R. When all LED indicators are OFF, the autoshift function is OFF. Auto Kickdown Operation

0008

When the ECM detects that the torque converter output speed has fallen below an engine speed dependent preset shift point, the ECM will automatically downshift the transmission. There are several auto kickdown setpoints. The operator can scroll through the setpoints or turn the auto kickdown function ON or Off by depressing the auto kickdown switch. For example, if the auto kickdown function is OFF when the operator presses the auto kickdown switch, the function will be turned ON and the first setpoint is activated. When the auto kickdown switch is pressed again, a different setpoint is activated. On some models, a third setpoint can be activated. When the auto kickdown switch is pressed after all of the setpoints have been scrolled, the auto kickdown function is turned OFF. The auto kickdown indicator displays the status of the auto kickdown operation to the operator. The indicator is located on the right side of the dash near the auto kickdown switch.

NOTE The auto kickdown operation is inhibited when the brakes are applied. Backup Alarm Operation

0008

The backup alarm alerts the surrounding personnel that the machine is backing up. Whenever the transmission direction control lever is in the REVERSE position, the ECM activates the backup alarm. Neutral Start Operation

0008

The powertrain electronic control system and the parking brake switch perform the neutral start function. The starting motor will not activate unless the parking brake switch is in the ON position. Whenever the operator places the parking brake switch in the ON position, the ECM will shift the transmission to Neutral and Third Speed (clutch 3).

0008-8

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Blade Float Mode

0008

The dozer has a pilot controlled bulldozer attachment system that has an electromagnet installed under the front of the blade control handle. This magnet is energized at +battery voltage by the ECM at all times unless the key switch is in the OFF position or the hydraulic lockout switch is in the LOCKED position. When the operator moves the blade control handle to the full forward position, the electromagnet will hold the blade in this position until the operator pulls the handle back. When the handle is in the full forward position, maximum pilot pressure will be applied to the main valve in order to shift the spool to float position. This will result in the pump port being blocked and both ends of the lift cylinders are ported to the tank. The blade control handle can be returned to the center position. The ECM will keep the blade float active until another “Y” axis (forward or rearward) handle movement is detected. Electrical Input Components

0008

The machine has several different types of devices that provide input data to the ECM. The ECM receives machine status information from the input devices and determines the correct output action that is needed in order to control machine operations based on memory and software parameters. The machine utilizes the following types of inputs: switch type and sensor type. Switches provide signals to the switch inputs of the ECM. The possible outputs of a switch are listed: an open signal, a grounded signal, and +battery signal. Sensors provide an electrical signal to the ECM that constantly changes. The sensor input to the ECM can be one of several different types of electrical signals such as switch to +battery signals, switch to ground signals, analog pulse width modulated (PWM) signals, and frequency input signals. The ECM monitors the circuits of the input components. If the ECM determines that an abnormal condition exists in one of the circuits, the ECM will log a diagnostic code for the involved component.

Figure 5. Inputs to the Powertrain ECM.

0008-9

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Switches

0008

Switches will provide one of the following types of inputs to the ECM: •

Open

•

Ground

•

+Battery

Switches are devices that have two contact states, either open or closed. •

When switch contacts are open, no signal is provided to the corresponding input of the ECM. This “no signal” condition is also referred to as floating.

•

When switch contacts are closed, either a ground signal or +battery signal is provided to the corresponding input of the ECM.

When a switch provides two inputs to the ECM, the ECM will usually monitor the switch circuits for diagnostics. If a switch provides only one input to the ECM, the ECM will not monitor the circuit for diagnostics. Ignition Switch

0008

The ignition switch sends three battery inputs to the ECM depending on the position of the ignition switch. When the ignition switch is in the ON position, +battery power is supplied to the ECM at connector contacts J1-1 and J1-14. When the ignition switch is in the START position, +battery power is supplied to the ECM at connector contact J2-1. These inputs allow the ECM to monitor the state of the ignition switch. In order for the ECM to energize the output for the start relay, the ECM must detect the correct states for the following inputs: •

Ignition switch in the START position

•

FNR position sensor in the N position (Neutral)

•

Parking brake switch in the ON position

When the ECM detects that these conditions are correct, the start relay will be energized which will send battery power to the starter motor solenoid.

Figure 6. Ignition Switch.

0008-10

0008

TM 5-2410-241-23-1

0008

Switch (Parking Brake)

0008

NOTE Normally Closed (N/C) and Normally Open (N/O) circuits are used for diagnostic purposes. If the N/C and N/O circuits are ever in the same state, a circuit failure is present and a diagnostic code for the ON/OFF pole is logged. The parking brake switch is a four-pole double-throw rocker switch that is located under the left hand console. The switch is actuated by a plunger that mechanically actuates the rocker switch. Two of the poles on the switch are not used. The purpose of the two poles that are used is listed below: “ON/OFF” – This pole informs the ECM that the switch is ON or that the switch is OFF. When the switch is ON, the ECM shifts the transmission to neutral and the ECM activates the left brake. “BRAKE BACKUP” – This pole provides the backup for the activation of the brake. When the switch is ON, the brake backup pole activates the parking brake solenoid, which engages the left brake. The parking brake switch applies the parking brake in two separate ways through the “ON/OFF” pole and the “brake backup” pole. ON/OFF Pole

0008

The ON/OFF pole of the parking brake switch is an input of the ECM. The ON/OFF pole informs the ECM that the operator wants the parking brake engaged. The ECM shifts the transmission to 1st Speed and the ECM activates the left brake. The ON/OFF pole has two input connections to the ECM. When the operator places the parking brake switch in the ON position, the Normally Closed circuit is open and the Normally Open circuit is closed to ground. When the switch is in the OFF position, the Normally Closed circuit is closed to ground and the Normally Open circuit is open.

0008-11

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Brake Backup Pole

0008

The brake backup pole of the parking brake switch operates independently of the ECM. The pole is a backup to the ECM and the ON/OFF pole of the parking brake switch. Normally, the ECM applies the left brake according to the status of the ON/OFF pole. The brake backup pole ensures that the brake is engaged if either the ON/OFF pole or the ECM is not functioning properly. When the parking brake switch is in the ON position, the brake backup pole sends a +battery signal to the parking brake solenoid. The parking brake solenoid engages the left brake. The fuse for the ECM is the source of the +battery signal.

NOTE The parking brake solenoid is also connected to the ECM. The ECM will send +battery voltage to the parking brake solenoid if the signal for the brake backup pole is not at +battery voltage and the parking brake switch is in the ON position.

NOTE The ON/OFF pole diagnoses an INCORRECT condition of the brake backup pole. The ECM monitors the status of the ON/OFF pole and the output for the parking brake solenoid. The ON/OFF pole tells the ECM whether the parking brake switch is in the ON or OFF position.

Figure 7. Mechanical Parking Brake Switch Actuator.

0008-12

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Push button Switch (Upshift)

0008

Push button Switch (Downshift)

0008

Limit Switch (Direction/Reverse)

0008

The upshift switch (Figure 8, Item 2), the downshift switch (Figure 8, Item 3), and the secondary reverse switch (Figure 8, Item 4) are components of the tiller handle. The switches are inputs to the ECM. The upshift switch informs the ECM that the operator wants the transmission to upshift one gear. The upshift switch is a single-pole double-throw (SPDT) switch. The upshift switch has two input connections to the ECM. One connector is for the Normally Closed (N/C) contacts and the other is for Normally Open (N/O) contacts. When the operator presses the upshift switch, the N/C circuit is open and the N/O circuit is closed to ground. When the switch is not activated, the N/C circuit is closed to ground and the N/O circuit is open. The downshift switch informs the ECM that the operator wants the transmission to downshift one gear. The downshift switch is a SPDT switch. The downshift switch has two input connections to the ECM. One connector is for the N/C contacts and the other is for the N/O contacts. When the operator presses the downshift switch, the N/C circuit is open and the N/O circuit is closed to ground. When the switch is not activated, the N/C circuit is closed to ground and the N/O circuit is open.

NOTE The status of the inputs (upshift and downshift) must be correct in order for the ECM to perform the shifting at the correct time. The direction switch informs the ECM that the operator wants the transmission to shift to the reverse direction. The transmission direction control lever (Figure 8, Item 1) actuates the direction switch. The direction switch is a backup to the position sensor for the transmission direction control lever, which normally tells the ECM when reverse is requested. The ECM only responds to the status of the direction switch when a failure in the position sensor for the transmission direction control lever is detected. The direction switch is a SPDT limit switch. The direction switch has two input connections to the ECM. One connection is for the N/C contacts and the other is for the N/O contacts. When the operator turns the transmission direction control lever to the REVERSE position, the reverse N/C circuit is open. When the operator turns the transmission direction control lever to the REVERSE position, the N/C is open and the reverse N/O circuit is closed to ground. When the transmission direction control lever is NOT in the REVERSE position, the switch is not activated. When the switch is not activated, the reverse N/C circuit is closed to ground and the reverse N/O circuit is open.

0008-13

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED

NOTE The ECM only responds to the direction switch when the signal from the position sensor for the transmission direction control lever is not correct.

NOTE N/C and N/O circuits are used for diagnostic purposes. If the N/C and N/O circuits are ever in the same state, a circuit failure is present and a diagnostic code for the switch is logged.

Figure 8.

FNR Direction Handle.

Push Button Switch (Autoshift)

0008

0008

Push Button Switch (Auto Kickdown)

0008

The push button switch is a SPDT switch with a momentary push button and two circuits. The switch is located on the dash in the cab of the machine.

Figure 9. Autoshift/Auto Kickdown Switch.

0008-14

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Autoshift Switch

0008

The autoshift switch informs the ECM that the operator wants the autoshift function to operate. The following selections can be made when the switch is activated sequentially: • 1F2R • 2F2R • 2F1R • OFF The switch has two input connections to the ECM. One connection is for the N/C contacts and the other is for the N/O contacts. When the operator presses the switch to the ON position, the N/C circuit is open and the N/O circuit is closed to ground. When the switch is in the released position, the N/C circuit is closed to ground and the N/O circuit is open.

NOTE N/C and N/O circuits are used for diagnostic purposes. If the N/C and N/O circuits are ever in the same state, a diagnostic code for the autoshift switch is logged. Auto Kickdown Switch

0008

The auto kickdown switch informs the ECM that the operator wants the function for the auto kickdown to operate. With the sequential activations of the switch, the operator can select ON or OFF position. The switch has one input connection to the ECM. When the operator presses the switch to the ON position, the circuit is closed to ground. When the switch is in the released position, the circuit is open.

0008-15

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Switch (Hydraulic Lockout)

0008

The hydraulic lockout switch is a double-pole double-throw (DPDT) rocker switch. The hydraulic lockout switch informs the ECM that the operator wants to lockout the hydraulics or unlock the hydraulics for the bulldozer attachment. The switch is located on the right hand console in the cab. The common switch contact 5 for the input pole is connected to frame ground. The N/C contact at switch contact 4 and the N/O contact at contact 6 provide two inputs to the ECM. When the switch is in the LOCKED position, the ECM input at switch contact 4 is switched to ground. This indicates to the ECM that the switch is in the LOCKED position. When the switch is in the UNLOCKED position, the ECM input at switch contact 6 is switch to ground. This indicates to the ECM that the switch is in the UNLOCKED position. When the switch is in the LOCKED position, the ECM outputs a power signal through the solenoid switch pole in order to energize the hydraulic lockout solenoid. The solenoid is located on the hydraulic relief valve. When the solenoid is energized, pilot pressure for the implement system will be blocked.

Figure 10. Hydraulic Lockout Switch.

0008-16

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Service Brake Pedal Switch

0008

The service brake pedal switch (Figure 11, Item 1) is used to activate the secondary brake. The N/O contacts for the switch are connected to a + battery wire and the wire for the secondary brake dump solenoid. When the service brake pedal is fully depressed, the N/O contacts of the switch will close. This will allow the + battery power to energize the secondary brake dump solenoid.

Figure 11. Service Brake Pedal Switch.

0008

The ECM monitors the secondary brake circuit. If the ECM detects an abnormal condition in the circuit, it will log a diagnostic code for the solenoid valve.

0008-17

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Sensors

0008

Sensors provide information to the ECM about changing conditions. Some types of information are about speed or position. The signal changes in a proportional manner in order to reflect the changing condition. The types of signals that are recognized by the ECM are listed below: Frequency (Hz) – The sensor produces a signal that varies the frequency as the condition changes. Pulse width modulation (PWM) – The sensor produces a signal that varies the duty cycle as the condition changes. The duty cycle is the percentage of time that the square wave PWM signal is “Hi” compared to the time that the signal is “Low.” The frequency of this signal is constant. Speed Sensor (Torque Converter Output)

0008

The torque converter output speed sensor (Figure 12, Item 1) is a frequency sensor, which produces a signal that varies the frequency (Hz) as the condition changes. The sensor generates a frequency by passing a metallic object such as the tooth of a gear in front of the sensor. The ECM measures the frequency and determines the speed of the component. The speed sensor has two input connections to the ECM (“+” and “-”).

Figure 12. Speed Sensor Torque Converter Output.

0008-18

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Speed Sensor (Transmission Output 1)

0008

Speed Sensor (Transmission Output 2)

0008

The two speed sensors for the transmission are located under the access cover (Figure 13, Item 1) that is on the left side of the transmission. The access cover is under the left hand side differential output shaft. These speed sensors are frequency sensors, which produce a signal that varies the frequency (Hz) as the condition changes. The sensor generates a frequency by passing a metallic object such as the tooth of a gear in front of the sensor. The ECM measures the frequency and determines the speed of the component. Each speed sensor has two input connections to the ECM (“+” and “-”). The speed sensors provide inputs to the ECM that indicate the speed of the transmission and the speed of the torque converter. The ECM will use this information to control the transmission. The ECM will use the input from the two transmission speed sensors in order to determine which gear the transmission is in. The ECM will compare the input speeds of the torque converter to the transmission speed to determine shifting points for the Autoshift function. The ECM will compare the input speeds of the torque converter to the transmission speed to enable calibration of the transmission clutch solenoids. The transmission speed sensors are used to diagnose each other during normal operation. The ECM periodically checks and compares the value from each speed sensor. If the ECM determines that an abnormal condition exists in one of the circuits, the ECM will log a diagnostic code for the involved component.

Figure 13. Speed Sensor Transmission Output 1 and 2.

0008-19

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Position Sensor

0008

These sensors continuously inform the ECM of the position of a particular lever or pedal that is controlled by the operator. The operator selects the position and the sensor indicates the position to the ECM. Each position sensor sends a pulse width modulated signal (PWM) to the ECM. A PWM signal is a square wave signal that is approximately between 0 VDC to 5 VDC. Position Sensor (Brake Pedal)

0008

This sensor continuously informs the ECM of the position of the brake pedal and is located on the linkage of the brake pedal. The ECM uses the duty cycle of the signal in order to determine the rate of modulation for the brakes. The duty cycle increases as the pedal is pressed. When the brake pedal is fully pressed, an additional brake function is activated. The service brake switch on the brake pedal closes and the secondary brake solenoid is energized. This relieves hydraulic pressure to the brakes, which will cause the brakes to engage.

Figure 14. Position Sensor for the Brake Pedal.

0008-20

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Position Sensor (Forward/Neutral/Reverse)

0008

The position sensor for the direction control handle continuously informs the ECM of the position of the transmission direction control lever. The three positions that can be selected are the FORWARD (F) position, the NEUTRAL (N) position, or the REVERSE (R) position. The ECM uses the duty cycle of the signal in order to determine the transmission directional clutch that must be engaged. The duty cycle of the sensor signal increases as the direction lever is turned to the FORWARD position and decreases as the direction lever is turned to the REVERSE position. The reverse direction switch acts as a backup for the position sensor in the event that the position sensor fails.

Figure 15. Position Sensor for the FNR Direction Handle.

0008-21

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Electronic Control Module

0008

The Powertrain ECM is located under the left console. The ECM makes decisions that are based on input and memory information. After the ECM receives the input information, it sends a corresponding response to the outputs. The inputs and outputs of the ECM are connected to the machine harness by two 70 contact connectors (J1 and J2). The ECM also sends the information to the MSD using Cat MIL ET.

NOTE The ECM is not serviceable. If the ECM fails or is damaged, it must be replaced. The failure rate for the ECM is very low. If the ECM is suspected to be faulty when there is a problem with an electrical circuit on the machine, replace the ECM only after all of the other possible causes of the problem have been investigated.

Figure 16. ECM Connectors and Contacts.

0008-22

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Inputs

0008

The machine has several different types of input devices. The ECM receives machine status information from the input devices and determines the correct output action that is needed in order to control machine operations based on memory and software parameters. The machine utilizes the following types of inputs: switch type and sensor type. Switches provide signals to the switch inputs of the ECM. The possible outputs of a switch are listed: an open signal, a grounded signal, and + battery signal. Sensors provide an electrical signal to the ECM that constantly changes. The sensor input to the ECM can be one of several different types of electrical signals such as switch to + battery signals, switch to ground signals, analog pulse width modulated (PWM) signals, and frequency input signals. Outputs

0008

The ECM sends electrical signals through the outputs. The outputs can create an action or the outputs can provide information to the ECM. The ECM can send output signals to the system components in one of several different electrical signal types such as: driver outputs, sinking driver outputs, sensor power supply outputs, and data link outputs. Input/Output

0008

Each ECM uses the Data Link to communicate with the other. The data link is bidirectional. The data link allows the ECM to receive or send information. The data link allows the sharing of information with the engine electronic control module. The ECM supports two types of data link systems: •

Data Link

•

CAN Data Link

0008-23

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED The two data links are the main structure for communication between the two electronic control modules on the machine. A module identifier (MID) is assigned to each ECM. The MID for the Powertrain ECM is 113. The MID for the engine ECM is 036. Electrical Output Components

0008

The ECM monitors the circuits of the output components. If the ECM determines that an abnormal condition exists in one of the circuits, the ECM will log a diagnostic code for the involved component.

Figure 17. Powertrain ECM Outputs.

0008-24

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Solenoid Valves

0008

Solenoid Valves (Transmission)

0008

The ECM uses solenoid valves to shift the transmission. The solenoids control the hydraulic circuits that modulate transmission clutch pressures. Each transmission clutch solenoid has a connector with two contacts. One contact is the PWM signal contact and the other is the return to ECM ground contact. The ECM applies electrical current to the appropriate transmission clutch solenoids. This is based on the operator’s request from the upshift switch, the downshift switch, or the transmission direction control lever. For the movement of the machine, two clutch solenoids are activated. One solenoid is activated for direction and one for speed. None of the transmission solenoids is energized when the transmission is in the NEUTRAL position. Solenoid Valve (Proportional, Secondary Brake, Parking Brake) Refer to Table 4.

0008

0008

Both service and parking brake systems share the same oil-bathed, multiple-disc arrangements. One brake assembly is contained in the steering differential and brake assembly located on the right side of the machine. The other brake assembly is contained in the planetary and brake assembly located on the left side of the machine. Both brake assemblies are spring applied and hydraulically released. A foot pedal is used to apply the service brakes for slowing and stopping machine. Parking brakes are controlled by an operator controlled parking brake switch on the left console. When the parking brakes are engaged, hydraulic pressure to the brake assemblies is released causing spring pressure to apply the brakes. The electronic brake control valve is mounted on top of the main case underneath the operator’s floor plate.

Figure 18. Electronic Brake Control. Table 4. Electronic Brake Control. Key Component 1

Secondary brake ON/OFF solenoid

2

Parking brake solenoid

3

Proportional brake solenoid

0008-25

0008

0008

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Proportional Brake Solenoid

0008

Refer to Table 5.

0008

The ECM uses the brake proportional solenoid to engage or disengage the service brakes. It receives a PWM input signal from the brake pedal position sensor and outputs a proportional PWM signal to energize the solenoid. The ECM will control the amount of electrical current that is sent to the solenoid depending on the position of the brake pedal. The service brakes are spring applied and hydraulically released.

Figure 19. Proportional Brake Solenoid.

0008

When the machine is operating and the service brake pedal is not depressed, the ECM will send the maximum current to the solenoid in order to disengage the service brakes. As the brake pedal is depressed, the ECM will DECREASE the current signal to the solenoid, which will cause the brakes to be applied. As the travel of the brake pedal is increased, the ECM will continue to DECREASE the current signal that is sent to the solenoid. This will cause the service brakes to increase the force of engagement.

0008-26

TM 5-2410-241-23-1

0008

ELECTRICAL SYSTEM – CONTINUED Solenoid Valve (Secondary Brake)

0008

The secondary brake solenoid is an ON/OFF type that is controlled by the secondary brake limit switch on the brake pedal. This switch is activated when the brake pedal is fully depressed. The ECM also has an output connection to the secondary brake solenoid. If the ECM detects a fully depressed pedal condition in the secondary brake solenoid circuit, it will energize the solenoid in order to engage the service brakes. When the brake pedal is completely depressed, the secondary brake limit switch will close and send +battery power to the secondary brake solenoid. This will cause the service brakes to engage. This works independently of the ECM. When the operator engages the parking brake, the ECM will also energize the secondary brake solenoid. Solenoid Valve (Parking Brake)

0008

During normal operation, the ON/OFF type solenoid valve for the parking brake operates independently of the ECM. Normally, the solenoid valve is energized by the parking brake switch. When the parking brake switch is in the ON position, the solenoid valve is energized. This results in the hydraulic oil pressure being “dumped” away from the brake actuator in order to engage (ON) the parking brake. When the parking brake switch is in the OFF position, the solenoid is de-energized, the hydraulic oil pressure is allowed to flow to the parking brake actuator in order to disengage (OFF) the parking brake. The parking brake solenoid is also connected to an ECM output contact. When the parking brake switch is ON, the signal at the ECM contact should measure 24 VDC. If the ECM determines that the signal is incorrect, the ECM will activate a level 2 diagnostic code. The ECM receives two inputs from the parking brake switch in order to determine the state of the switch. When the ECM determines that the parking brake switch is in the ON position, the ECM will also energize the secondary brake solenoid. The parking brake state and the states of the three machine braking solenoids are indicated in the following table. Table 5. Machine Solenoids.

0008

Parking Brake Switch ON (Engaged)

Parking Brake Switch OFF (Dis-engaged)

Proportional Brake Solenoid

Not Active

Active

Secondary Brake Solenoid

Active

Not Active

Park Brake Solenoid

Active

Not Active

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0008

ELECTRICAL SYSTEM – CONTINUED Relays

0008

Relay (Start)

0008

The start relay is located in the fuse panel enclosure. This enclosure is located under the left console over the left fender. The ECM must detect that the following input information is correct before energizing the start relay. •

The FNR position sensor must indicate that the direction handle is in the NEUTRAL position

•

The parking brake switch must be in the ON position

•

The key switch must be in the START position

When the ECM detects that the machine systems input information is correct, it will send a +battery signal to the coil of the start relay in order to energize the relay. This will cause the secondary contacts of the relay to close. This will send +battery power from the main buss to the start motor solenoid. The ECM monitors the circuit for the start relay. If it determines that an abnormal condition exists in the circuit, the ECM will log a diagnostic code. Alarm (Backup)

0008

The backup alarm is an output of the ECM. The backup alarm alerts nearby personnel that the machine is backing up. When the FNR position sensor indicates that the direction handle is in the REVERSE position, the ECM will activate the output for the backup alarm. Magnet (Blade Float)

0008

The blade float magnet detent coil is mounted internally on the front side of the bulldozer attachment control handle base. When the key switch is in the ON position, the float solenoid is energized unless the hydraulic lockout switch is in the LOCKED position. When the control handle is moved to the full blade down position (full forward), the magnetic force that is created by the energized coil will hold the handle in the forward position. When this occurs, the hydraulic flow to the cylinders will be blocked and both ends of the cylinders will be open to the tank.

Figure 20. Blade Float.

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0008

ELECTRICAL SYSTEM – CONTINUED Engine Electronic Control System Components

0008

The electronic control system has the following major components: •

Speed sensor or timing sensor

•

Coolant temperature sensor

•

Inlet air temperature sensor

•

Boost pressure sensor

•

Fuel temperature sensor

•

Atmospheric pressure sensor

•

Oil pressure sensor

•

Engine wiring harness

•

Electronic Control Module (ECM)

•

A remote mounted throttle position sensor

The electronic control system is integrally designed into the engine’s fuel system and the engine’s air inlet and exhaust system in order to control fuel delivery and injection timing electronically. The electronic control system provides increased timing control and fuel air ratio control in comparison to conventional mechanical engines. Injection timing is achieved by precise control of injector firing time, and engine RPM is controlled by adjusting the firing duration. The ECM energizes the solenoid in the unit injector in order to start the injection of fuel and deenergizes the unit injector solenoids in order to stop injection of fuel. The engine uses the following three types of electronic components: •

Input

•

Control

•

Output

An input component is one that sends a signal to the electronic control module of the system. The signal that is sent varies in either voltage or frequency. The variation of the signal is in response to a change in some specific system of the vehicle. The electronic control module sees the input sensor signal as information about the condition, environment, or operation of the vehicle. A control component receives the input signals. Electronic circuits inside the control evaluate the signals from the input components. These electronic circuits also supply electrical energy to the output components of the system. The electrical energy that is supplied to the output components is based on predetermined combinations of input signal values. An output component is one that is operated by a control module. The output component receives electrical energy from the electronic control group. The output component uses the electrical energy in one of two ways. The output component can use that electrical energy in order to perform work or to provide information. 1. A moving solenoid plunger will perform work by functioning to regulate the vehicle. 2. A dash panel light or an alarm will provide information to the operator of the vehicle.

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ELECTRICAL SYSTEM – CONTINUED These electronic components provide the ability to control the engine operation electronically. Engines with electronic controls offer the following advantages: •

improvement in performance

•

improvement in fuel consumption

•

reduction in emissions levels

END OF WORK PACKAGE

0008-30

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24 TM 5-2410-241-23-1

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FIELD MAINTENANCE 0 0 0

9

-

THEORY OF OPERATION: PRIMARY POWERTRAIN

PRIMARY POWERTRAIN

0009

Transfer of Mechanical Power

0009

The engine (Figure 1, Item 3) is the source of the mechanical power. Power flows from engine (Figure 1, Item 3) to tracks (Figure 1, Item 4) through the powertrain: torque divider (Figure 1, Item 5), drive shaft (Figure 1, Item 6), power shift transmission (Figure 1, Item 8), bevel and transfer gears (Figure 1, Item 7), steering differential and brake (Figure 1, Item 1), planetary gears and brake (Figure 1, Item 9), and final drives (Figure 1, Item 2). The engine (Figure 1, Item 3) transfers power from the engine flywheel to the torque converter (Figure 1, Item 5). The torque divider (Figure 1, Item 5) consists of a planetary gear arrangement and a torque converter. The torque divider (Figure 1, Item 5) transfers power through the planetary gears and through the torque converter turbine to the drive shaft (Figure 1, Item 6). The planetary gears are a mechanical connection and the torque converter is a hydraulic connection. The drive shaft (Figure 1, Item 6) transfers power to the transmission (Figure 1, Item 8). The transmission (Figure 1, Item 8) has three speeds in the FORWARD position and three speeds in the REVERSE position. The speed clutches and the direction clutches are electronically controlled. The clutches engage in order to transfer power. The power output from the transmission (Figure 1, Item 8) turns the bevel and transfer gears (Figure 1, Item 7). The bevel and transfer gears (Figure 1, Item 7) turn the inner axle shaft, which sends power to the steering differential and brake (Figure 1, Item 1) and the planetary gears and brake (Figure 1, Item 9). The steering differential is used to turn the machine. The brakes are used to stop the machine. The steering differential and brake (Figure 1, Item 1) works with the planetary gears and brake (Figure 1, Item 9) in order to send power through the two outer axle shafts to final drives (Figure 1, Item 2). The final drives (Figure 1, Item 2) use two planetary gear arrangements for double speed reduction. The planetary gears increase the torque in each stage. The sprockets on the final drives transfer mechanical power to tracks (Figure 1, Item 4) that move the machine.

Figure 1. Powertrain Components.

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PRIMARY POWERTRAIN – CONTINUED Powertrain Hydraulic System

0009

Refer to Figure 2.

0009

The powertrain hydraulic system uses a three-section oil pump. The oil pump is mounted on the gear case for the bevel and transfer gears and is driven by an auxiliary drive shaft from the engine. Torque Converter and Lubrication Section

0009

Section (A) sends oil from the bevel gear case through a magnetic screen. The oil flows to the torque converter inlet relief valve located in the lubrication distribution manifold. The torque converter inlet relief valve limits the maximum oil pressure to the torque converter. The inlet relief valve sends most of the oil to the torque converter. The rest of the oil is sent to the lubrication distribution manifold and is used to lubricate the brakes and the transmission. The oil from the torque converter exits through the outlet relief valve. Next, the oil is routed to the oil cooler. Then, the oil flows back to the lubrication distribution manifold. At the lubrication distribution manifold, the oil combines with the oil that bypassed the torque converter. The combined oil flows from the lubrication distribution manifold to lubricate the transmission and brakes and then drains to the bevel gear case. A small portion of the oil is diverted from the torque converter inlet in order to lubricate the drive gears and bearing Transmission and controls section

0009

Section (B) of the oil pump draws oil from the bevel gear case. The oil goes through a magnetic screen and flows to the oil filter. Next, the oil flows to the brake control valve, the modulating valves, the accumulator, and main relief valve. The main relief valve is located in the manifold on the top of the transmission and controls the pressure in the circuit. The oil that flows past the main relief valve provides part of the lubrication and cooling for the transmission and bevel gear. The primary use of oil from section (B) is for control of the brakes and the transmission clutches. Transmission and Torque Converter Scavenge Section

0009

Section (C) removes oil from the torque converter and from the transmission. The oil goes through both screens and it is used as lubrication for the steering differential and brake. The oil is then allowed to return to the bevel gear case.

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PRIMARY POWERTRAIN – CONTINUED

Figure 2. Schematic for the Powertrain Hydraulic System.

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PRIMARY POWERTRAIN – CONTINUED Powertrain Electronic Control System Components

0009

The powertrain ECM on the D7R dozer enables electronic control for the transmission and operation of the braking system.

Figure 3. Electronic Control System of the D7R Dozer Powertrain.

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PRIMARY POWERTRAIN – CONTINUED Magnetic Screen

0009

A magnetic screen is attached to the bevel gear case at the inlet to the powertrain oil pump. Oil from the bottom of the bevel gear case flows through an inlet passage. As the oil flows through the screen, foreign particles in the oil are stopped by the screen. The screen prevents the particles from entering the powertrain oil system.

Figure 4. Location of Magnetic Screen. Gear Pump (Powertrain)

0009

0009

The powertrain oil pump is mounted on the front of the bevel gear case. The pump is driven by an auxiliary drive shaft from the engine. The bevel gear case is the sump for the powertrain oil system. The transmission oil pump is a gear type pump that contains three sections: (A) – Torque converter and lubrication (B) – Transmission and controls (C) – Transmission and torque converter scavenge

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PRIMARY POWERTRAIN – CONTINUED Oil Cooler (Powertrain)

0009

The powertrain oil cooler (Figure 5, Item 1) is mounted vertically on the right side of the engine and is a water to oil type cooler. The oil cooler uses the coolant from the engine cooling system to cool the oil. The engine coolant enters the oil cooler at the inlet (Figure 5, Item 3) of the oil cooler and flows through the tubes in the cooler. The coolant then flows out of the oil cooler through the outlet passage (Figure 5, Item 2) of the oil cooler where it is cooled by the engine cooling system. High temperature powertrain oil enters the cooler from the torque converter outlet relief valve. This oil enters the oil cooler at inlet (Figure 5, Item 4) at the bottom of the oil cooler and flows along the tubes in the oil cooler. The powertrain oil exits through the outlet passage (Figure 5, Item 5) at the top of the oil cooler and has a cooler temperature. The cooled oil then flows to the lubrication distribution manifold, which divides the flow between the transmission and brakes for lubrication and cooling.

Figure 5. Powertrain Oil Cooler.

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PRIMARY POWERTRAIN – CONTINUED Relief Valve (Main)

0009

Pump supply oil enters the main relief valve through the passage (Figure 6, Item 1) and enters a hole in the spool (Figure 6, Item 5) flowing through an internal passage in the spool. The pressure of this oil is felt in the slug chamber (Figure 6, Item 6). The oil acts on the slug (Figure 6, Item 7). The slug cannot move to the left. The oil pressure will push the spool (Figure 6, Item 5) to the right. When the oil pressure in the slug chamber (Figure 6, Item 6) exceeds the force of the spring (Figure 6, Item 4), the spool moves to the right. When the spool moves to the right, pump oil is allowed to exit through the passage (Figure 6, Item 2) and is used to lubricate the transmission. When the pressure in the passage (Figure 6, Item 1) is no longer high enough to overcome the force of the spring (Figure 6, Item 4), the spool (Figure 6, Item 5) shifts back to the left. The pressure setting of the main relief valve may be adjusted with the adjustment screw (Figure 6, Item 3).

Figure 6. Relief Valve (Main). Accumulator

0009

0009

The accumulator for the powertrain is located on top of the bevel gear case at the back of the machine. The accumulator stores potential energy by accumulating a quantity of pressurized powertrain oil, which is stored in an accumulator cylinder. The accumulator is charged to 250 psi (1,724 kPa) with dry nitrogen. The pressurized powertrain oil enters the accumulator and creates pressure. Energy is stored within the accumulator as the gas behind the cylinder inside the accumulator is compressed by the powertrain oil. The accumulator supplements powertrain oil flow in low flow conditions.

Figure 7. Accumulator.

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PRIMARY POWERTRAIN – CONTINUED Torque Divider

0009

The torque divider is a unit of a planetary gear set and a torque converter turbine. The torque divider connects the engine to the planetary transmission both hydraulically and mechanically. The hydraulic connection is through the torque converter turbine. The mechanical connection is through a planetary gear set. The torque converter uses oil from the torque converter charging section of the pump to multiply the torque to the transmission. When the machine works against a low load, the torque multiplication is low. When the machine works against a high load, the torque multiplication is higher. A higher torque can then be sent to the transmission during high load conditions. The planetary gear set multiplies the torque from the engine by increasing the mechanical advantage through the gears as the load on the machine increases. During no-load conditions, neither the torque converter nor the planetary gears can multiply the torque from the engine. The torque divider and housing is installed onto the engine flywheel (Figure 8, Item 1) and housing. The output shaft (Figure 8, Item 8) is connected to the yoke (Figure 8, Item 7), which is connected to the planetary transmission through a drive shaft. The main components of the planetary gear set are the sun gear (Figure 8, Item 12), planetary carrier (Figure 8, Item 14), planetary gears (Figure 8, Item 13), and ring gear (Figure 8, Item 2). The sun gear (Figure 8, Item 12) is connected to the flywheel by splines. The planetary gears (Figure 8, Item 13) are mounted on the planetary carrier (Figure 8, Item 14). They engage the sun gear (Figure 8, Item 12) and the ring gear (Figure 8, Item 2). The main components of the torque converter are the housing (Figure 8, Item 3), impeller (Figure 8, Item 4), turbine (Figure 8, Item 11), and stator (Figure 8, Item 10). The housing (Figure 8, Item 3) is connected to flywheel (Figure 8, Item 1) by splines. The Impeller (Figure 8, Item 4) is connected to the housing (Figure 8, Item 3). The turbine (Figure 8, Item 11) is connected to the ring gear (Figure 8, Item 2) by splines. The stator (Figure 8, Item 10) is connected to the carrier (Figure 8, Item 6) and cannot turn. Torque Converter Operation

0009

Oil for the operation of the torque converter flows through the inlet passage (Figure 8, Item 5) in the carrier (Figure 8, Item 6) to the impeller (Figure 8, Item 4). The rotation of the impeller gives force to the oil and sends the oil toward the outside of the impeller, around the inside of the housing (Figure 8, Item 3) to the turbine (Figure 8, Item 11). The force of the oil against the blades of the turbine turns the turbine. The turbine is connected to the ring gear (Figure 8, Item 2), so that torque is sent to the planetary gears (Figure 8, Item 13). The torque that is sent to the turbine by the force of the oil from the impeller cannot be more than the torque output of the engine to the impeller. The oil that is flowing from the turbine moves in a direction that is opposite to the rotation of the impeller (Figure 8, Item 4). The stator (Figure 8, Item 10) changes the direction of the oil. The stator is connected to the carrier (Figure 8, Item 6) and cannot turn. Therefore, most of the oil is sent back to the impeller (Figure 8, Item 4). The remainder of the oil flows from the stator, through the outlet passage (Figure 8, Item 9) to the oil cooler. The force of the oil from the stator can now add to the torque output from the engine to the impeller. The extra force adds to the torque output of the engine to the turbine. The force of the oil that is coming from the stator is determined by the difference in speed between the turbine and the impeller. The amount of force of the oil increases as the difference in the speed of the two components increases. The load on the machine changes the speed of the turbine. When the load is higher, the difference in speed between the turbine and the impeller increases. The different loads on the machine control the amount of torque multiplication that can be added by the force of the oil from the stator.

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PRIMARY POWERTRAIN – CONTINUED Torque Divider Operation

0009

The torque converter is driven by the engine through the housing (Figure 8, Item 3). The planetary gear set is driven by the engine through the sun gear (Figure 8, Item 12). These connections allow the torque output of the engine to go in two separate directions. Because of the larger radius of the ring gear (Figure 8, Item 2), most of the torque is sent by the torque converter through the ring gear to the planetary gears (Figure 8, Item 13). The remainder of the torque is sent by the sun gear (Figure 8, Item 12) to the planetary gears (Figure 8, Item 13). The sun gear (Figure 8, Item 12), planetary gears (Figure 8, Item 13), planetary carrier (Figure 8, Item 14) and ring gear (Figure 8, Item 2) turn at the same speed when the planetary carrier (Figure 8, Item 14) has no resistance to rotation. The torque from the torque converter turbine and the planetary gear set is sent through the planetary carrier to the output shaft (Figure 8, Item 8) and the planetary transmission. When the torque converter and the planetary gears turn at the same speed, torque from the engine cannot be multiplied. When the machine operates under a load, the planetary carrier (Figure 8, Item 14) has a resistance to rotation. Since the sun gear (Figure 8, Item 12) turns at the speed of the engine, the resistance to rotation turns the planetary gears (Figure 8, Item 13). The rotation is opposite to the rotation of the ring gear, which decreases the speed of the ring gear. The turbine (Figure 8, Item 11) is connected to the ring gear so a decrease in speed causes the torque converter to multiply the torque of the engine from the housing (Figure 8, Item 3). The torque multiplication is sent to the planetary carrier (Figure 8, Item 14) and to the output shaft through the ring gear.

Figure 8. Torque Divider.

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PRIMARY POWERTRAIN – CONTINUED As the speed of the ring gear (Figure 9, Item 1) decreases, the torque of the engine is multiplied through the sun gear (Figure 9, Item 4) and through the planetary gear set. The torque multiplication is sent to the planetary carrier (Figure 9, Item 6) and to the output shaft (Figure 9, Item 3). When the machine operates under higher load, the resistance to rotation of the planetary carrier (Figure 9, Item 6) increases and the speed of the ring gear decreases. The slower speed allows higher torque multiplication through the torque converter turbine and through the sun gear. If the resistance to rotation of the planetary carrier becomes high enough, the ring gear stops. During some very high load conditions, the rotation of the planetary carrier and the rotation of the output shaft also stop. The stopped output shaft causes the ring gear to turn slowly in the opposite direction. The torque multiplication of the torque converter turbine and the sun gear is at the maximum. Torque Divider Lubrication

0009

Lubrication oil for the torque divider bearings and for the planetary gears (Figure 9, Item 5) comes from the supply (Figure 9, Item 2) to the torque converter. The bearings constantly run in oil. Bearings and gears in the planetary gear set and the pilot bearings receive lubrication through passages in the output shaft.

Figure 9. Torque Divider.

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PRIMARY POWERTRAIN – CONTINUED Relief Valve (Torque Converter Inlet) (Lubrication Distribution Manifold)

0009

The torque converter inlet relief valve (Figure 10) is part of the lubrication distribution manifold. The torque converter inlet relief valve limits the maximum oil pressure to the torque converter. The purpose of inlet relief valve is to prevent damage to the torque converter when the engine is started and the oil is cold. Relief Valve (Torque Converter Outlet)

0009

The outlet relief valve for the torque converter is fastened to the torque divider case and maintains pressure in the torque converter.

Figure 10. Relief Valve (Torque Converter Inlet and Outlet).

0009-11

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PRIMARY POWERTRAIN – CONTINUED Transmission

0009

The transmission has five hydraulically activated clutches. Combinations of the clutches allow the transmission to provide three speeds FORWARD and three speeds REVERSE (Table 1). The speed and direction are electronically controlled. The five transmission clutches are disc types and are in separate housings. Each clutch has friction discs (Figure 11, Item 5) and clutch plates (Figure 11, Item 3). The inside teeth of the friction discs (Figure 11, Item 5) are engaged with the outside teeth of ring gear (Figure 11, Item 6). Notches on the outside diameter of the clutch plates (Figure 11, Item 3) are engaged with pins in the clutch housing. The pins prevent the rotation of the clutch plates. The spring (Figure 11, Item 2) is located between the clutch housing (Figure 11, Item 4) and the piston (Figure 11, Item 1). The spring is in compression. When the pressure of the oil in the area behind the piston increases, the piston moves to the right against the force of the spring (Figure 11, Item 2), pushing the friction discs and clutch plates together. The clutch is now engaged. The friction discs keep the ring gear (Figure 11, Item 6) from rotation. The clutch is released when the pressure in the area behind piston (Figure 11, Item 1) decreases and the force of the spring (Figure 11, Item 2) moves the piston to the left. The friction discs and clutch plates now move apart and the clutch is no longer engaged.

Figure 11. Clutch Operation (Typical Example).

0009-12

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PRIMARY POWERTRAIN – CONTINUED Both a speed clutch and a direction clutch must be engaged in order to send power through the transmission. Table 1 lists the combination of the clutches that are engaged for the different FORWARD and REVERSE speeds. Table 1. Transmission Clutch Engagement.

0009

Speed

Direction

Engaged Clutches

First Speed

FORWARD

2 and 5

Second Speed

FORWARD

2 and 4

Third Speed

FORWARD

2 and 3

Neutral

3

First Speed

REVERSE

1 and 5

Second Speed

REVERSE

1 and 4

Third Speed

REVERSE

1 and 3

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PRIMARY POWERTRAIN – CONTINUED Transmission Components

0009

The transmission is fastened to the main case at the rear of the machine. Power from the torque divider is sent to the input shaft by a drive shaft. Power flows from the transmission through the output shaft. The power flows from the output shaft to the transfer gears. The transmission has five hydraulically activated clutches. The No. 1 and the No. 2 clutches are the direction clutches. These clutches are located at the rear of the transmission. The No. 1 clutch is the REVERSE direction clutch and the No. 2 clutch is the FORWARD direction clutch. The No. 3, No. 4, and No. 5 clutches are the speed clutches. The No. 3 clutch actuates THIRD speed. The No. 4 clutch actuates SECOND speed. The No. 5 clutch actuates FIRST speed and is the only clutch that turns. Table 2 identifies the callouts of Figure 12.

Figure 12. Section View of the Transmission.

0009

Table 2. Transmission.

0009

Key Component 1

Coupling gear

9

Ring gear (No. 4 Clutch)

17

Sun gear (No. 3 Clutch)

2

Reverse (No. 1 Clutch)

10

First speed (No. 5 Clutch)

18

Planetary gear (No. 3 Clutch)

3

Carrier (No. 2 and No. 3 Clutches)

11

Hub

19

Planetary gear (No. 2 Clutch)

4

Forward (No. 2 Clutch)

12

Carrier (No. 4 Clutch)

20

Sun gear (No. 2 Clutch)

5

Ring gear (No. 2 Clutch)

13

Sun gear (No. 4 Clutch)

21

Ring gear (No. 1 Clutch)

6

Third speed (No. 3 Clutch)

14

Input shaft

22

Planetary gear (No. 1Clutch)

7

Ring gear (No. 3 Clutch)

15

Output shaft

23

Sun gear (No. 1 Clutch)

8

Second speed (No. 4 Clutch)

16

Planetary gear (No. 4 Clutch)

24

Carrier (No. 1 Clutch)

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Transmission Hydraulic Control

0009

Modulating Valves

0009

The transmission hydraulic controls are attached to the top of the planetary transmission on the inside of the transmission case. Proportional solenoid valves are mounted on the relief valve manifold. The machine has one modulating valve for each clutch. Each modulating valve has a pilot stage that is similar to the type of proportional solenoid valve that is used for the brakes. Each modulating valve also contains a pressure reducing spool. Modulating valve allows the corresponding clutch to fill to a pressure that is proportional to the current to solenoid. The ECM determines the amount of current that is required by the solenoids. The current is based on the response of the machine, which is measured by speed sensors. Modulating valves are designed to be individually replaced if a malfunction occurs. Transmission clutch pressures can be measured from the pressure taps that are remotely located on the back of the transmission case.

NOTE Transmission modulating valves must be recalibrated when any of the following tasks are performed: •

A transmission modulating valve and/or a solenoid is replaced.

•

The transmission is serviced or the transmission is replaced.

•

The ECM is replaced.

Main Relief Valve

0009

The main relief valve is located in the relief valve manifold on the top of the planetary transmission and maintains the system pressure in the high pressure circuit (control section) of the powertrain oil pump.

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PRIMARY POWERTRAIN – CONTINUED Transmission Lubrication

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Planetary Lubrication

0009

The oil for lubrication of the transmission comes from the lubrication distribution manifold and the main relief valve. Oil from the oil cooler flows through the tube assembly (Figure 13, Item 5) to the manifold (Figure 13, Item 6). Oil from manifold flows through the passage (Figure 13, Item 3) to the cavity (Figure 13, Item 9) and the drilled passages in the input shaft (Figure 13, Item 8). The passage (Figure 13, Item 3) is formed by the clutch housings. Cavity (Figure 13, Item 9) sends oil to cavity (Figure 13, Item 2). Drilled passages in the No. 1 carrier (Figure 13, Item 10) and the No. 2 and 3 carrier (Figure 13, Item 1) send oil to the direction clutches and the No. 3 clutch. Oil is metered to the direction clutches. The FORWARD ring gear and the REVERSE ring gear have drilled oil passages. Oil flows through the drilled passages to the direction clutches. Oil comes through the drilled passages in the input shaft (Figure 13, Item 8) and flows to the clearance between the input shaft and the output shaft. The oil lubricates bearings at both ends of the output shaft. The oil then flows through drilled passages in the output shaft to cavity (Figure 13, Item 4) and hub (Figure 13, Item 7). Planetary bearings and thrust discs get oil from cavities (Figure 13, Item 9) and (Figure 13, Item 4) through the drilled passages in the planetary shafts. Drilled passages in the hub (Figure 13, Item 7) and the ring gear for the No. 4 clutch send oil to the No. 5 and No. 4 clutches for lubrication. The gears throw oil around the housing and this lubricates the rest of the components. Oil is also released at pressure/flow points. Lubrication oil flows through the clutches and drains to the bottom of the transmission case.

Figure 13. Planetary Lubrication.

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PRIMARY POWERTRAIN – CONTINUED Oil Filter (powertrain)

0009

Pressure oil from the pump goes into the housing assembly through the inlet passage (Figure 14, Item 2). The oil flows through the passage (Figure 14, Item 1) in order to fill the space between the inside of the housing assembly and the filter element. The oil also flows through passage (Figure 14, Item 10) in order to fill chamber (Figure 14, Item 8). During normal operation, the oil flows through the filter element and out through passage (Figure 14, Item 4) to outlet passage (Figure 14, Item 3). The oil then travels to the transmission main relief valve and the brake control valve. The filter element stops any debris that is in the oil. The springs (Figure 14, Item 6) force the bypass valve spool (Figure 14, Item 7) to the left. If the filter element becomes full of debris, the restriction to the flow of oil causes a pressure increase inside chamber (Figure 14, Item 8) and a pressure decrease in the chamber (Figure 14, Item 5). The pressure oil that is in the chamber (Figure 14, Item 8) can now force the bypass valve spool (Figure 14, Item 7) to move to the right against the force of the springs (Figure 14, Item 6). The oil is then allowed to flow from the passage (Figure 14, Item 10) through the passage (Figure 14, Item 11) to the outlet passage (Figure 14, Item 3). When the bypass valve spool (Figure 14, Item 7) is shifted to the right, this allows the switch (Figure 14, Item 9) to open. The switch informs the ECM that the filter element is being bypassed. When the oil pressure increases above the bypass valve setting of 50 ± 3 psi (345 ± 21 kPa), the oil bypasses the filter element.

CAUTION When the oil does not go through the filter element, the debris in the oil causes damage to other components in the hydraulic system. Correct maintenance is necessary to make sure that the filter element does not become full of debris. A filter element that is clogged with debris will stop the flow of clean oil to the hydraulic system.

Figure 14. Oil Filter Components.

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PRIMARY POWERTRAIN – CONTINUED Transfer and Bevel Gears

0009

The transfer and bevel gears are located in the transfer case. The transfer case is attached to the transmission case. The transfer and bevel gears transfer mechanical power from the transmission through the brakes to the final drive. A drive shaft connects the yoke on the torque converter to the yoke on the transfer case. The yoke on the transfer case is connected to the transmission input shaft (Figure 15, Item 4) by splines. When a speed clutch and a direction clutch are engaged, power is sent from the planetary transmission to the transmission output shaft (Figure 15, Item 5). Then, the power is sent to the transfer gear (Figure 15, Item 3). The transfer gear (Figure 15, Item 3) turns the transfer gear (Figure 15, Item 2). The transfer gear (Figure 15, Item 2) is connected to the pinion (Figure 15, Item 1) by splines. The pinion (Figure 15, Item 1) turns the bevel gear (Figure 15, Item 6), which is fastened to the bevel gear shaft (Figure 15, Item 7) by bolts. The inner axle shafts send power to the brakes. The bevel gear, the pinion, and the transfer gears are lubricated with oil from the powertrain oil system. Oil flows through passages in the transfer case and through a tube in the bevel gear case. Oil from the tube lubricates the gears by spray lubrication.

Figure 15. Transfer and Bevel Gears. Brake Control Valve

0009

0009

The brake control valve is installed on top of the case above the left front side and is operated electrically by the ECM. The ECM responds to the operator’s movement of the service brake pedal. The service brake pedal modulates the engagement of both of the brakes in order to stop the machine. The parking brake switch engages both of the brakes to prevent movement of the machine. The brakes are engaged with spring force. Hydraulic pressure is required to disengage the brakes. If hydraulic pressure is lost, the brakes fully engage due to the action of the spring force. The brake control valve includes a valve body and a manifold. The valve contains a separate manifold for the service brakes. The valve also contains parking or secondary valves for the brakes. One pilot valve is used for both brakes. Proportional valve, accumulator piston, and reducing spool are used to operate the pilot valve.

0009-18

TM 5-2410-241-23-1

0009

These components control the brake pressure for both brakes. In addition, the brake control includes a shutoff valve. If the pressure from pilot valve drops suddenly, the shutoff valve gradually drains the brake pressure. This shutoff valve prevents sudden brake engagement due to an electrical failure. At the same time, the operator can rapidly apply the brakes. The brakes also have parking and secondary valves operated by two on/off solenoids. The two solenoids are connected to the parking brake switch and to the service brake switch (end of travel). The two solenoids for brake valves are controlled by these two switches and by the ECM. The parking brake valve and the secondary brake valve enable the operator to apply the brakes immediately without modulation by the shutoff valve. Table 3 identifies the callouts in Figure 16.

Figure 16. Brake Control Valve (Side View of Valve). Table 3. Brake Control Valve.

0009

Key Component 1

Solenoid to the parking or secondary brake valve

7

Reducing spool

13

Passage

2

Accumulator piston

8

Chamber for pressure feedback

14

Shutoff valve

3

Parking and secondary brake valves

9

Chamber for supply oil

15

Chamber for pilot pressure

4

Drain

10

Chamber for pilot pressure

16

Chamber for drain

5

Brake chamber

11

Spool

17

Pilot valve

6

Passage

12

Drilled hole

18

Proportional solenoid valve

0009-19

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TM 5-2410-241-23-1

0009

PRIMARY POWERTRAIN – CONTINUED Service Brake Pedal Operation

0009

When the operator pushes the service brake pedal toward the floor, the rotary sensor sends a signal to the ECM. This signal tells the ECM the brake pedal position. The ECM decreases the current to proportional valve (Figure 17, Item 6) relative to the brake pedal position. The decreased current reduces pilot oil pressure, which moves reducing spools (Figure 17, Item 2) and (Figure 17, Item 4) to the left. The movement drains the oil in both brake circuits (Figure 17, Item 1) and (Figure 17, Item 5). When the oil is drained, the brake oil pressure is lowered. The current to the proportional solenoid valve is dependent upon the position of the brake pedal. The solenoid sets the pilot oil pressure. The pressure in the brake circuit is directly affected by the position of the brake pedal. When the brake pedal is partially depressed, the pilot pressure is reduced. The machine brakes lightly. When the brake pedal is fully depressed, the pilot pressure is reduced until the pressure reaches zero psi (kPa). The oil is drained from the brake circuit. The machine brakes fully. Once the pedal is to the floor, the switch (end of travel) for the service brake opens. The switch connects one of the secondary solenoid valves (Figure 17, Item 3) to the battery. The ECM sends an electrical signal to the other secondary solenoid valve (Figure 17, Item 3). The energized solenoid valves move reducing spools (Figure 17, Item 2) and (Figure 17, Item 4) to the left. The movement routes the oil in both brake circuits (Figure 17, Item 1) and (Figure 17, Item 5) to the drain. When the pilot oil is drained, the machine brakes fully.

Figure 17. Brake Control Valve.

0009-20

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TM 5-2410-241-23-1

0009

PRIMARY POWERTRAIN – CONTINUED Steering Differential and Brake

0009

This section provides a short introduction to the hydraulic motor, the hydraulic pump, and the steering controls. The machine uses a differential steering system. The basic system includes a steering differential, a hydraulic pump, a hydraulic steering motor, and steering controls. The steering differential receives power from two components. One power input is from the transmission for control of the speed and for FORWARD or REVERSE movement. The other input is from the hydraulic motor for control of the steering. The steering motor feeds hydraulic power to the steering differential. The steering differential increases the speed of one track. The steering differential decreases the speed of the other track. The speed difference of the tracks turns the machine. The direction of rotation of the hydraulic motor determines the direction of the turn. A higher motor speed results in a sharper turn of the machine. The steering differential includes two planetary gear trains, a bevel gear set, and a set of brakes, which are mechanically connected with the steering differential. The planetary gears, the bevel gears, and the brakes are connected by components in the powertrain. Two outer axle shafts, an inner axle shaft, and the bevel gear shaft of the transmission connect these components of the powertrain. Power flow through the differential steering system is in three parts: •

Transmission

•

Steering

•

Combined Transmission and Steering

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0009

PRIMARY POWERTRAIN – CONTINUED Service Brakes

0009

The brakes are included in two different components of the machine. One component, which is located on the left side of the machine, is called the steering differential and brake. The other component, which is located on the right side of the machine, is called the planetary gears and brake. The brakes are used to stop the machine. The brakes do not assist in the steering of the machine. The brake components include: •

hub (Figure 18, Item 13),

•

carrier (Figure 18, Item 6),

•

brake pistons (Figure 18, Items 10 and 4),

•

retainer (Figure 18, Item 12),

•

stationary ring gear (Figure 18, Item 1),

•

Belleville springs (Figure 18, Item 9) and (Figure 18, Item 5),

•

housings (Figure 18, Items 14 and 3),

•

and friction discs and brake plates (Figure 18, Items 11 and 2).

The brakes are engaged by Belleville springs (Figure 18, Items 9 and 5). The brakes are released by pressure oil from the brake control valve. The operator controls the brake control valve with a service brake foot pedal. During movement of the machine, pressure oil is sent through passages in the brake housings (Figure 18, Items 14 and 3) to chambers (Figure 18, Items 7 and 8). Since the brakes are held in the released position, the outer axle shafts rotate freely. When the service brake pedal is pushed, pressure oil to chambers (Figure 18, Items 7 and 8) is stopped. The chambers are opened to the drain. Belleville springs (Figure 18, Items 9 and 5) then push brake pistons (Figure 18, Items 10 and 4) against friction discs and brake plates (Figure 18, Items 11 and 2). Friction discs and brake plates (Figure 18, Items 11 and 2) stop the rotation of powertrain components: hub (Figure 18, Item 13), carrier (Figure 18, Item 6), and the outer axle shafts. The machine stops. The engine is in torque converter stall condition.

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0009

PRIMARY POWERTRAIN – CONTINUED

Figure 18. Steering Differential and Brake with Planetary Gears and Brake. END OF WORK PACKAGE

0009-23/(24 blank)

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10 TM 5-2410-241-23-1

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FIELD MAINTENANCE 0 0 1 0

-

THEORY OF OPERATION: FINAL DRIVE AND UNDERCARRIAGE

FINAL DRIVE SYSTEM

00010

Outer axle shaft (Figure 1, Item 1) sends power to the final drive. Inner sun gear (Figure 1, Item 5) is fastened by splines to outer axle shaft (Figure 1, Item 1). The rotation of the axle shaft and inner sun gear (Figure 1, Item 5) turns inner planetary gears (Figure 1, Item 3). Ring gear (Figure 1, Item 9) is a stationary component and inner planetary gears (Figure 1, Item 3) rotate around the inside of the ring gear (Figure 1, Item 9). The rotation of inner planetary gears (Figure 1, Item 3) around the inside of the ring gear (Figure 1, Item 9) turns the inner carrier (Figure 1, Item 7), which is connected to outer sun gear (Figure 1, Item 6) by splines. The rotation of inner carrier (Figure 1, Item 7) and outer sun gear (Figure 1, Item 6) causes the outer planetary gears (Figure 1, Item 4) to turn. The rotation of outer planetary gears (Figure 1, Item 4) around the inside of ring gear (Figure 1, Item 9) turns outer carrier (Figure 1, Item 8), which is fastened to hub (Figure 1, Item 10). The rotation of hub (Figure 1, Item 10) sends power to sprocket segments (Figure 1, Item 2) and the track. The oil level in the final drives is maintained through a filler plug. All components receive splash lubrication oil as the gears move. The gears throw oil on all of the components.

Figure 1. Final Drives.

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UNDERCARRIAGE SYSTEM

00010

Undercarriage Arrangement

00010

The undercarriage of the machine is not suspended. Pivot shafts (Figure 2, Item 5) connect the roller frames at the rear of the machine. The equalizer bar connects the two roller frames at the front of the tractor. The equalizer bar keeps the roller frames in a constant position relative to the main frame and to each other. The track roller frames consist of front frame (Figure 2, Item 2) and rear frame (Figure 2, Item 3). The front idler (Figure 2, Item 1) is installed on the front frame. The rear idler (Figure 2, Item 6) and track rollers (Figure 2, Item 4) are installed on the rear frame. The tracks (Figure 2, Item 7) are sealed and lubricated for increased wear resistance. A recoil mechanism is installed in the roller frame in order to keep the track adjusted. Standard

00010

The standard undercarriage on each side of the machine has seven track rollers. Four of the rollers are singleflange track rollers and three of the rollers are double-flange track rollers. The installation of the track rollers is arranged from the front of the machine in the following order: 1. Single-flange 2. Double-flange 3. Single-flange 4. Double-flange 5. Single-flange 6. Double-flange 7. Single-flange

Figure 2. Undercarriage.

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FINAL DRIVE AND UNDERCARRIAGE

00010

Pivot Shaft

00010

The pivot shaft (Figure 3, Item 4) connects the machine frame (Figure 3, Item 3) with the two track frames (Figure 3, Item 2). Each track roller frame can rotate about the pivot shaft. The pivot shaft (Figure 3, Item 4) extends through the pivot shaft cavity in the machine frame (Figure 3, Item 3). Two sleeve bearings in the machine frame (Figure 3, Item 3) support the machine on the pivot shaft (Figure 3, Item 4). The pivot shaft (Figure 3, Item 4) is supported by two bearings (Figure 3, Item 1) in the track roller frame (Figure 3, Item 2). The track roller frame (Figure 3, Item 2) is filled with oil in order to lubricate the pivot shaft bearings in the track roller frame (Figure 3, Item 2). The seal (Figure 3, Item 5) contains the oil in the cavity on the track roller frame (Figure 3, Item 2) and in the pivot shaft cavity.

Figure 3. One Side of Pivot Shaft.

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FINAL DRIVE AND UNDERCARRIAGE – CONTINUED Lubrication of Pivot Shaft

00010

The oil for lubrication of the pivot shaft (Figure 4, Item 2) comes from the pivot shaft oil reservoir (Figure 4, Item 1). Oil flows by gravity from the reservoir (located above the left fender of the machine) to the pivot shaft. The hose assembly (Figure 4, Item 4) connects the reservoir to a port that is located in the machine frame (Figure 4, Item 3), which allows lubrication oil to reach the pivot shaft. The pivot shaft oil level can be checked with the dipstick cap assembly. Oil is added by removing the cap assembly that is located on the top of the reservoir.

Figure 4. Lubrication of Pivot Shaft.

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FINAL DRIVE AND UNDERCARRIAGE – CONTINUED Equalizer Bar

00010

The track roller frames are connected at the front by the equalizer bar (Figure 5, Item 3), which is a solid steel piece. The equalizer bar (Figure 5, Item 3) keeps the roller frames in a constant position relative to the machine frame and to each other. The equalizer bar is connected to roller frames (Figure 5, Item 6) and to the machine frame (Figure 5, Item 1) by pins (Figure 5, Item 2). One bearing (Figure 5, Item 5) is installed in each end of the equalizer bar. Seals (Figure 5, Item 4) prevent foreign material from contacting the bearing that is used between the equalizer bar and the machine frame.

Figure 5. Equalizer Bar.

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FINAL DRIVE AND UNDERCARRIAGE – CONTINUED Track Roller Frame

00010

The track roller frame can be separated into two sections. Front roller frame has a large tube assembly. The tube assembly slides into rear roller frame. Tube contains a recoil spring and track adjustment valves. A groove is machined in the outer diameter of the tube. Guide assemblies are installed in rear roller frame. The guides are aligned with the groove. The guides will prevent any rotation of tube inside the rear roller frame.

Figure 6. Track Roller.

Key Components 1

Rear Track Roller Frame

5

Pivot Shaft

2

Track Adjuster Cover

6

Seal

3

Guide Assembly

7

Guide Assembly

4

Front Track Roller Frame

8

Recoil Group

0010-6

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TM 5-2410-241-23-1

0010

FINAL DRIVE AND UNDERCARRIAGE – CONTINUED Track adjustment valves are used for moving front roller frame to adjust the track tension. Grease is pumped into the filler valve causing the piston to move to the right. This causes the front track roller to move out of the rear roller frame. The movement of the recoil rod and the front idler tightens the track. The tension on the track is released by a relief valve.

Figure 7. Recoil Group.

Key Components 1

Track Adjustment Valves

4

Tube

2

Cylinder Assembly

5

Nut

3

Recoil Spring

6

Piston

0010-7

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TM 5-2410-241-23-1

0010

FINAL DRIVE AND UNDERCARRIAGE – CONTINUED Sealed and Lubricated Track

00010

The track that is standard on this machine is sealed and lubricated. Each track assembly has links, pins, bushings, thrust rings, polyurethane seal assemblies, rubber stoppers, and polyurethane plugs. Each of the track links (Figure 8, Items 1 and 5) fits over the preceding track link. Link (Figure 8, Item 1) fits over link (Figure 8, Item 8). Link (Figure 8, Item 5) fits over link (Figure 8, Item 7). The connection of the track links make the track assembly. Each track link is designed with a counterbore in the end in order to fit over the preceding track link. Seals (Figure 8, Item 12) are installed in the counterbores. Each seal includes a load ring and a seal ring. The load ring pushes the seal ring against the end of bushing (Figure 8, Item 2) and against the link counterbore. The seal ring makes a positive seal between the bushing and the link counterbore. Thrust rings (Figure 8, Item 9) are installed on pin (Figure 8, Item 6). The thrust rings compress the seals to a specific tolerance. The thrust rings also control the end play (free movement) of the track joint. The seals and the thrust rings keep foreign materials out of the track joint. The seals and the thrust rings keep lubricating oil in the track joint. Each pin (Figure 8, Item 6) is designed with an oil reservoir (Figure 8, Item 4), which runs most of the length of the axis of the pin. A radial hole (Figure 8, Item 3) is drilled in the middle of the length of the pin, which directs oil to the surface between pin (Figure 8, Item 6) and bushing (Figure 8, Item 2) and to the lips of the seal rings. The pin, the bushing, and the lips of the seal rings are lubricated in order to prevent wear. The oil is kept in the pin by stopper (Figure 8, Item 11) and by plug (Figure 8, Item 10). The pin is filled with oil through a hole in the center of stopper (Figure 8, Item 11). When the chamber in the pin is filled, a plug (Figure 8, Item 10) is installed in stopper (Figure 8, Item 11).

Figure 8. Track Assembly.

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FINAL DRIVE AND UNDERCARRIAGE – CONTINUED Master Link

00010

Two-piece master links (Figure 9, Item 3) and a master shoe (Figure 9, Item 1) are bolted together (Figure 9, Item 2). Each assembled track link is sealed. Independent lubrication is provided for components. The seals and the lubrication oil help to prevent internal wear on the track joints. Significant wear occurs only on the outside of the bushings and on the outside of the track links.

Figure 9. Master Links and Master Shoe. Track Idler

0010

00010

The machine has a front and a rear idler for each roller frame. Stabilizer (Figure 10, Item 3) controls the position of seal (Figure 10, Item 4). The amount of side movement or end clearance of the shaft cannot be adjusted. Each idler (Figure 10, Item 1) has Duo-Cone seals (Figure 10, Item 4) at both ends of shaft (Figure 10, Item 2). The center of shaft (Figure 10, Item 2) is an oil reservoir. The oil is used for lubrication of the bearing surfaces.

Figure 10. Idlers.

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TM 5-2410-241-23-1

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FINAL DRIVE AND UNDERCARRIAGE – CONTINUED Track Roller

00010

Both single and double flange track rollers are located on each side of the machine. The track rollers are fastened to the bottom section of the track roller frame and are in contact with the rails on the track links. The flanges on the track rollers prevent the lateral movement of the track links. A bushing (Figure 11, Item 4) puts the side load on the roller. The amount of lateral movement or end clearance of the shaft cannot be adjusted. Duo-Cone seals (Figure 11, Item 5) are attached to both of the ends of shaft (Figure 11, Item 1). Track Roller Lubrication

00010

The roller is lubricated with the oil in a center passage (Figure 11, Item 3). Oil is added through shaft (Figure 11, Item 1) at a stopper (Figure 11, Item 2) and forced through the center passage (Figure 11, Item 3) to the lubrication holes in shaft (Figure 11, Item 1). Duo-Cone seals (Figure 11, Item 5) seal the oil in the roller at each end.

Figure 11. Track Roller (Double Flange). END OF WORK PACKAGE

0010-10

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52 TM 5-2410-241-23-1

0011

FIELD MAINTENANCE 0

0 1 1

-

THEORY OF OPERATION: IMPLEMENT AND STEERING HYDRAULIC

IMPLEMENT AND STEERING HYDRAULIC SYSTEM

00011

The hydraulic system controls the steering, the bulldozer, and the ripper or winch (depending on which implement is installed). The hydraulic system is a load sensing, pressure compensated system. In a load sensing, pressure compensated system, oil flow does not change according to the load conditions. Cylinder speeds remain constant under all load conditions. Hydraulic pump (Figure 1, Item 1) is a variable displacement piston pump. The pump provides oil for all implement circuits and for the steering circuit. The pump is oversized so that the steering circuit and the implement circuit can be operated simultaneously. The maximum pump flow is set at 76 US gal/min (289 L/min). The pump destrokes to keep the pressure in the system at a minimum. When a control lever is moved to an operating position, higher oil pressure is needed in the system. The destroked pump compensates for system leakage with a small output and maintains an approximate system pressure of 525 psi (3,620 kPa).

Figure 1. Hydraulic Pump.

0011-1

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TM 5-2410-241-23-1

0011

IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED When an implement circuit is activated, the compensator valve on hydraulic pump senses the load increase from the signal resolver network causing the pump to upstroke. The pump continues to upstroke until the system pressure is approximately 305 psi (2,100 kPa) higher than the load signal from the control valve. Pressure limiters in the implement control valves control the maximum pressure in the implement circuits. The system pressure will be less than 305 psi (2,100 kPa) higher than the load signal from the control valve under two circumstances. This lower system pressure occurs when the pump reaches the maximum displacement and the pump does not achieve the necessary flow. This also occurs when the pressure cutoff setting is reached. If the steering circuit is activated, the pump upstrokes in the same manner. However, pressure in the steering circuit is controlled by the cutoff spool in the pump compensator valve. When the steering circuit pressure reaches an approximate pressure of 5585 psi (38,500 kPa), the pump destrokes enough to maintain the pressure until the system pressure decreases. The main relief valve is located on the inlet manifold at the bottom of the valve stack. It limits the pressure increases (spikes) to approximately 6,100 psi (42,580 kPa).

Figure 2. Components of the Hydraulic System.

0011-2

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED An open loop hydraulic system is used for steering. The operator uses the steering control lever to initiate a turn. The steering control lever (Figure 3, Item 1) is mechanically connected to the steering control valve, which is part of the valve stack.

Figure 3. Steering Control Lever.

0011

The steering control valve directs oil to the steering motor (Figure 4, Item 1) which is a fixed displacement motor, and drives the steering differential gears. Power is transferred from one track to the other track during the steering operation. This allows an efficient application of power to the ground. The counterbalance valve (Figure 4, Item 2) is attached to the steering motor and controls the speed of steering motor so that additional torque from the transmission and from the tracks does not drive the motor beyond the control of the operator.

Figure 4. Counterbalance Valve And Steering Motor.

0011-3

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TM 5-2410-241-23-1

0011

IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED The steering motor and the hydraulic pump are equipped with a flushing system. The flushing system uses oil that has passed through the oil cooler, implements and attachments to assist in cooling the steering motor and the hydraulic pump during high ambient temperature conditions. A pilot control lever (Figure 5, Item 1) is used for operator control of the bulldozer blade. A pilot control lever (Figure 5, Item 3) is used for operator control of the winch or ripper. The hydraulic lockout switch (Figure 5, Item 2) is located next to the pilot control levers.

Figure 5. Pilot Control Levers.

0011-4

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TM 5-2410-241-23-1

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED When the pilot control lever is moved to an operating position, the pilot supply oil instructs the implement control valve to send oil to the cylinder. A manifold and reducing valve (Figure 6, Item 3) supplies pilot oil to the control valves for the bulldozer blade and the implements. The manifold and reducing valve includes a pressure reducing valve, a screen, a relief valve, a check valve, and an attached accumulator (Figure 6, Item 2). The accumulator and the check valve are used to maintain supply pressure during momentary drops in system pressure and for a short time after the engine is shut off. A shutoff valve (Figure 6, Item 1) is located in the manifold of the pressure reducing valve. A solenoid operates the shutoff valve that is in the manifold and is energized when the hydraulic lockout switch is activated. When the solenoid valve is energized, pilot supply oil from the pressure reducing valve enters the shutoff valve of the manifold. In the LOCK position, the line from the pressure reducing valve is blocked and the oil is diverted to the tank line. This allows the oil from the pilot control valves to drain to the hydraulic tank. When the hydraulic lockout switch is toggled to the LOCK position, the solenoid valve is de-energized and spring force moves the shutoff valve to the LOCK position. When this occurs, a lamp on the instrument panel is activated.

Figure 6. Solenoid for the Shutoff Valve.

0011-5

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TM 5-2410-241-23-1

0011

IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED The valve stack has an inlet manifold (Figure 7, Item 5) and an end cover (Figure 7, Item 1) and can have as many as five control sections. The implement control valves are in parallel with each other. The steering control valve (Figure 7, Item 4) is controlled by a mechanical linkage from the steering control lever. The steering control valve has priority over the implement control valves. This means that no less than half of the steering speed is available at all times. The steering control has three positions: STEER RIGHT, HOLD, and STEER LEFT. The control valves for the bulldozer, the ripper (if equipped) and winch (if equipped) are controlled by the pilot control system. The implement and steering hydraulic system bulldozer blade lift control valve (Figure 7, Item 3) has four positions: RAISE, HOLD, LOWER, and FLOAT. The bulldozer tilt control valve (Figure 7, Item 2) has three positions: TILT RIGHT, HOLD, and TILT LEFT. The ripper lift control valve has three positions: RAISE, HOLD, and LOWER. The ripper tip control valve has three positions: TIP OUT, HOLD, and TIP IN. The winch control valve has three positions: REEL IN, HOLD, and REEL OUT.

Figure 7. Valve Stack for Machine without Ripper.

0011-6

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Hydraulic Tank and Filter

00011

The hydraulic oil tank (Figure 8, Item 1) is located on the front of the right fender of the machine and is sealed in order to prevent contamination of the hydraulic oil. The suction port (Figure 8, Item 6) supplies hydraulic oil to the hydraulic pumps. Oil flows from the hydraulic components into hydraulic oil tank (Figure 8, Item 1) through five passages. One passage (Figure 8, Item 7) collects oil from the pressure reducing valve. This passage (Figure 8, Item 7) also collects oil from the pilot control valve (bulldozer angle), if equipped. Oil from this passage (Figure 8, Item 7) flows directly into hydraulic oil tank (Figure 8, Item 1). Another passage (Figure 8, Item 8) collects implement return oil that drains through the inlet manifold. Oil from this passage (Figure 8, Item 8) flows into the hydraulic oil tank (Figure 8, Item 1) through the implement return oil filter (Figure 8, Item 5). The implement return oil filter (Figure 8, Item 5) stops any debris that is in the hydraulic oil. Another passage (Figure 8, Item 9) collects return oil from the following sources: •

Case drain from the implement pump

•

Case drain from the steering motor

Oil from this passage (Figure 8, Item 9) flows into hydraulic oil tank (Figure 8, Item 1) through the case drain filter (Figure 8, Item 3). The case drain filter (Figure 8, Item 3) stops any debris that is in the hydraulic oil. A fourth passage (Figure 8, Item 10) collects pilot return oil from the pilot control valves. Oil from this passage (Figure 8, Item 10) flows directly into the hydraulic oil tank (Figure 8, Item 1). The fifth passage (Figure 8, Item 11) collects pilot return oil from the implement control valves and from the pilot manifold. Oil from this passage (Figure 8, Item 11) flows directly into hydraulic oil tank (Figure 8, Item 1). A port at (Figure 8, Item 12) is for the temperature sensor.

Figure 8. Hydraulic Oil Tank.

0011-7

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TM 5-2410-241-23-1

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Oil Filter (Case Drain)

00011

The case drain oil filter is located within the hydraulic oil tank and removes debris from the hydraulic oil that returns through the case drain return port (Figure 9, Item 3). Hydraulic oil flows through filter base (Figure 9, Item 4) and into a cavity (Figure 9, Item 7). The oil fills the space between the inside of the filter element (Figure 9, Item 1). Oil flows through the filter element (Figure 9, Item 1) and back to the hydraulic oil tank (Figure 9, Item 2). The filter element (Figure 9, Item 1) stops any debris that is in the hydraulic oil. If the filter element (Figure 9, Item 1) becomes full of debris, the restriction to the flow of oil causes a pressure increase inside the filter element (Figure 9, Item 1). The pressure of the oil causes the filter bypass valve (Figure 9, Item 5) to move against spring (Figure 9, Item 6). Unfiltered oil is allowed to pass through the bypass valve (Figure 9, Item 5) and flow directly into the hydraulic oil tank (Figure 9, Item 2). Unfiltered oil can cause damage to all components in the hydraulic system. Correct maintenance procedures must be followed in order to ensure that the filter element does not become full of debris, which will stop the flow of clean oil to the hydraulic tank.

Figure 9. Oil FIlter (Case Drain).

0011-8

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TM 5-2410-241-23-1

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Oil Filter (Implement Return Oil)

00011

The implement return oil filter is located within the hydraulic oil tank and removes debris from the hydraulic oil that returns through the implement return port (Figure 10, Item 7). Hydraulic oil flows through the filter base (Figure 10, Item 6) and into a cavity (Figure 10, Item 3). The oil fills the space between the inside of the filter element (Figure 10, Item 2). Oil flows through the filter element (Figure 10, Item 2) and back to the hydraulic oil tank (Figure 10, Item 1). The filter element (Figure 10, Item 2) stops any debris that is in the hydraulic oil. If the filter element (Figure 10, Item 2) becomes full of debris, the restriction to the flow of oil causes a pressure increase inside the filter element (Figure 10, Item 2). The pressure of the oil causes the filter bypass valve (Figure 10, Item 5) to move against the spring (Figure 10, Item 4). Unfiltered oil is allowed to pass through the bypass valve (Figure 10, Item 5) and flow directly into the hydraulic oil tank (Figure 10, Item 1). Unfiltered oil can cause damage to all components in the hydraulic system. Correct maintenance procedures must be followed in order to ensure that the filter element does not become full of debris, which will stop the flow of clean oil to the hydraulic tank.

Figure 10. Oil Filter (Implement Return Oil).

0011-9

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Oil Cooler and Bypass Valve

00011

The oil cooler bypass valve is installed at the port for the implement return oil (Figure 11, Item 3) and is located on the hydraulic oil tank (Figure 11, Item 8). When the implement or steering circuits are active, the return oil flows through the bypass valve. A valve (Figure 11, Item 5) and spring (Figure 11, Item 6) cause a back pressure of approximately 39 psi (270 kPa), which causes the flow of part of the return oil through an outlet (Figure 11, Item 4) to the oil cooler (Figure 11, Item 1). The larger part of the return oil flows through outlet (Figure 11, Item 7) to the tank (Figure 11, Item 8). The bypass valve opens quickly in order to relieve the increases (surges) of flow of the return oil. The bypass valve keeps pressure increases (spikes) from the oil cooler. The oil that flows out of the oil cooler outlet (Figure 11, Item 2) is sent to the implement pump case and the steering motor case in order to lubricate the pump and the motor.

Figure 11. Oil Cooler and Bypass Valve. Piston Pump (Implement)

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00011

Engine Off

00011

The hydraulic pump for the implements and for the steering is an automatically controlled slipper type piston pump. The pump senses pressure in order to determine the flow that is needed by the system. When the drive shaft rotates, the cylinder barrel also turns. Nine pistons are held against the non-rotating swashplate by the retaining plate. As illustrated, at the maximum swashplate angle, part of pistons are pulled out of the cylinder barrel (not illustrated). The remaining pistons are pushed into the cylinder barrel. Rotation of the cylinder barrel causes the pistons to move in and out of the cylinder barrel. Oil is pulled into the pump and oil is pushed out of the pump by the push-pull movement of the pistons. The angle of the swashplate determines the amount of oil that is pulled into each piston bore or is pushed out of each piston bore by the drive shaft rotation. There are infinite swashplate angle positions between the neutral angle (zero degrees) and the maximum angle. A greater amount of oil is pulled into the pump and a greater amount of oil is pushed out of the pump by an increased swashplate angle. When the swashplate angle is zero degrees, pistons do not move in and out of the rotating cylinder barrel. Therefore, no oil is pulled into the pump, no oil is pushed out of the pump and there is zero displacement from the pump. This means the pump is not generating oil flow there is not a restriction to flow that can generate pressure.

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED The pump is only at the zero swashplate angle when signal oil pressure suddenly drops to zero or when system pressure suddenly surges to the maximum pressure cutoff setting. These conditions can cause the swashplate to move momentarily to the zero angle position. The compensator valve keeps pump oil flow at a level that is needed to fulfill the system load and flow needs. These needs are met by the compensator valve in two ways: Either pump oil is sent to the large actuator piston or pump oil is drained from the large actuator piston. The large actuator piston works with the small actuator piston and the spring in order to continually adjust the swashplate angle. Pressure at the pump outlet is kept at about 305 psi (2,100 kPa) above the signal oil pressure by the margin spool in the compensator valve. The compensator valve also has a pressure cutoff spool that prevents overloads of the pump and of the system. When work port pressure goes over 5,585 psi (38,500 kPa), the cutoff spool will override the margin spool and lower pump output while system pressure is maintained at 5,585 psi (38,500 kPa).

Figure 12. Pump and Compensator Operation (Engine Off).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED The following schematics show the actions of the pump and the compensator valve under different conditions in the hydraulic system. Upstroking

00011

Upstroking means that the pump is increasing the displacement (output) and occurs when the signal oil pressure increases due to an increased load. The highest signal oil pressure from the control valves flows through the line and the oil fills a chamber. The force of the signal oil pressure plus the force of the springs now move the margin spool to the left. The spool movement blocks the flow of pump oil to the large actuator piston. The spool movement also opens the passages to the large actuator piston to the case drain. The combined force — of the actuator spring and of the system oil pressure that is behind the small actuator piston — moves the swashplate toward the maximum angle (upstroke). Pump output is increased by upstroking until the pressure in passage moves the margin spool right to the metering position. When the margin spool is first at the metering position, system oil pressure in passage is higher than the signal oil pressure and the force of springs in chamber. The greater pressure moves the margin spool farther to the right. This sends system oil pressure through passages and to the large actuator piston. Because the force of the large actuator piston is greater than the force of the small actuator piston, plus the force of the actuator spring, the force that is on the swashplate toward the minimum angle is greater than the force that is on the swashplate, toward the maximum angle. The difference in force causes a decrease in the angle of the swashplate and the pump output. The decrease in the pump output causes a decrease in pressure. When the pump flow decreases enough, the combined signal pressure and the force of springs in chamber cause the margin spool to move to the left. The pump oil that is behind the large actuator piston flows to the case drain again. The small actuator piston and the actuator spring increase the swashplate angle. The continuous oscillation (metering) of margin spool maintains the system pressure in chamber at 305 psi (2,100 kPa) higher than the signal pressure that is in the chamber, because the force of the springs is equal to 305 psi (2,100 kPa). The difference is called the margin pressure.

Figure 13. Pump and Compensator Operation (Upstroking).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Destroking

00011

Destroking means that the pump is decreasing the displacement (output) and occurs when the signal oil pressure decreases from lower loads. Destroking also occurs when all of the control valves are in the HOLD position and signal oil pressure decreases to 0 psi (0 kPa). The lower signal oil pressure in the chamber causes the higher system oil pressure in the chamber to move the margin spool to the right. The spool movement allows the system oil pressure to flow through passages and to the large actuator piston. The force that is created by the system oil pressure (that is behind large actuator piston) is now higher than the force of the actuator spring, and the system oil pressure (that is behind small actuator piston). The angle of the swashplate decreases. Pump output decreases until the pump flow is not adequate to maintain system pressure, and system pressure decreases. When system pressure approaches 305 psi (2,100 kPa) (margin pressure) above the signal oil pressure, the margin spool moves to the left, and the spool begins to meter oil at the large actuator piston to case drain. When system pressure approaches 525 psi (3,600 kPa) (low pressure standby), the margin spool moves to the left and the spool begins to meter oil at the large actuator piston to the case drain. Signal oil pressure is zero when the control valves are in the HOLD position. The swashplate increases the angle slightly, so that the pump output makes up system leakage. Also, the higher swashplate angle maintains the margin pressure in the system.

Figure 14. Pump and Compensator Operation (Destroking).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Low Pressure Standby

00011

When the engine is running with the control valves in the HOLD position, there is no signal oil pressure in the line to the chamber. Without signal oil pressure in the chamber, system oil pressure in the chamber moves the margin spool to the right against the force of springs. Pump oil then flows through two passages to the large actuator piston. The large actuator piston moves the swashplate toward the minimum angle that is required for enough output to maintain system pressure at 525 psi (3,600 kPa).

NOTE Do not confuse low pressure standby with the margin pressure. Margin pressure is 305 psi (2,100 kPa). The pressure that is required to compress the springs is 305 psi (2,100 kPa). This pressure is not sufficient to move the swashplate against the force of the actuator spring and of the small actuator piston. Pump output increases until the swashplate can move against the small actuator piston and the actuator spring. System pressure then stays at 525 psi, (3,600 kPa) which is Low Pressure Standby. Margin pressure can only be measured in a non-stall load sensing condition. Some variation in low pressure standby can occur from low idle to high idle.

Figure 15. Pump and Compensator Operation (Low Pressure Standby).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED High Pressure Stall

00011

When the hydraulic system stalls under a load in the steering circuit, the oil pressure increases. A stall occurs when system oil pressure gets to 5,585 psi (38,500 kPa). Signal oil pressure in the line and the chamber now equals system oil pressure in the chamber. Springs keep the margin spool moved to the left which puts the pump in an upstroking position. As system oil pressure approaches 5,585 psi (38,500 kPa), the pressure cutoff spool moves to the left against the spring. Pump oil flows through passage to the large actuator piston. The pressure that is behind the large actuator piston moves the swashplate until the system pressure is maintained at 5,585 psi (38,500 kPa). When the pump output flow is insufficient for maintaining the system pressure and the pressure decreases below 5,585 psi (38,500 kPa), the force of the spring moves the pressure cutoff spool further to the right. This spool movement stops the flow of oil past the spool to the large actuator piston. As system pressure decreases further, the pressure cutoff spool moves further to the right and the large piston actuator opens to the margin spool. When system pressure approaches margin pressure over signal oil pressure, the margin spool moves to the metering position. The metering position allows the swashplate angle to increase until pump flow is sufficient to make up system leakage and the lower required pressure is maintained. If there is no signal oil pressure, system pressure goes to low pressure standby.

Figure 16. Pump and Compensator Operation (High Pressure Stall).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Constant Flow

00011

Constant flow is achieved when the force of the pressure of the pump supply in passage is equal to the sum of the force of the springs and the signal pressure in the signal line. The forces on both sides of the margin spool will be equal. The equal forces move the spool to a metering position. The metering of the margin spool provides a stabilized system with constant flow. As the signal pressure in line decreases, the force on the left of the margin spool is greater than the sum of the force of the signal pressure and the force of the springs. The decrease in signal pressure causes the margin spool to move to the right. The spool movement allows pump oil pressure to flow through passages and to the large actuator piston. The large actuator piston will decrease the angle of the swashplate which decreases pump output. As pump output decreases, the pressure on the left of the margin spool decreases. The decrease in pressure allows the margin spool to move into a metering position again.

Figure 17. Pump and Compensator Operation (Constant Flow).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Piston Motor (Steering)

00011

The steering motor (Figure 18, Item 1) is located between the counterbalance valve and an adapter. The adapter is attached to the frame below the operator’s station.

Figure 18. Piston Motor (Steering) Location.

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED The steering motor is a fixed displacement bent axis motor of the piston type and is operated by oil from the variable displacement piston pump. The steering motor can produce the same amount of output torque in either direction. Oil flow through the steering motor can be in either direction. A change in the direction of oil flow causes a change in the direction of rotation for barrel (Figure 19, Item 4), for pistons (Figure 19, Item 2), and for shaft (Figure 19, Item 10). The parts of the motor that turn are: shaft (Figure 19, Item 10), snap ring and shims (Figure 19, Item 15), retaining plate (Figure 19, Item 9), pistons (Figure 19, Item 2), and barrel (Figure 19, Item 4). The parts that do not turn are: head (Figure 19, Item 7), case (Figure 19, Item 6), port plate (Figure 19, Item 5), shims (Figure 19, Item 14), ring (Figure 19, Item 12), and cover (Figure 19, Item 16). Oil from the pump flows to the steering motor through the steering control valve and through the counterbalance valve. Then, oil flows through the inlet control slot in the head (Figure 19, Item 7) to the inlet control slot in the port plate (Figure 19, Item 5).

NOTE The direction of rotation determines the inlet and the outlet of the two slots in the head (Figure 19, Item 7). Likewise, the direction of rotation determines the inlet and the outlet of the two slots in the port plate (Figure 19, Item 5). Oil through the port plate flows into the cylinders of the barrel that are over the inlet control slot of the port plate. The cylindrical ends of pistons (Figure 19, Item 2) are held in sockets in shaft (Figure 19, Item 10) by a retaining plate (Figure 19, Item 9). The sealed end of pistons (Figure 19, Item 2) are positioned in barrel (Figure 19, Item 4). Barrel (Figure 19, Item 4) rotates around pivot pin (Figure 19, Item 1), which is at a fixed angle of 40 degrees to the axis of the shaft (Figure 19, Item 10). Because the steering motor is a bent axis type motor, seven pistons (Figure 19, Item 2) move in and out of the cylinders as oil leaves the cylinders and as oil enters the cylinders. The motion forces the pistons to rotate around a pivot pin (Figure 19, Item 1). Rotation of the pistons forces shaft (Figure 19, Item 10) and barrel (Figure 19, Item 4) to rotate. As shaft (Figure 19, Item 10), pistons (Figure 19, Item 2), and barrel (Figure 19, Item 4) continue rotation, the pistons reach the top center (full retracted position). At the same time, the cylinder begins to overlap the outlet control slot in the port plate (Figure 19, Item 5). The piston begins to move downward. Because the piston moves downward, the piston pushes oil out of the cylinder, into the outlet control slot in the port plate (Figure 19, Item 5), and through the outlet control slot in the head (Figure 19, Item 7). The same oil is then pushed to the counterbalance valve, to the steering control valve, and to the tank. The ball end of the pivot pin (Figure 19, Item 1) is the pivot point for the barrel (Figure 19, Item 4). Oil passage (Figure 19, Item 8) provides lubricating oil to a drilled passage in the pivot pin (Figure 19, Item 1). The oil then flows to the pivot pin, the pivot pin socket, and on through passages to bearings (Figure 19, Items 11 and 13). The oil drains from the case (Figure 19, Item 6) through the port (Figure 19, Item 3).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED

Figure 19. Piston Motor (Steering).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Counterbalance Valve (Steering)

00011

The counterbalance valve (Figure 20, Item 1) is attached to the steering motor which is located below the operator’s station.

Figure 20. Counterbalance Valve (Steering) Location.

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The counterbalance valve is used in order to keep the steering motor under the operator’s control during overspeed steering load conditions. An overspeed condition exists when the machine is working in conditions that involve an underfoot side slope and the fast track drawbar pull is lower than the slow track. This decreased pull causes feedback torque through the steering gears that are attempting to turn the steering motor faster than the demand of the steering control valve.

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED During a normal left turn, oil from the steering control valve flows into the valve port (Figure 21, Item 5) and through the stem (Figure 21, Item 6) to the check valve (Figure 21, Item 3). Oil also flows through passage (Figure 21, Item 4), around the stem (Figure 21, Item 6), and through the orifice (Figure 21, Item 2) into the chamber (Figure 21, Item 1). Oil opens the check valve (Figure 21, Item 3) flows through the stem (Figure 21, Item 6), through the passage (Figure 21, Item 18), and to the motor port (Figure 21, Item 16). Oil then flows through the steering motor and the oil turns the steering motor clockwise. Oil flows through the motor to the motor port (Figure 21, Item 15). The motor port (Figure 21, Item 15) sends oil through the passage (Figure 21, Item 13) to the check valve (Figure 21, Item 9). Oil at the check valve (Figure 21, Item 9) is temporarily blocked and the pressure of the oil increases. When the oil pressure reaches a threshold of approximately 1,015 psi (7,000 kPa), the stem (Figure 21, Item 6) moves to the right. Now, oil in the passage (Figure 21, Item 13) flows through passages (Figure 21, Item 12) and through the stem (Figure 21, Item 6) to the valve port (Figure 21, Item 7) and to the tank. As the stem (Figure 21, Item 6) moves to the right, oil in the chamber (Figure 21, Item 11) is sent through an orifice (Figure 21, Item 10) to a passage (Figure 21, Item 8). The oil flows through the valve port (Figure 21, Item 7) to the tank. Once the stem (Figure 21, Item 6) has moved approximately 0.08 inch (2 mm), oil in the chamber (Figure 21, Item 11) flows directly through a passage (Figure 21, Item 8) and the valve port (Figure 21, Item 7) to the tank and the stem is allowed to move faster to the right. During overspeed conditions, feedback torque that comes through the steering gears attempts to turn the steering motor at a faster speed than the speed that is necessary. This feedback causes reduced pressure on the inlet side of the counterbalance valve command valve port (Figure 21, Item 5), passage (Figure 21, Item 18), and motor port (Figure 21, Item 16). When the inlet pressure decreases lower than threshold pressure, the stem (Figure 21, Item 6) moves to the left. The flow of oil through the outlet side of the counterbalance valve motor port (Figure 21, Item 15), passage (Figure 21, Item 13), and valve port (Figure 21, Item 7) is restricted. The restricted oil flow counteracts the feedback torque that drives the steering motor. Now, the steering motor speed is sustained close to the speed that is demanded by the steering control valve. Crossover relief valves (Figure 21, Items 14 and 17) prevent damage to the steering system from pressure increases (spikes). These valves are pilot controlled relief valves that open at approximately 6,000 psi (41,500 kPa). When the crossover relief valves open, the valves send oil to the opposite motor port.

Figure 21. Counterbalance Valve (Steering).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Control Valve (Implement/Attachment)

00011

The implement and attachment control valves are assembled in a valve stack which is located below the platform in the right side of the cab. The machine equipped with a ripper has two additional control valves added to the valve stack. The machine equipped with a ripper has a valve stack that includes the following valves: •

Ripper tip control valve

•

Ripper lift control valve

•

Bulldozer tilt control valve

•

Bulldozer lift control valve

•

Steering control valve

•

Inlet manifold and main relief valve

The machine equipped with a winch has an additional control valve added to the valve stack. •

Winch control valve

•

Bulldozer tilt control valve

•

Bulldozer lift control valve

•

Steering control valve

•

Inlet manifold and main relief valve

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED

Figure 22. Implement Control Valves. Key Component 1

Identification Plate

8

Bulldozer Tilt Control Valve

2

Float Boost Signal

9

Bulldozer Lift Control Valve

3

Housing (Drain)

10

Steering Control Valve

4

Drain to Tank

11

Signal to Pump

5

Cover

12

Main Relief Valve

6

Ripper Tilt Control Valve

13

Pump Supply

7

Ripper Lift Control Valve

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Control Valve (Steering)

00011

The steering control valve is the first control valve in the valve stack and has priority over the remaining control valves. This is important so that the tractor has the ability to turn regardless of the load requirements and flow requirements of the implement circuits that are down stream. The steering control valve controls the speed of the steering motor and the direction of rotation for the steering motor. The pump oil flows to the steering control valve from the inlet manifold. The control valve has a control valve spool, makeup valves #1 and #2 and resolver, priority flow control valve, and load check valve. The steering valve is spring centered. The control valve spool is a closed center spool and a manually operated spool with three positions: STEER RIGHT, HOLD, and STEER LEFT. The spring keeps the spool in the HOLD position when the steering circuit is not active. Movement of the spool is controlled manually by the operator. The steering control lever is connected to a valve spool by a linkage. The resolver is a two-way check valve which sends the signal oil with the highest pressure to the inlet manifold. The inlet manifold sends the signal oil to the compensator valve on the pump. The priority flow control valve gives flow priority to the steering control valve over all of the implement control valves. Descriptions of the resolver and of the priority flow control valve are in this section. These descriptions are given with the steering valve spool in different positions. Descriptions for makeup valves and for the load check valve are in separate sections. a. Load Check Valve

00011

The load check valve will not open until pump oil pressure in the chamber becomes greater than the force of the spring for the load check valve and the steering oil pressure in the passage. b. Makeup Valves

00011

Makeup valves open when steering oil pressure in a passage drops 2 psi (14 kPa) below the return oil pressure in outlet passage #1. Makeup valves add return oil in outlet passage #1 to steering oil passages. The additional oil keeps the lines for the steering motor full and the additional oil prevents cavitation (vacuum) and aeration in the steering motor.

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED c. Basic Valve Operation

00011

When the control valve spool and all implement valve spools are in the HOLD position, pump oil from the inlet manifold flows to the inlet passage. Oil flows through metering holes in the priority flow control valve. The oil moves the priority flow control valve against the spring. Pump oil flows out of outlet passage #2 to the next control valve. Because all implement control valves are in the HOLD position, pump oil fills the parallel oil passages at approximately 525 psi (3,600 kPa). Signal oil passage, resolver, passage #1 and passage #2, and chamber are drained. The oil that is in steer left and steer right passages and passage #3 is blocked.

Figure 23. Steering Control Valve (HOLD).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Steering Control Valve (Steer Left)

00011

When the control valve spool is moved to the STEER LEFT position, the chamber is closed off from the outlet passage. Signal oil passage is opened to the steer left passage. Even when the priority flow control valve is moved to the right, some pump oil flows through the metering holes in the priority flow control valve. The flow opens the load check valve and the pump oil flows around the control valve spool to the steer left passage. The pressure in the steer left passage increases and oil is sent through the signal oil passage to the chamber. The oil now becomes signal oil. Some of the signal oil flows through passage #2 to the spring chamber that is behind the priority flow control valve. The signal oil moves the priority flow control valve to the left. The remaining signal oil pushes the resolver to the side and the signal oil flows through passage #1 to the inlet manifold. The inlet manifold sends the signal oil to the compensator valve on the pump. The signal oil causes the pump to upstroke until system pressure is reached. System pressure is approximately 305 psi (2,100 kPa) above the pressure of the signal oil. As pump oil flow and system pressure increases, the steering oil flow and the pressure through the steer left passage increases. The increased oil flow through the steer left passage flows through the counterbalance valve to the steering motor and the machine turns left. Return oil comes to the steer right passage from the steering motor and from the counterbalance valve. The return oil flows around the control valve spool and through the outlet passage to the tank.

Figure 24. Steering Control Valve (STEER LEFT).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Steering Control Valve (Steer Right)

00011

When the steering valve spool is moved to the STEER RIGHT position, the chamber is closed off from the outlet passage #2. Passage is opened to the steer right passage. Pump oil flows through the priority flow control valve, opens the load check valve and flows around the control valve spool to the steer right passage. The pressure in the steer right passage increases and oil is sent through the passage to the chamber. The oil now becomes signal oil. Some of the signal oil flows through passage #2 to the spring chamber that is behind the priority flow control valve. The priority flow control valve moves to the left. The remaining signal oil pushes the resolver to the side and the signal oil flows through passage #1 to the inlet manifold. The inlet manifold sends the signal oil to the compensator valve in order to upstroke the pump. As pump oil flow and system pressure increases, the steering oil flow and the pressure through the steer right passage increases. The increased oil flow through the steer right passage flows through the counterbalance valve to the steering motor and the machine turns right. Return oil comes to the steer left passage from the steering motor and from the counterbalance valve. The return oil flows around the control valve spool and through outlet passage #1 to the tank.

Figure 25. Steering Control Valve (STEER RIGHT).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Bulldozer Lift Control Valve

00011

The bulldozer lift control valve is located between the steering control valve and the bulldozer tilt control valve in the valve stack. Pilot supply oil from the pilot control valve is used to control the position of the control valve spool. When the pilot supply oil with sufficient pressure enters the bulldozer lift control valve at port control, the valve spool is shifted to the left causing the pilot supply oil at the opposing end of the control valve spool to flow out of the port. This oil flows to the pilot control valve and to the tank. When the spool is shifted to the left, the valve is in the RAISE position. Similarly, when pilot supply oil with sufficient pressure enters the bulldozer lift control valve at pilot port #1 the control valve spool is shifted to the right. This action causes the pilot supply oil at the opposing end of the control valve spool to flow out of pilot port #2. This oil flows to the pilot control valve and to the tank. When the spool is shifted to the right, the valve is in the LOWER position. The lift valve has four positions. •

RAISE

•

HOLD

•

LOWER

•

FLOAT

The bulldozer lift control valve is spring centered. The springs that are located at the left end of the control valve spool to keep the spool in the HOLD position when the lift circuit is not active. The resolver is a two-way check valve. Signal oil from the previous resolver enters signal oil passage #2. The resolver compares the pressure signal that is between the bulldozer lift control valve and the following control valve. The pressure signal from the bulldozer lift control valve enters the resolver through passage #1. The higher pressure of signal oil exits signal oil passage #3. a. Flow Control Valve

00011

Flow control valve limits the maximum flow of the oil to the lift circuit. As the oil flows from passage #5 to either rod end passage or head end passage, the design of control valve spool causes a pressure drop. The left end of flow control valve is at the same pressure as passage #5. The right end of the flow control valve is at the same pressure as either rod end passage or head end passage. As the flow increases from passage #5 through control valve spool to the cylinders, the pressure differential between the left and the right ends of flow control valve increases. Flow control valve moves to the right against the spring, closing off metering slots and reducing pump oil flow into passage #5 through the load check valve. The flow control valve limits the flow of oil to the lift cylinders at 50 US gal./min (190 L/min).

NOTE Different designs of the control valve stem that are used in the various valves change the limits of the maximum flow into the various cylinders. b. Pressure Limiter Valve Operation

00011

Pressure limiter valve is used in the bulldozer lift control valve in order to limit the pressure to the lift circuit. The pressure setting of the pressure limiter valve is 3,300 ± 45 psi (22,750 ± 300 kPa). When the bulldozer lift control valve is in an operating position, cylinder oil flows through passage and the oil becomes signal oil. Signal oil flows to the chamber and then to the resolver and through passage #4 to spring chamber #1.

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED When the signal oil pressure in spring chamber #1 reaches approximately 3,300 psi (22,750 kPa), the spool in pressure limiter valve moves from the valve seat. Oil is sent through the outlet passage to the tank. The signal oil causes the flow control valve to move to the right. The flow of pump oil to the lift circuit decreases until the pressure of the cylinder oil decreases. c. Load Check Valve

00011

The load check valve prevents reverse oil flow from the lift cylinders which can cause cylinder drift or load loss. The load check valve will not open until pump oil pressure in chamber #2 creates a force against the load check valve that is higher than the opposing force against the other side of the check valve. The opposing force is the sum of the force of the spring and the force that is created by the oil pressure in passage. d. Makeup Valve

00011

Makeup valve is in the head end of the lift circuit.The makeup valve opens when cylinder oil pressure in head end passage drops approximately 2 psi (14 kPa) below the return oil pressure in the outlet passage. Makeup valve adds return oil in the outlet passage to cylinder oil in head end passage. The additional oil prevents cavitation (vacuum) in the lift cylinders.

Figure 26. Bulldozer Lift Control Valve (General Information).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Basic Valve Operation

00011

a. Bulldozer Lift Control Valve (Hold)

00011

When the control valve spools, all of the implement/attachment valve spools, and the steering valve spools are in the HOLD position, pump oil through the steering control valve flows to the inlet passage. Oil flows around the flow control valve and into the metering slots which moves the flow control valve against the spring. This valve movement allows all the oil flow through the inlet passage to flow to the next control valve. Because all the valve spools are in the HOLD position, pump oil fills the parallel oil passage of the control valves. The pump maintains the pressure at approximately 525 psi (3,600 kPa). Signal oil passage, chamber, passage #1, resolver, and passage #2 are drained. The oil that is in the rod end passage, head end passage, and passage #3 is blocked.

Figure 27. Bulldozer Lift Control Valve (HOLD).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED b. Bulldozer Lift Control Valve (Raise)

00011

When pilot control pressure causes the control valve spool to move to the RAISE position, cylinder oil from rod end passage flows through the passage to the chamber. The oil now becomes signal oil. Some of the signal oil flows through an orifice to spring chamber #1 that is behind the flow control valve. Then, flow control valve moves to the left. The remaining signal oil moves to the resolver and the signal oil flows through passage #1 to the previous control valve. Then, the signal oil flows to the inlet manifold which sends signal oil to the compensator valve in order to upstroke the pump. The increased pump oil flows to the inlet passage and through the metering slots to chamber #2 and the load check valve opens. The oil through the load check valve flows to passage #2, around control valve spool, and out of the rod end passage to the rod end of the lift cylinders. The bulldozer blade raises. Return oil from the head end of the lift cylinders comes through the head end passage, around the control valve spool, and through the outlet passage to the tank.

Figure 28. Bulldozer Lift Control Valve (RAISE).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED c. Bulldozer Lift Control Valve (Lower)

00011

When pilot control pressure causes the control valve spool to move to the LOWER position, the same pilot oil flows into the resolver network at passage #1 causing the pump to upstroke to the pilot control pressure plus margin pressure. The oil now becomes signal oil. Some of the signal oil flows through the orifice to spring chamber #1 that is behind the flow control valve. The remaining signal oil moves the resolver to the right, if the signal oil is the highest resolved pressure. The signal oil flows through passage #2 to the previous control valve and to the inlet manifold which sends the signal oil to the compensator valve in order to upstroke the pump. System pressure is approximately 305 psi (2,100 kPa) above the pressure of the signal oil. The increased pump oil flows to the inlet passage and through the metering slots to chamber #2. The pump oil opens load check valve. The oil flows to passage #3, around control valve spool, and through head end passage to the head end of the lift cylinders. The bulldozer blade lowers. Return oil comes from the rod end of the lift cylinders, through rod end passage, around control valve spool, and through outlet passage to the tank.

Figure 29. Bulldozer Lift Control Valve (LOWER).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED d. Bulldozer Lift Control Valve (Float)

00011

When pilot control pressure causes the control valve spool to move to the FLOAT position, there is no signal oil pressure. The chamber is open to the outlet passage. Pilot control pressure enters the signal resolver network at the passage.The pressure at the passage is the same pressure that is supplied by the pilot signal pressure at pilot port that is causing the control valve spool to move to the FLOAT position. This causes the pump to maintain margin pressure over the pilot control pressure. The margin pressure over the pilot control pressure is required in order to shift the control valve spool to the FLOAT position. Because of the position of the control valve spool, rod end and head end passages are open to two outlet passages. Because both ends of the lift cylinders are opened to the tank, the cylinder rods move freely in either direction. The amount and direction of the force on the blade controls the movement of the blade.

Figure 30. Bulldozer Lift Control Valve (FLOAT).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Control Valve (Bulldozer Tilt)

00011

a. Flow Control Valve

00011

The flow control valve limits the maximum flow of the oil to the tilt circuit. As the oil flows from passage to either rod end passage or head end passage, the design of the control valve spool causes a pressure drop. The left end of the flow control valve is at the same pressure as the passage. The right end of the flow control valve is at the same pressure as either rod end passage or head end passage. As the flow increases from the passage through the control valve spool to the cylinders, the pressure differential between the left and the right ends of the flow control valve increases. The flow control valve moves to the right against spring #1, closing off metering slots and reducing pump oil flow into the passage through the load check valve. The flow control valve limits the flow of oil to the tilt cylinders at 21 US gal./min (80 L/min).

NOTE Different designs of the control valve stem that are used in the various valves change the limits of the maximum flow into the various cylinders. b. Pressure Limiter Valve Operation

00011

The pressure limiter valve is used in the bulldozer tilt control valve in order to limit the pressure to the tilt circuit. The pressure setting of the pressure limiter valve is 2,500 ± 45 psi (17,225 ± 300 kPa). When the bulldozer tilt control valve is in an operating position, cylinder oil flows through the passage and the oil becomes signal oil. Signal oil flows to the chamber then to the resolver. When the signal oil pressure in spring chamber #1 reaches approximately 2,500 psi (17,225 kPa), the spool in the pressure limiter valve moves from the valve seat. Oil is sent through the outlet passage to the tank. The system oil causes the flow control valve to move to the right. The flow of pump oil to the tilt circuit decreases until the pressure of the cylinder oil decreases. c. Load Check Valve

00011

The load check valve prevents reverse oil flow in the tilt cylinder which can cause cylinder drift or load loss. The load check valve will not open until system pressure in chamber #2 creates a force against the load check spring #2 that is higher than the opposing force against the other side of the check valve. The opposing force is the sum of the force of spring and the force that is created by the oil pressure in the passage.

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED d. Tilt Hold

00011

When the control valve spools are in the HOLD position, pump oil flows to the inlet passage. Oil flows around the flow control valve and into metering slots which moves the flow control valve against the spring. Pump oil also flows through the inlet passage to the next control valve. Since all the valve spools are in the HOLD position, pump oil fills the parallel oil passages of the control valves. The pump maintains oil pressure at 525 psi (3,600 kPa). Signal oil passage, chamber, and resolver are drained. Rod end passage, head end passage and passage are blocked.

Figure 31. Bulldozer Tilt Control Valve (HOLD).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Bulldozer Tilt Control Valve (Tilt Left)

00011

When pilot control pressure causes the control valve spool to move to the TILT LEFT position, passage is opened to the rod end passage. Cylinder oil from the rod end passage flows through the passage to the signal oil chamber. The oil functions as signal oil. Part of the signal oil flows to the spring chamber #1 behind flow control valve. The rest of the signal oil flows through the resolver to the inlet manifold and to the compensator valve in order to upstroke the pump. The increase of pump oil flow to the inlet passage flows through metering slots into chamber #2. The pump oil opens and flows through the load check valve. The oil then flows through passage around the control valve spool and out the rod end passage to the head end of the tilt cylinder. The tilt cylinder then tilts the bulldozer blade to the left. Return oil from the rod end of the tilt cylinder flows through head end passage, around the control valve spool, and through outlet passage to the oil tank. a. Tilt Right

00011

The operation of the tilt control valve in the TILT RIGHT position is similar to the operation of the tilt control valve in the TILT LEFT position. When pilot control pressure causes the control valve spool to move to the TILT RIGHT position, passage is opened to passage. Cylinder oil from passage flows through the passage to the chamber. The oil functions as signal oil. Part of the signal oil flows to spring chamber #1 behind the flow control valve. The rest of the signal oil flows through the resolver to the inlet manifold and to the compensator valve in order to upstroke the pump. The increase of pump oil flow to inlet passage flows through the metering slots into chamber #2. The pump oil opens and flows through load check valve. The oil then flows through the passage around the control valve spool and out the passage to the rod end of the tilt cylinder. The tilt cylinder then tilts the bulldozer blade to the right. Return oil from the head end of the tilt cylinder flows through the passage, around the control valve spool, and through the outlet passage to the oil tank.

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED

Figure 32. Bulldozer Tilt Control Valve (Tilt Left and Tilt Right).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Control Valve (Ripper Lift)

00011

When the machine is equipped with a bulldozer and a ripper, the ripper lift control valve is the fourth valve in the valve stack. The ripper lift control valve controls the raising and lowering of the ripper. The control valve is equipped with these components: makeup valve, resolver, pressure limiter valve, load check valve, and valve spool. The ripper lift control valve is spring centered. The control valve spool is a closed center spool and a pilot operated spool with three positions: RAISE, HOLD, and LOWER. The spring keeps the valve spool in the HOLD position when the ripper lift control valve is not active. Movement of the spool is controlled by the pilot control system which connects the ripper control lever to the valve spool. The resolver is a double check valve. The functions of the resolver and of the control valve spool are described in the sections on positions of the control valve. The descriptions of the functions of the makeup valve, pressure limiter valve, and the load check valve are in the following separate sections. a. Load Check Valve

00011

The load check valve prevents reverse oil flow in the ripper lift cylinders, which can cause cylinder drift or load loss. The load check valve does not open until pump oil pressure in the chamber overcomes the force of the spring for the load check valve and of the cylinder oil pressure in the passage. b. Makeup Valve

00011

The makeup valve is in the head end of the lift circuit. The makeup valve opens when cylinder oil pressure in passage drops 2 psi (14 kPa) below the return oil pressure in the outlet passage. The makeup valve adds return oil in outlet passage to cylinder oil in passage. The additional oil prevents cavitation (vacuum) in the lift cylinders. c. Pressure Limiter Valve Operation

00011

The pressure limiter valve is used in the ripper lift control valve in order to limit the pressure to the lift circuit. The pressure setting of the pressure limiter valve is 3,300 ± 45 psi (22,750 ± 300 kPa). When the ripper lift control valve is in an operating position, cylinder oil flows through the passage and the oil becomes signal oil. Signal oil flows to the chamber then to the resolver. When the signal oil pressure in spring chamber #2 reaches approximately 3300 psi (22,750 kPa), the spool in pressure limiter valve moves from the valve seat. Oil is sent through the outlet passage to the tank. The signal oil causes the flow control valve to move to the right. The flow of pump oil to the lift circuit decreases until the pressure of the cylinder oil decreases. Basic Valve Operation

00011

When the control valve spools are in the HOLD position, pump oil flows to the inlet passage. This passage is common to all sections of the valve stack and this passage has no outlet. Since all the valve spools are in the HOLD position, pump oil fills the parallel oil passages of the control valves. The pump maintains oil pressure at 525 psi (3,600 kPa). Signal oil passage, chamber #1, and resolver are drained. Rod end passage, head end passage, and chamber #1 are blocked.

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED

Figure 33. Ripper Lift Control Valve (HOLD).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Ripper Lift Control Valve (Ripper Raise)

00011

When the pilot control pressure causes the valve spool to move to the RAISE position, cylinder oil from the passage flows through the passage to the chamber. The oil functions as signal oil. The signal oil opens the resolver and flows to the previous control valve and to the inlet manifold. The increase of pump oil flow to the inlet passage opens the load check valve. The oil flows through the load check valve, through the passage, and around the valve spool. The oil flows through the rod end passage to the rod end of the ripper lift cylinders. The ripper lift cylinders then raise the ripper. Return oil from the head end of the ripper lift cylinders flows through the head end passage, around the valve spool, and through the outlet passage to the tank.

Figure 34. Ripper Lift Control Valve (RIPPER RAISE).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Ripper Lift Control Valve (Ripper Lower)

00011

When the pilot control pressure causes the valve spool to move to the LOWER position, cylinder oil from the passage flows through the passage to the chamber. The oil functions as signal oil. The signal oil opens the resolver. The signal oil flows to the previous control valve and to the inlet manifold. The increase of pump oil flow to the inlet passage opens the load check valve. The oil flows through the load check valve. The oil then flows around the valve spool and out the head end passage to the head end of the ripper lift cylinders. The ripper lift cylinders then lower the ripper. Return oil from the rod end of the ripper lift cylinders flows through the rod end passage, around the valve spool, and through the outlet passage to the tank.

Figure 35. Ripper Lift Control Valve (RIPPER LOWER).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Control Valve (Ripper Tip)

00011

When the machine is equipped with a bulldozer and with a ripper, the ripper tip control valve is the fifth valve in the valve stack and controls the angle of insertion of the ripper. The control valve is equipped with these components: makeup valve, resolver, pressure limiter valve, load check valve, and valve spool. The ripper tip control valve is spring centered. The control valve spool is a closed center spool and a pilot operated spool with three positions: TIP IN, HOLD, and TIP OUT. A spring keeps the valve spool in the HOLD position when the ripper tip control valve is not active. Movement of the spool is controlled by the pilot control system. The pilot control system connects the ripper control lever to the valve spool. The resolver is a double check valve. The functions of the resolver and of the control valve spool are described in the sections on positions of the control valve. The descriptions of the functions of the makeup valve, pressure limiter valve, and load check valve are in the following separate sections: a. Load Check Valve

00011

The load check valve prevents reverse oil flow in the ripper tip cylinders, which can cause cylinder drift or load loss. The load check valve does not open until the pump oil pressure in chamber #3 overcomes the force of the spring for the load check valve and of the cylinder oil pressure in the passage. b. Makeup Valve

00011

The makeup valve is in the rod end of the tip circuit. The makeup valve opens when cylinder oil pressure in the passage drops 2 psi (14 kPa) below the return oil pressure in the outlet passage. The makeup valve adds return oil in the outlet passage to cylinder oil in the passage. The additional oil prevents cavitation (vacuum) in the tip cylinders. c. Pressure Limiter Valve Operation

00011

Pressure limiter valve is used in the ripper tip control valve in order to limit the pressure to the tip circuit. The pressure setting of the pressure limiter valve is 3,300 ± 45 psi (22,750 ± 300 kPa) 3,300 ± 45 psi. When the ripper tip control valve is in an operating position, cylinder oil flows through the passage and the oil becomes signal oil. Signal oil flows to chamber #1. Then, the oil flows to the resolver. When the signal oil pressure in spring chamber #2 reaches approximately 3,300 psi (22,750 kPa), the spool in the pressure limiter valve moves from the valve seat. Oil is sent through the outlet passage to the tank. The signal oil causes the flow control valve to move to the right. The flow of pump oil to the tip circuit decreases until the pressure of the cylinder oil decreases.

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED d. Basic Valve Operation

00011

When the control valve spools are in the HOLD position, pump oil flows to the inlet passage. This passage is common to all sections of the valve stack and this passage has no outlet. Since all the valve spools are in the HOLD position, pump oil fills the parallel oil passages of the control valves. The pump maintains oil pressure at 525 psi (3,600 kPa). Signal oil passage, chamber #1, and resolver are drained. Head end passage, rod end passage, and passage are blocked.

Figure 36. Ripper Tip Control Valve (HOLD).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Ripper Tip Control Valve (Ripper Tip In)

00011

When the pilot control pressure causes the valve spool to move to the TIP IN position, cylinder oil from the head end passage flows through the signal oil passage to the chamber. The oil functions as signal oil. The signal oil opens the resolver and flows to the previous control valve and to the inlet manifold. The increase of pump oil flow to the inlet passage opens the load check valve. The oil flows through the load check valve, through the passage, and around the valve spool. The oil flows through the head end passage to the head end of the ripper tip cylinders. The ripper tip cylinders tip the ripper inward. Return oil from the rod end of the ripper tip cylinders flows through the rod end passage, around the valve spool, and through the outlet passage to the tank.

Figure 37. Ripper Tip Control Valve (RIPPER TIP IN).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Ripper Tip Control Valve (Ripper Tip Out)

00011

When the pilot control pressure causes the valve spool to move to the TIP OUT position, cylinder oil from the rod end passage flows through the signal oil passage to the chamber. The oil functions as signal oil. The signal oil opens the resolver. The signal oil flows to the previous control valve and to the inlet manifold. The increase of pump oil flow to the inlet passage opens the load check valve. The oil flows through the load check valve. The oil then flows around the valve spool and out the rod end passage to the rod end of the ripper tip cylinders. The ripper tip cylinders tip the ripper outward. Return oil from the head end of the ripper tip cylinders flows through the head end passage, around the valve spool, and through the outlet passage to the tank.

Figure 38. Ripper Tip Control Valve (RIPPER TIP OUT).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Control Valve (Winch)

00011

Winch Control Valve (Reel In)

00011

When the machine is equipped with a winch, the winch control valve is at the top of the valve stack. The winch control valve controls the operation of the winch motor. The control valve is equipped with these components: control valve spool, resolver, flow control valve, and load check valve. The winch control valve is spring centered. The control valve spool is a closed center spool and a pilot operated spool with three positions: REEL IN, HOLD, and REEL OUT. A spring keeps the spool in HOLD position when the winch motor is not active. Movement of the spool is controlled by the pilot control system. The pilot control system connects the winch control lever to the control valve spool. The resolver is a double check valve. The flow control valve limits the maximum flow of oil to the winch motor. The functions of the resolver and of the control valve spool are described in the sections on positions of the control valve. The description of the function of the load check valve is in a separate section. a. Load Check Valve

00011

The load check valve prevents reverse oil flow in the winch motor, which can cause circuit drift or load loss. The load check valve does not open until pump oil pressure in chamber #3 becomes greater than the combined forces of the spring for the load check valve and of the oil pressure in the passage. b. HOLD Position

00011

When all the control valve spools are in the HOLD position, pump oil fills the parallel oil passages of the control valves. The pump maintains oil pressure at 435 psi (3,000 kPa). Signal oil passage, chamber #1, and resolver are drained. Reel out passage, reel in passage, and passage are blocked. c. REEL IN Position

00011

When pilot control pressure causes the control valve spool to move to the REEL IN position, signal oil passage is opened to reel in passage. Winch oil from the reel in passage flows through the signal oil passage to chamber #1. The oil functions as signal oil. Part of the signal oil flows to chamber #2 behind the flow control valve. The signal oil opens the flow control valve. The rest of the signal oil flows through the resolver to the inlet manifold. The increase of pump oil flow to the inlet passage flows through the primary metering holes into chamber #3. The pump oil opens and directs oil through the load check valve. The oil flows through the passage, around the control valve spool, and through the passage to the winch motor. The winch then reels in the cable. Return oil from the winch motor flows through the reel out passage, around the control valve spool, and through the outlet passage to the tank.

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED

Figure 39. Winch Control Valve (REEL IN).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED d. REEL OUT Position

00011

When pilot control pressure causes the control valve spool to move to the REEL OUT position, winch oil from the reel out passage flows through the signal oil passage to the chamber. The oil functions as signal oil which opens the resolver. The signal oil flows to the next control valve and to the inlet manifold. The increase of pump oil flow to the inlet passage opens the load check valve. The oil flows through the load check valve. The oil flows through the passage, around the control valve spool, and through the reel out passage to the winch motor. The winch motor then reels out the cable. Return oil from the winch motor flows through the reel in passage, around the valve spool, and through the outlet passage to the tank.

Figure 40. Winch Control Valve (REEL OUT).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Relief Valve (Main)

00011

The main relief valve (Figure 41, Item 1) is located in the inlet manifold. The inlet manifold is attached to the bottom of the control valve stack.

Figure 41. Main Relief Valve in Inlet Manifold.

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED The main relief valve is a directly operated valve. Since the setting of the main relief valve is above all of the operating pressures, the valve serves as a backup valve. The main relief valve limits the increases (spikes) in pump pressure.

NOTE The main relief valve is not capable of handling full pump flow. Pump oil flows through the inlet passage (Figure 42, Item 4) to the valve (Figure 42, Item 3). A spring (Figure 42, Item 2) keeps the valve (Figure 42, Item 3) closed when the oil pressure is less than the setting of the relief valve. When the oil pressure increases to the setting of the relief valve, the valve (Figure 42, Item 3) opens. The oil in passage (Figure 42, Item 4) flows around the valve (Figure 42, Item 3). The oil flows through drain passages (Figure 42, Item 5) to the tank. The pump pressure can not exceed the setting of the main relief valve. The compressed length of spring (Figure 42, Item 2) determines the force that is applied by the spring (Figure 42, Item 2) to the valve (Figure 42, Item 3). An increase or a decrease in the force that is applied by the spring (Figure 42, Item 2) changes the pressure setting of the relief valve. Loosen nut (Figure 42, Item 1) and turn setscrew (Figure 42, Item 6) clockwise in order to increase the pressure setting. Loosen nut (Figure 42, Item 1) and turn setscrew (Figure 42, Item 6) counterclockwise in order to decrease the pressure setting. The pressure setting is specified in the following table. The test was completed at a temperature of 120°F ± 5°F (49°C ± 3°C).

Figure 42. Main Relief Valve.

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Pressure and Flow Pressure Inlet 42,000 ± 400 kPa (6,090 ± 60 psi)

Flow Outlet

70 ± 7 kPa (10 ± 1 psi)

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Inlet 5 ± 1 L/min (1.3 ± 0.3 US gal.min)

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM – CONTINUED Signal Resolver Network

00011

The resolver network consists of a resolver (ball check valve) in each implement control valve. Each resolver compares the pressure signal from the previous control valve and the pressure signal from the current control valve. The resolver ball shifts in order to allow the higher signal to flow to the next resolver. For example, Figure 43 indicates the resolver network when the ripper lift control valve is activated. The resolver in the ripper lift control valve compares the float boost signal (Figure 43, Item 1) to the signal (Figure 43, Item 2) from the ripper tip control valve. Since the ripper tip control valve is activated, the signal (Figure 43, Item 2) is higher. The resolver ball shifts and the signal (Figure 43, Item 2) is sent to the next resolver. The next resolver in the bulldozer angle control valve compares the signal from the ripper tip control valve to the signal (Figure 43, Item 3) from the ripper lift control valve. Since the ripper lift control valve is not activated, the signal from the resolver in the ripper tip control valve is higher. The ball shifts in order to send the higher signal to the next resolver in the blade tilt control valve (Figure 43, Item 4). The signal from each of the implement control valves is compared in this way. The steering control valve (Figure 43, Item 6) also has a signal. The highest resolved signal from the implement control valves goes through the line (Figure 43, Item 7) to the compensator valve on the implement pump. The signal to pump compensator instructs the pump to vary output in order to meet the highest load requirement. The pump compensator valve adds margin pressure to the load requirement.

NOTE The resolver network does not add various loads together. Instead, the single highest resolved load governs the pump output. When the blade lift control valve (Figure 43, Item 5) is in the FLOAT position or in the LOWER position, pilot oil enters the end of the resolver network as the float boost signal (Figure 43, Item 1). When the blade lift control valve is in FLOAT and none of the other implements are activated, the float boost signal (Figure 43, Item 1) is sent through the resolver network to the pump compensator valve. This adjusts the pump output in order to maintain the necessary supply pressure that is required for pilot oil to keep the valve spool in the FLOAT position. When all of the implements are in HOLD, the pressure in the resolver network is equal to the tank pressure. The pump compensator valve keeps the implement pump at LOW PRESSURE STANDBY until an implement is activated.

Figure 43. Ripper Tilt Control Valve Activated. END OF WORK PACKAGE

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FIELD MAINTENANCE 0 0 1 2

THEORY OF OPERATION: AIR CONDITIONING AND HEATING

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AIR CONDITIONING AND HEATING SYSTEM

0012

00012

Refrigerant Orifice Tube System

00012

The air conditioner refrigerant begins to flow in the air conditioning system at the refrigerant compressor (Figure 1, Item 1). The compressor is designed to change the air conditioner refrigerant from a vapor that has low pressure into a vapor that has high pressure. Also, the compressor changes the refrigerant from a vapor with low temperature to a vapor with high temperature. The increase in pressure causes the increase in temperature. The refrigerant is sent through a condenser coil (Figure 1, Item 2) where heat is transferred from the refrigerant to the outside air. This changes the refrigerant to a high temperature and high pressure liquid. From the condenser coil (Figure 1, Item 2), the refrigerant moves to the in-line dryer (Figure 1, Item 3). The in-line dryer, moisture is removed from the refrigerant by a desiccant (Figure 1, Item 4). Next, the refrigerant flows to the orifice tube. When the refrigerant is at the orifice tube (Figure 1, Item 5), the refrigerant is changed from a high pressure and high temperature liquid to a liquid vapor mixture that is low pressure and low temperature. The low pressure and low temperature refrigerant moves to the evaporator coil (Figure 1, Item 6). While the refrigerant is in the evaporator coil, the refrigerant absorbs heat from the cab. This changes the refrigerant to a low pressure and low temperature vapor. After the evaporator coil, the refrigerant flows to the accumulator (Figure 1, Item 7). The accumulator (Figure 1, Item 7) stores liquid refrigerant that is exiting the evaporator and the accumulator allows only vapor to continue to the compressor. The low pressure and low temperature vapor returns to the compressor. This marks the end of the cycle. The cycle is repeated continuously.

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AIR CONDITIONING AND HEATING SYSTEM – CONTINUED

Figure 1. Refrigerant System.

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AIR CONDITIONING AND HEATING SYSTEM – CONTINUED Orifice Tube

00012

The orifice tube assembly (Figure 2, Item 1) contains a plastic body, two screens (Figure 2, Item 4), and a small brass tube. The small brass tube is referred to as an orifice tube (Figure 2, Item 2), and it is located in the center of the body. The O-ring seals (Figure 2, Item 3) are positioned on the body of the orifice tube to seal against leakage around the orifice tube. The orifice tube assembly is contained within the in-line dryer. The orifice tube (Figure 2, Item 2) restricts the flow of refrigerant. This restriction creates a pressure drop across the orifice tube. This changes the refrigerant from a high temperature high pressure liquid into a liquid vapor mixture that is low temperature and low pressure. The flow rate is controlled by the pressure difference across the orifice tube.

Figure 2. Orifice Tube. Accumulator

0012

00012

Low temperature and low pressure refrigerant leaves the evaporator coil and passes into the accumulator (Figure 3, Item 1) through the inlet (Figure 3, Item 2). Liquid refrigerant that was not evaporated in the evaporator is stored in the bottom of the accumulator. Vapor refrigerant passes through the standpipe (Figure 3, Item 3) before exiting through the outlet (Figure 3, Item 5). The oil goes to the compressor through a filter for the oil drain (Figure 3, Item 4). The accumulator stores some refrigerant in order to compensate for the changing system demands. These system demands can result from changing speeds in the compressor, varying heat loads, or small losses of refrigerant.

Figure 3. Accumulator.

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AIR CONDITIONING AND HEATING SYSTEM – CONTINUED Compressor

00012

The compressor is driven by the engine. A belt (Figure 4, Item 2) connects the engine to the clutch and pulley assembly (Figure 4, Item 1). The pulley assembly is located on the clutch. The drive plate (Figure 4, Item 3) is fastened to the shaft of the compressor. The clutch and pulley assembly (Figure 4, Item 1) turns on the bearing (Figure 4, Item 5). The clutch and pulley assembly (Figure 4, Item 1) are not connected to the shaft (Figure 4, Item 4). The electric current from the thermostat controls a magnetic field in the coil assembly (Figure 4, Item 6). The magnetic field pulls the drive plate (Figure 4, Item 3) against the clutch and pulley assembly (Figure 4, Item 1). The clutch and the pulley assembly (Figure 4, Item 1) turns the shaft (Figure 4, Item 4) that operates the compressor. When the current to the coil assembly (Figure 4, Item 6) is stopped, the magnetic field is removed. This allows the drive plate (Figure 4, Item 3) to move away from the clutch and pulley assembly (Figure 4, Item 1). The clutch and the pulley assembly (Figure 4, Item 1) will turn freely on the bearing (Figure 4, Item 5). The sequence of connecting and disconnecting the pulley to the compressor shaft (Figure 4, Item 4) is called compressor cycling. The compressor cycling is controlled by the thermostat. The thermostat is controlled by the capillary tube, which is installed between the fins of the evaporator coil.

Figure 4. Compressor.

0012-5

0012

TM 5-2410-241-23-1

0012

AIR CONDITIONING AND HEATING SYSTEM – CONTINUED Condenser Coil

00012

When the refrigerant leaves the compressor, the refrigerant is a vapor. The temperature of the refrigerant is high and the pressure of the refrigerant is high when the refrigerant leaves the compressor. The increase in pressure of the refrigerant causes an increase in temperature of the refrigerant. The refrigerant vapor leaves the compressor and the refrigerant enters the condenser (Figure 5, Item 1). The refrigerant must be converted into a liquid that has high temperature and high pressure. The refrigerant must be converted into a liquid in order to increase the efficiency of the air conditioning system. The condenser (Figure 5, Item 1) converts the refrigerant vapor into a liquid that has high temperature and high pressure. When the refrigerant vapor leaves the compressor, the refrigerant vapor enters the condenser. The condenser is in a location that is exposed to outside air. In order to convert the refrigerant into a liquid, the refrigerant must lose heat. The refrigerant must reach the temperature of saturation. At the temperature of saturation, the refrigerant vapor will become a liquid. The temperature of saturation of the refrigerant depends on the pressure of the refrigerant. As the high temperature, high pressure refrigerant vapor passes through the condenser (Figure 5, Item 1), the condenser absorbs heat from the refrigerant vapor. The condenser transfers the heat to the outside air. The temperature of the refrigerant and the pressure of the refrigerant decrease until the temperature of saturation is reached. When the temperature of the refrigerant vapor is equal to the temperature of saturation, the refrigerant becomes a high temperature, high pressure liquid. When the refrigerant is converted into a liquid, the refrigerant leaves the condenser (Figure 5, Item 1).

Figure 5. Condenser Coil.

0012-6

0012

TM 5-2410-241-23-1

0012

AIR CONDITIONING AND HEATING SYSTEM – CONTINUED Evaporator Coil

00012

In an expansion valve system, the evaporator coil (Figure 6, Item 1) receives liquid refrigerant from the expansion valve. In an orifice tube system, the evaporator receives liquid refrigerant from the orifice tube assembly. The liquid refrigerant that is received by the evaporator has low pressure and low temperature. Since the pressure of the liquid refrigerant is low, the temperature of saturation of the refrigerant is low. At the temperature of saturation, the refrigerant changes from a liquid into a vapor. The temperature of saturation of a fluid increases when the pressure of a fluid increases. The evaporator coil (Figure 6, Item 1) is exposed to the air that is inside of the cab. The heat from the air that is inside of the cab is absorbed by the evaporator. The evaporator transfers the heat to the refrigerant. The amount of heat that is required to reach the temperature of saturation is called the latent heat of vaporization. When this heat is absorbed by the refrigerant, the temperature of the refrigerant will reach the temperature of saturation. The refrigerant will change from a liquid into a vapor. The vaporized refrigerant will leave the evaporator. The vaporized refrigerant will carry away the heat from the cab. The vaporized refrigerant will return to the compressor when the refrigerant leaves the evaporator. This process is repeated continuously.

Figure 6. Evaporator Coil.

0012-7

0012

TM 5-2410-241-23-1

0012

AIR CONDITIONING AND HEATING SYSTEM – CONTINUED In-Line Refrigerant Dryer

00012

The in-line dryer (Figure 7, Item 4) receives the high temperature high pressure liquid refrigerant from the condenser coil. The refrigerant passes through the desiccant (Figure 7, Item 3). The moisture is removed in the desiccant (Figure 7, Item 3). The refrigerant continues to the orifice tube assembly (Figure 7, Item 2), which is the location where the high temperature high pressure liquid is changed into a liquid vapor mixture that is low temperature low pressure. After exiting the in-line dryer, the refrigerant continues to the evaporator coil. The in-line dryer connects to the refrigerant circuit with a quick disconnect fitting (Figure 7, Item 1).

Figure 7. Refrigerant Dryer.

0012-8

0012

TM 5-2410-241-23-1

0012

AIR CONDITIONING AND HEATING SYSTEM – CONTINUED Heating System with Water Valve Control

00012

The heating system is a water valve control type system. The control system for the water valve regulates the amount of hot engine coolant that is circulated through the heater coil. The water valve is regulated by a mechanical cable. The hot coolant from the engine circulates through the heating system. This coolant flows from the outlet valve of the engine cooling system (Figure 8, Item 1), through the heater control valve (Figure 8, Item 4), through the heater coil (Figure 8, Item 2), and back to the return valve (Figure 8, Item 3) for the engine cooling system. The temperature control knob, which is located on the control panel within the cab, regulates the flow of coolant. With the temperature control knob in the maximum cold position, the heater control valve (Figure 8, Item 4) is closed. This prevents the flow of coolant into the heater coil (Figure 8, Item 2). When the control knob is moved away from the maximum cold position toward the maximum heating position, the heater control valve begins to open. As the control valve opens, coolant begins to flow from the outlet valve for engine cooling system (Figure 8, Item 1) through the heater control valve and into the heater coil. As the hot coolant flows through the heater coil, the temperature of the air that is flowing through the coil increases. The temperature of the air that is flowing out of the heater coil (Figure 8, Item 2) and into the cab is controlled by the amount of coolant that circulates through the heater coil. The coolant transfers the heat into the air stream. By increasing the amount of coolant that is circulating through the heater coil (Figure 8, Item 2), the temperature of the air that is flowing out of the coil also increases. The coolant leaves the heater coil at a reduced temperature and flows back into the return valve (Figure 8, Item 3) for the engine cooling system.

Figure 8. Heating System.

0012-9

0012

TM 5-2410-241-23-1

0012

AIR CONDITIONING AND HEATING SYSTEM – CONTINUED Heater Coil

00012

The heater coil is a device that is similar to a radiator. The heater coil heats the cab of the machine. The heater coil is exposed to the air which passes across the evaporator coil. The heater transfers the heat from the hot engine coolant into the air that is traveling across the heater coil. The heat transfer will heat up the air that is flowing to the cab, which also reduces the temperature of the coolant that is flowing back to the engine cylinder. Water Valve

00012

The water valve is a device that is used to regulate the flow of engine coolant to the heater coil and the flow of engine coolant from the heater coil. The water valve is connected to a mechanical cable. The mechanical cable is connected between the control knob in the cab and the water valve. The control knob opens the valve and the control knob closes the valve. END OF WORK PACKAGE

0012-10

2 TM 5-2410-241-23-1

CHAPTER 2 TROUBLESHOOTING PROCEDURES

6 TM 5-2410-241-23-1

0013

FIELD MAINTENANCE 0 0 1 3

-

TROUBLESHOOTING INDEX

Malfunction/Symptom

Troubleshooting Procedure Page

ENGINE TROUBLESHOOTING PROCEDURES

00013

1

Alternator (Charging Problem) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-2

2

Coolant in Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-2

3

Engine Cranks but Will Not Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-2

4

Oil in Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-4

5

Engine Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-5

6

Engine Will Not Crank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-5

7

Excessive Engine Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-5

8

Low Power/ Poor or No Response to Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-6

Engine Fault Code

00013

1-11 Cylinder #1 Injector Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-7 2-11 Cylinder #2 Injector Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-10 3-11 Cylinder #3 Injector Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-14 4-11 Cylinder #4 Injector Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-17 5-11 Cylinder #5 Injector Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-20 6-11 Cylinder #6 Injector Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-24 41-3 8 Volt DC Supply Short to +Batt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-27 41-4 8 Volt DC Short to Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-28 91-2 Incorrect Throttle Switch Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-30 100-3 Engine Oil Pressure Open/Short to +Batt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-37 100-4 Engine Oil Pressure Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-39 110-3 Engine Coolant Temperature open/short to +Batt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-40 110-4 Engine Coolant Temperature Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-42 168-2 System Voltage Intermittent/Erratic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-43 172-3 Intake Manifold Air Temp Open/Short to +Batt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-50 172-4 Intake Manifold Air Temp Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-52 174-3 Fuel Temperature Open/Short to +Batt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-53 174-4 Fuel Temperature Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-55 190-2 Loss of Engine Speed Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-56 190-11 Engine Speed Sensor Mechanical Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-58 247-9 J1939 Data Link Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-59 253-2 Personality Module Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-63 261-13 Engine Timing Calibration Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-63 262-3 5 Volt DC Power Supply Short to +Batt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-63 262-4 5 Volt DC Power Supply Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-66 264-8 Decel Throttle Position Signal Abnormal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-69 266-2 Incorrect Crank without Inject Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-71 268-2 Check Programmable Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-73

0013-1

TM 5-2410-241-23-1

0013

ENGINE TROUBLESHOOTING PROCEDURES – CONTINUED Engine Fault Code – Continued

00013

273-3 Turbo Outlet Pressure Open/Short to +Batt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-73 273-4 Turbo Outlet Pressure Short to Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-75 274-3 Atmospheric Pressure Open/Short to +Batt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-76 274-4 Atmospheric Pressure Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-78 275-3 Turbo Inlet Pressure Open/Short to +Batt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-79 275-4 Turbo Inlet Pressure Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-80 296-9 Unable to Communicate with Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-81 342-2 Loss of Secondary Engine Speed Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-84 342-11 Secondary Engine Speed Sensor Mechanical Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-86 545-5 Ether Start Relay Open/Short to +Batt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-87 545-6 Ether Start Relay Short to Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-88 E017 High Engine Coolant Temperature Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0019-92 E027 High Inlet Air Temperature Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-93 E031 Air Inlet Restriction Derate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-93 E039 Low Engine Oil Pressure Derate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-93 E100 Low Engine Oil Pressure Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-93 E190 Engine Overspeed Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-94 E272 Inlet Air Restriction Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019-94 POWERTRAIN TROUBLESHOOTING PROCEDURES Powertrain Fault Code

00013

00013

70-2 Parking Brake Switch Data Erratic, Intermittent, or Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-2 70-3 Parking Brake Switch Voltage Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-4 70-4 Parking Brake Switch Voltage Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-6 168-3 Electrical System Voltage Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-8 168-4 Electrical System Voltage Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-9 177-3 Transmission Oil Temperature Sensor (Sump) Voltage Above Normal. . . . . . . . . . . . . . . . . . . . . 0020-20 177-4 Transmission Oil Temperature Sensor (Sump) Voltage Below Normal . . . . . . . . . . . . . . . . . . . . . 0020-24 247-9 Data Link Abnormal Update Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-27 298-2 Service Brake Pedal Switch Data Erratic, Intermittent, or Incorrect . . . . . . . . . . . . . . . . . . . . . . . 0020-32 299-8 Transmission Lever Position Sensor Out of Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-39 299-13 Transmission Lever Position Sensor Out of Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-48 368-2 Autoshift Switch Data Erratic, Intermittent, or Incorrect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-55 444-3 Starter Motor Relay Voltage Above Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-58 444-5 Starter Motor Relay Voltage Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-62 444-6 Starter Motor Relay Current Above Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-66 468-3 Service Brake Pedal Position Sensor Voltage Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-70 468-4 Service Brake Pedal Position Sensor Voltage Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-81 468-8 Service Brake Pedal Position Sensor Signal Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-83 585-2 Transmission Output Speed Sensor #1 Data Erratic, Intermittent, or Incorrect. . . . . . . . . . . . . . . 0020-88 588-2 Monitoring System Display Data Erratic, Intermittent or Incorrect. . . . . . . . . . . . . . . . . . . . . . . . . 0020-92 588-9 Monitoring System Display Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-94

0013-2

TM 5-2410-241-23-1

0013

POWERTRAIN TROUBLESHOOTING PROCEDURES – CONTINUED Powertrain Fault Code – Continued

00013

588-12 Monitoring System Display Bad Device or Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-96 590-2 Engine Control Module Data Erratic Intermittent or Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-98 590-9 Engine Control Module Abnormal Update. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-101 590-12 Engine Control Module Data Erratic Intermittent or Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-104 618-2 Left Service Brake Switch Data Erratic Intermittent or Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . 0020-107 621-2 Downshift Switch Data Erratic Intermittent or Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-109 622-2 Upshift Switch Data Erratic Intermittent or Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-112 650-2 Harness Code Data Erratic Intermittent or Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-115 668-12 Shift Lever Bad Device or Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-118 672-2 Torque Converter Output Speed Sensor Data Erratic Intermittent or Incorrect . . . . . . . . . . . . . . 0020-118 673-2 Transmission Output Speed Sensor #2 Data Erratic, Intermittent, or Incorrect. . . . . . . . . . . . . . 0020-122 681-3 Parking Brake Solenoid Voltage Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-126 681-5 Parking Brake Solenoid Voltage Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-129 681-6 Parking Brake Solenoid Current Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-132 689-3 Left Brake Solenoid Voltage Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-134 689-5 Left Brake Solenoid Voltage Below Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-137 689-6 Left Brake Solenoid Current Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-138 689-13 Left Brake Solenoid Out of Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-140 722-3 Service Brake Solenoid Voltage Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-147 722-5 Service Brake Solenoid Voltage Below Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-149 722-6 Service Brake Solenoid Current Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-151 1326-2 ECM Location Code Data Erratic, Intermittent, or Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-153 1401-3 Transmission Solenoid Valve #1 Voltage Above Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-154 1401-5 Transmission Solenoid Valve #1 Voltage Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-158 1401-6 Transmission Solenoid Valve #1 Current Above Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-162 1401-13 Transmission Solenoid Valve #1 Out of Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-167 1402-3 Transmission Solenoid Valve #2 Voltage Above Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-169 1402-5 Transmission Solenoid Valve #2 Current Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-173 1402-6 Transmission Solenoid Valve #2 Current Above Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-177 1402-13 Transmission Solenoid Valve #2 Out of Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-182 1403-3 Transmission Solenoid Valve #3 Voltage Above Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-184 1403-5 Transmission Solenoid Valve #3 Current Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-188 1403-6 Transmission Solenoid Valve #3 Current Above Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-192 1403-13 Transmission Solenoid Valve #3 Out of Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-198 1404-3 Transmission Solenoid Valve #4 Voltage Above Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-200 1404-5 Transmission Solenoid Valve #4 Current Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-204 1404-6 Transmission Solenoid Valve #4 Current Above Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-208 1404-13 Transmission Solenoid Valve #4 Out of Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-213 1405-3 Transmission Solenoid Valve #5 Voltage Above Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-215 1405-5 Transmission Solenoid Valve #5 Current Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-219 1405-6 Transmission Solenoid Valve #5 Current Above Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-223 1405-13 Transmission Solenoid Valve #5 Out of Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-228

0013-3

TM 5-2410-241-23-1

0013

POWERTRAIN TROUBLESHOOTING PROCEDURES – CONTINUED Powertrain Fault Code – Continued

00013

2122-2 Reverse Switch Data Erratic, Intermittent, or Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-230 2122-7 Reverse Switch Mechanical System Not Responding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020-232 CHASSIS AND IMPLEMENT TROUBLESHOOTING PROCEDURES

00013

1

Hydraulic Oil Temperature is Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-2

2

Machine Has Low Turning Force in Both Directions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-2

3

Machine Has Low Turning Force in One Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-2

4

Machine Will Not Turn in Either Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-3

5

Steering is Jerky or Unstable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-3

6

Machine Continues to Turn When Steering Control Lever is Returned to NEUTRAL . . . . . . . . . . . . . . 0021-3

7

Machine Will Not Turn or Steering Radius is Very Large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-4

8

All Implement Cycle Times are Too Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-4

9

Implement Droops When Control Lever is Moved from HOLD to LIFT . . . . . . . . . . . . . . . . . . . . . . . . . 0021-4

10

Implement Drift Is Excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-5

11

Hydraulic Circuits Have Weak Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-5

Chassis Fault Code

00013

96-3 Fuel Level Sender Voltage Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-6 248-2 Display Data Link Data Erratic, Intermittent, or Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-7 271-3 Action Alarm Voltage Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-11 271-5 Action Alarm Voltage Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-12 324-3 Action Lamp Voltage Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-13 490-3 Hydraulic Lockout Solenoid Voltage Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-14 490-4 Hydraulic Lockout Solenoid Voltage Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-20 600-4 Hydraulic Oil Temperature Sensor Voltage Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-25 600-8 Hydraulic Oil Temperature Sensor Voltage Abnormal Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-26 819-2 Display Data Link Abnormal Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-28 821-3 Display Power Supply Voltage Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-31 821-4 Display Power Supply Voltage Below Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-32 826-4 Powertrain Oil Temperature Sensor Voltage Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-34 882-3 Hydraulic Lockout Solenoid Voltage Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-36 882-5 Hydraulic Lockout Solenoid Current Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-40 882-6 Hydraulic Lockout Solenoid Current Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021-45 CAB TROUBLESHOOTING PROCEDURES

00013

1

Front Cylinder Mounted Flood Lamp(s) Do Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-2

2

ROPS Mounted Forward Facing Flood Lamp(s) Do Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-14

3

ROPS Mounted Rearward Facing Flood Lamp(s) Do Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-27

4

Engine Flood Lamp Does Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-39

5

All Windshield Wipers and Washers Do NOT Operate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-44

6

Front Windshield Wiper Does Not Operate Properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-68

7

Left Door Windshield Wiper Does Not Operate Properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-75

0013-4

TM 5-2410-241-23-1

0013

CAB TROUBLESHOOTING PROCEDURES – CONTINUED 8

Right Door Windshield Wiper Does Not Operate Properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-82

9

Rear Windshield Wiper Does Not Operate Properly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-89

10

Front Windshield Washer Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-95

11

Left Door Windshield Washer Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-97

12

Right Door Windshield Washer Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0022-99

13

Rear Windshield Washer Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-101

14

Horn Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-103

15

There is Little or No COLD Airflow when Air Conditioning is On . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-111

16

Little or No Warm Airflow when Heater Control is Set for Maximum Heating . . . . . . . . . . . . . . . . . . . 0022-113

17

A/C Compressor will Not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-113

18

Blower Motor Does Not Function in One or More Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-121

19

No Power with Ignition Switch ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0022-131

20

Ether Aid Does Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022-139

END OF WORK PACKAGE

0013-5/(6 blank)

2 TM 5-2410-241-23-1

0014

FIELD MAINTENANCE 0 0 1 4

-

TROUBLESHOOTING INTRODUCTION

INTRODUCTION

00014

NOTE Before beginning a task, find out how much repair, modification, or replacement is needed to fix equipment as described in this manual. Sometimes the reason for equipment failure can be seen right away and complete teardown is not necessary. Disassemble equipment only as far as necessary to repair or replace damaged or broken parts. 1. This chapter provides information for identifying and correcting malfunctions that may develop during operation of the D7R Dozer with Winch and D7R Dozer with Ripper. 2. The Troubleshooting Index in (WP 0013) lists common malfunctions that may occur and refers to the proper page in Engine Troubleshooting Procedures (WP 0019), Powertrain Troubleshooting Procedures (WP 0020), Chassis Troubleshooting Procedures (WP 0021), and Cab Troubleshooting Procedures (WP 0022). 3. If you are unsure of the location of an item mentioned in troubleshooting, refer to General Information (WP 0001) or Equipment Description and Data (WP 0002). 4. Before performing troubleshooting, read and follow all safety instructions found in the Warning Summary at the front of this manual. 5. Troubleshooting Index in (WP 0013) cannot list all malfunctions that may occur, nor can troubleshooting list all tests or inspections and corrective actions. 6. Troubleshooting Index in (WP 0013) also lists all possible trouble codes for the machine. If an error/event code is active along with a symptom, perform the error/event code troubleshooting first. Document all of the codes and symptoms before troubleshooting. Some codes may set in the course of testing and should not be diagnosed in addition to those noted before testing. 7. When troubleshooting a malfunction: a. Locate the symptom or symptoms in Troubleshooting Index in (WP 0013) that best describe the malfunction. b. Turn to the page in the correct troubleshooting procedures (WP 0019, WP 0020, WP 0021, and WP 0022) where the troubleshooting procedures for that error are described. c.

Perform the task, answer the question, and perform the corrective action in the order listed until the malfunction is corrected. Do not perform any maintenance task unless the troubleshooting procedure tells you to do so.

EXPLANATION OF COLUMNS

00014

The columns in the troubleshooting table are defined as follows: a. MALFUNCTION. A visual or operational indication that something is wrong with the equipment. b. TEST OR INSPECTION. A procedure to isolate the problem in a system or component. c.

CORRECTIVE ACTION. A procedure to correct the problem.

END OF WORK PACKAGE

0014-1/(2 blank)

4 TM 5-2410-241-23-1

0015

FIELD MAINTENANCE 0 0 1

5

-

HOW TO USE ON-BOARD DIAGNOSTICS

GENERAL

0015

The D7R Dozer has three electronic control modules (ECMs): engine, powertrain, and implement. An ECM has the ability to detect problems with the electrical/electronic system and with engine or machine operation. When an ECM detects an electrical or electronic system malfunction, the ECM will generate a diagnostic code. The diagnostic codes are logged with the time and number of occurrences. Codes may be retrieved using two methods: •

On-Board diagnosis using the instrument cluster monitoring system and messenger module

•

Electronic Technician (ET)

This work package describes On-Board diagnostics.

0015-1

TM 5-2410-241-23-1

0015

INTRODUCTION

0015

Machine Monitoring System

00015

The machine monitoring system is an electronic monitoring system that continuously watches machine systems. The system includes the following devices: a main display module, various switches and sensors, an action lamp (Figure 1, Item 7), an action alarm, and a quad gauge module (Figure 1, Item 1). The main display module is the controller of the system. This module receives information from switches, sensors and other electronic controls. Information is sent through the data link communication circuit. The main display module processes all information, and will then activate various outputs for the following displays: • display area of upper display module (Figure 1, Item 4) • display area of lower display module (Figure 1, Item 6) • quad gauge module (Figure 1, Item 1) • action lamp (Figure 1, Item 7) • action alarm Displayed components show condition of machine systems. The operator can also obtain system diagnostic information. The three modules which constitute machine monitoring system have the following characteristics: 1. Upper Display Module. a. A digital display area (Figure 1, Item 4) is provided, and shows engine speed and gear indicator. The display area contains 10 indicators (Figure 1, Item 2). b. Ten different indicators (Figure 1, Item 2) may be shown in upper display area. Indicators are engine oil pressure, charging system, inlet manifold temperature, fuel level, parking brake, three bi-directional shift indicators, auto kick down indicator, and hydraulic lockout. 2. Lower Display Module (Figure 1, Item 6). a. A digital display area (Figure 1, Item 6) is provided and has three modes: Service Meter mode, Travel Distance mode, Service Code mode. The information for the quad gauge module can be shown on the display. The operator selects the system information that is shown in the display area (TM 5-2410-241-10). b. Service Meter mode shows machine operational hours. SERV CODE will display when there is an active service code while in this mode. c.

Travel Distance mode shows total distance of travel, total distance of travel in forward and total distance of travel in reverse. SERV CODE will display when there is an active service code while in this mode.

d. Service Code mode shows diagnostic codes to alert the operator that an ECM detected fault is active. All active and logged diagnostic codes will be displayed in order. SERV CODE will display when the diagnostic code is an active diagnostic service code. e. Six different indicators may be shown in lower display area (Figure 1, Item 5). Indicators shown are air filter restriction, powertrain oil filter by-pass, implement system alert, engine system alert, transmission system alert, and a brake system alert. 3. Quad Gauge Module (Figure 1, Item 1). Four electronic gauges indicate condition of machine, and indicate the following: engine coolant temperature, transmission oil temperature, hydraulic oil temperature, and fuel level. An external action lamp (Figure 1, Item 7) and an action alarm indicate the severity (warning category) of a problem. The machine monitoring system performs a self-test of the instrument cluster each time start switch (Figure 1, Item 3) is set to ON position. During self test, all gauge needles are set to middle position, then minimum position, then will quickly and smoothly move to maximum position, and return to current actual value. All icons and segments will illuminate, all indicators will illuminate. The duration of the self-test will take approximately three seconds, and the action alarm will activate at the beginning of the self-test for approximately one second. Upon completion of the self-test the machine monitoring system will enter normal mode.

0015-2

TM 5-2410-241-23-1

0015

INTRODUCTION – CONTINUED

0015

During machine operation if an abnormal condition is detected the machine monitoring system will display the value on the gauges and illuminate an action indicator. If the abnormal condition is related to an ECM function a diagnostic code may be set and SERV CODE will appear in the lower display area.

Figure 1. Instrument Cluster. Messenger Monitoring System

0015

00015

The Messenger module receives information from the powertrain ECM, implement ECM, engine ECM, and the ET tool through the data link communication circuit. The messenger is an on-board monitoring system that displays ECM diagnostic codes.

0015-3

TM 5-2410-241-23-1

INTRODUCTION – CONTINUED

0015

0015

Messenger Module Menu Navigation

00015

The Messenger module (Figure 2, Item 1) has two menus available for navigation. The menus will display on the LCD screen (Figure 2, Item 2). The menus of the Messenger module allow the user to view more information about the machine. Due to the size of the display, only one menu will appear at a time. Use navigation buttons to move between menu options. The Messenger module always returns to base or default menu when machine is turned off. To access other menus, press and release back arrow (Figure 2, Item 6). Press and release left/up button (Figure 2, Item 5), and right/down button (Figure 2, Item 4) to scroll through available menus or to view additional screens within a menu. Press and release the OK button (Figure 2, Item 3) to select highlighted menu. Press and release back arrow (Figure 2, Item 6) to return to previous menu selection.

Figure 2. Messenger Module.

0015

On the Diagnostics/Events list page, the SRC column (Figure 3, Item 1) shows the module identification (MID) code. The CODE column (Figure 3, Item 2) displays the diagnostic code and is the component identifier (CID) and failure mode identifier (FMI). The OCC column (Figure 3, Item 3) is the occurrence and indicates the number of times the code has set. The ACT column (Figure 3, Item 4) will display the letter “A” if the code is active, and will be empty if the code is not currently active. Use the left/up button (Figure 3, Item 7), or the right/down button (Figure 3, Item 6) to scroll through the list of diagnostic codes. Press and release the OK button (Figure 3, Item 5) to view the diagnostic code detail.

Figure 3. Diagnostic Code Screen. END OF TASK END OF WORK PACKAGE

0015-4

0015

10 TM 5-2410-241-23-1

0016

FIELD MAINTENANCE

-

HOW TO USE ELECTRONIC TECHNICIAN (ET) Software Installation, Connecting MSD, Status Groups, Disconnecting MSD 0 0 1 6

INITIAL SETUP Tools and Special Tools Adapter Kit, Test (WP 0302, Item 5) Software Kit (Mil ET) (WP 0302, Item 55) Test Set, Electronic (MSD) (WP 0302, Item 62) References WP 0017

0

0

0

Equipment Condition Machine parked (TM 5-2410-241-10) Tracks chocked Estimated Time to Complete

0

0

0

0016-1

1.0 Hr

0

0

0

0

0

TM 5-2410-241-23-1

0016

SOFTWARE INSTALLATION

00016

NOTE •

First time users, review MSD operator’s training installed on MSD.

•

If this is the first use of Electronic Technician (ET), perform steps 1 through 3.

1. Install communication adapter driver software (Figure 1, Item 3) on MSD (Figure 1, Item 1) if required. 2. Install ET software (Figure 1, Item 4) on MSD (Figure 1, Item 1). 3. Review tutorial on built-in trainer in ET. END OF TASK CONNECTING MSD

00016

1. Turn ignition switch and battery disconnect switch to off position. 2. Connect cable (Figure 1, Item 8) to COMPUTER end of communication adapter (Figure 1, Item 9) and to USB port (Figure 1, Item 11) of MSD (Figure 1, Item 1). 3. Connect cable (Figure 1, Item 10) to DATA LINK end of communication adapter (Figure 1, Item 9). 4. If power supply is available, connect supply power cable (Figure 1, Item 6) to power supply port (Figure 1, Item 2) on MSD (Figure 1, Item 1). 5. If power supply is available, connect supply power cable (Figure 1, Item 7) to power supply (Figure 1, Item 5) and power source.

Figure 1. Electronic Technician (ET).

0016-2

0016

TM 5-2410-241-23-1

0016

CONNECTING MSD – CONTINUED

00016

6. Remove protective cap (Figure 2, Item 1) from diagnostic connector (Figure 2, Item 2) on inside rear of cab.

Figure 2. Diagnostic Connector.

0016-3

0016

TM 5-2410-241-23-1

CONNECTING MSD – CONTINUED

0016

00016

7. Connect cable (Figure 3, Item 1) to diagnostic connector (Figure 3, Item 2).

Figure 3. Diagnostic Connector Cable.

0016

8. Turn battery disconnect switch and engine start switch to on position (TM 5-2410-241-10) to establish communications with ECMs.

NOTE Electronic Technician (ET) will display list of all ECMs on machine. 9. Select ET icon on computer screen. 10. Select OK button (Figure 4, Item 2) if What’s New dialog box (Figure 4, Item 1) is displayed.

Figure 4. What’s New Dialog Box.

0016-4

0016

TM 5-2410-241-23-1

CONNECTING MSD – CONTINUED

0016

00016

NOTE •

Software will display fault codes for all ECMs.

•

Under Preferences in Utilities menu, make sure ET is set to adapter in use.

11. Select desired ECM (Figure 5, Item 1).

Figure 5. ECM Selection.

0016-5

0016

TM 5-2410-241-23-1

0016

CONNECTING MSD – CONTINUED

00016

NOTE Software will display fault codes for all ECMs. 12. To display active codes (Figure 6, Item 5), active events (Figure 6, Item 4), or status flags (Figure 6, Item 3) select the buttons (Figure 6, Item 1) at bottom of screen (Figure 6, Item 2).

Figure 6. Diagnostic Code Selection. 13. If diagnostic codes are logged or active on your machine, and a troubleshooting step does not appear in this manual, notify supervisor. END OF TASK

0016-6

0016

TM 5-2410-241-23-1

STATUS GROUPS

0016

00016

Status groups are lists of the machine’s parameters that are monitored by each ECM, and are shown in real time. To view machine parameters, select the status icon (Figure 7, Item 1), and select a status group (Figure 7, Item 11) for an ECM (Figure 7, Item 12) in left window of screen (Figure 7, Item 2). A list of parameters (Figure 7, Item 3) for selected status group (Figure 7, Item 11) is displayed on the right window of screen (Figure 7, Item 10). A description of the parameter is displayed in the Description column (Figure 7, Item 4). The Value column (Figure 7, Item 5) indicates the current real time value of component or system. A Unit column (Figure 7, Item 6) identifies the type of measurement associated with parameter. The Min column (Figure 7, Item 7), and the Max column (Figure 7, Item 8) display the minimum and maximum values observed during the current session. An ECM column (Figure 7, Item 9) identifies the ECM monitoring and reporting parameter.

Figure 7. Status Group and Parameter List. END OF TASK

0016-7

0016

TM 5-2410-241-23-1

DISCONNECTING MSD

0016

00016

1. Select the Disconnect icon (Figure 8, Item 1). 2. Close the ET program (Figure 8, Item 2).

Figure 8. Close ET Program.

0016-8

0016

TM 5-2410-241-23-1

0016

DISCONNECTING MSD – CONTINUED 3. Turn the ignition switch and battery disconnect switch to the OFF position. 4. Disconnect cable (Figure 9, Item 1) from diagnostic connector (Figure 9, Item 2) to disconnect MSD from machine.

Figure 9. Diagnostic Connector Cable.

0016-9

0016

TM 5-2410-241-23-1

0016

DISCONNECTING MSD – CONTINUED 5. Install diagnostic connector cover (Figure 10, Item 1) on diagnostic connector (Figure 10, Item 2).

Figure 10. Diagnostic Connector. 6. Disconnect power supply cable from power supply, and power source if required. 7. Disconnect cable from Computer end of communication adapter and from USB port of MSD. 8. Shut down MSD. END OF TASK END OF WORK PACKAGE

0016-10

0016

14 TM 5-2410-241-23-1

0017

FIELD MAINTENANCE

-

ELECTRONIC CONTROL MODULE (ECM) PROGRAMMING Recording Diagnostic Codes and Copying Configuration from ECM, ECM Unable to Communicate, Initializing ECM, Flash Programming, Copy Configuration to ECM, Fuel Injector Trim File 0 0 1 7

INITIAL SETUP Tools and Special Tools Adapter Kit, Test (WP 0302, Item 5) Software Kit (Mil ET) (WP 0302, Item 55) Test Set, Electronic (MSD) (WP 0302, Item 62) References WP 0013

0

0

0

Equipment Condition

0

Machine parked (TM 5-2410-241-10) Electronic Technician (ET) and MSD connected to machine (WP 0016) 0

0

0

0

Estimated Time to Complete 2.0 Hr

0

NOTE Verify engine serial number is on Electronic Technician (ET).

0017-1

0

0

TM 5-2410-241-23-1

0017

RECORDING DIAGNOSTIC CODES AND COPYING CONFIGURATION FROM ECM

00017

NOTE If ECM and MSD are not able to communicate, refer to ECM unable to communicate, in this work package. 1. Use Diagnostic drop down menu (Figure 1, Item 1) and select Active Diagnostic Codes (Figure 1, Item 2), or Active Codes icon (Figure 1, Item 4) at the bottom of the Electronic Technician (ET) screen (Figure 1, Item 3) and record all active diagnostic codes.

Figure 1. Active Code Menu.

0017-2

0017

TM 5-2410-241-23-1

0017

RECORDING DIAGNOSTIC CODES AND COPYING CONFIGURATION FROM ECM – CONTINUED

00017

2. Copy ECM configuration data as follows: a. Select Service drop down menu (Figure 2, Item 1), then Copy Configuration (Figure 2, Item 2), and then ECM Replacement (Figure 2, Item 3). (1) If a file open dialogue box is displayed, select Cancel. (2) If a data file is unavailable, No data is available. Load from ECM now? dialogue box (Figure 2, Item 4) will be displayed. Select Yes (Figure 2, Item 5) to load data from ECM.

Figure 2. ECM Configuration Menu.

0017-3

0017

TM 5-2410-241-23-1

RECORDING DIAGNOSTIC CODES AND COPYING CONFIGURATION FROM ECM – CONTINUED

0017

00017

b. ECM Select window (Figure 3, Item 1) will display. Highlight correct ECM (Figure 3, Item 2) and select OK button (Figure 3, Item 3). Configuration data is now copied from that ECM to MSD (Figure 3, Item 4).

NOTE By default, file is saved in Downloads\ECM Replacement folder. File name is saved by engine serial number, date, and time of download. c.

Select Save to File (Figure 3, Item 5) and select location for files to be saved.

Figure 3. ECM Select Window.

0017-4

0017

TM 5-2410-241-23-1

0017

RECORDING DIAGNOSTIC CODES AND COPYING CONFIGURATION FROM ECM – CONTINUED d. Enter file name (Figure 4, Item 2), or select file (Figure 4, Item 1), and select Save button (Figure 4, Item 3) to accept download. e. Select OK button (Figure 4, Item 5) when ECM Replacement data saved successfully dialogue box (Figure 4, Item 4) displays.

Figure 4. ECM Configuration Save. 3. Refer to appropriate work package for ECM replacement instructions. Then, return to this work package to copy saved configuration data to new ECM. Refer to Copy Configuration to ECM in this work package. END OF TASK

0017-5

0017

TM 5-2410-241-23-1

0017

ECM UNABLE TO COMMUNICATE

00017

NOTE This procedure is for non-communicating ECMs. The first steps will verify that the data link circuit between diagnostic connector and ECM is not causing communication problem. 1. Turn engine start switch to OFF position (TM 5-2410-241-10). 2. Turn battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Check ECM and Ignition Power and Ground (WP 0013) 4. Disconnect J1 connector from all modules connected to data link. 5. At each harness, connect a jumper wire between data link (+) (circuit 893-GN) and data link (-) (circuit 892-BR). 6. The following chart provides data link pin information for various ECM J1 connectors.

Table 1. PIN NUMBER ECM

Data Link (+) Circuit 893 - GN

Data Link (-) Circuit 892 - BR

Engine

9

8

Powertrain

10

20

Machine Monitoring System

5

14

Messenger

6

5

0017-6

TM 5-2410-241-23-1

0017

ECM UNABLE TO COMMUNICATE – CONTINUED 7. At diagnostic connector (Figure 5, Item 1), measure resistance between data link (+) pin D (Figure 5, Item 2) circuit 893, and data link (-) pin E (Figure 5, Item 3) circuit 892. •

If resistance is less than 5.0 ohms, circuit is OK. Remove jumper wire. Refer to appropriate work package for ECM replacement instructions. Return to this work package once ECM is replaced. Refer to Initializing ECM.

•

If resistance is greater than 5.0 ohms, there is an open or a poor connection in data link circuit. Check and repair data link circuit, then try to establish communication with ECM. If ECM will still not communicate, proceed to appropriate ECM Replacement work package. Return to this work package once ECM is replaced. Refer to Initializing ECM in this work package.

Figure 5. Diagnostic Connector.

0017

END OF TASK INITIALIZING ECM

00017

NOTE Two key start ON/OFF cycles are required for correct initialization of new ECM. 1. Turn battery disconnect switch to ON position (TM 5-2410-241-10). 2. Turn engine start switch to ON position (TM 5-2410-241-10). 3. Wait one minute to allow ECM to initialize. 4. Turn engine start switch to OFF position (TM 5-2410-241-10). 5. Turn engine start switch to ON position (TM 5-2410-241-10). a. Cat Mil ET will indicate whether ECM has been programmed or not. b. If ECM is not programmed, program ECM using WinFlash software contained with Cat Mil ET. Proceed to FLASH PROGRAMMING in this work package. c.

If ECM is programmed, Cat Mil ET will allow access to ECM to load configuration data. Proceed to Copy Configuration to ECM in this work package.

END OF TASK

0017-7

TM 5-2410-241-23-1

0017

FLASH PROGRAMMING

00017

1. Highlight applicable ECM and select OK button.

NOTE Flash File CD should be contained in MSD. If Flash File is not available, contact your supervisor. 2. Insert flash file CD, open Windows Explorer, select drive with CD, open and read the “read me first” file. Note correct ECM flash file and folder name. 3. Select WinFlash (Figure 6, Item 2) from Utilities menu (Figure 6, Item 1). WinFlash will detect all installed ECMs.

Figure 6. Utilities Menu.

0017

4. Read and close WinFlash Quick Help guide (Figure 7, Item 1).

Figure 7. Win Flash Quick Help Menu.

0017-8

0017

TM 5-2410-241-23-1

FLASH PROGRAMMING – CONTINUED

0017

00017

5. Highlight applicable ECM (Figure 8, Item 1). 6. Select Browse (Figure 8, Item 4) to My Computer and select ET Flash Files. 7. Open Flash Files folder (Figure 8, Item 2) and select system folder (Figure 8, Item 3).

Figure 8. Flash File Menu.

0017-9

0017

TM 5-2410-241-23-1

0017

FLASH PROGRAMMING – CONTINUED

00017

8. Select correct flash file noted in Step 2. 9. Select Begin Flash button (Figure 9, Item 1). Flash process will proceed automatically.

Figure 9. Flash File Programming.

NOTE If any error messages are received during flash programming, click “Cancel” to stop process. Verify file and component (engine, transmission, implement) match. Repeat Steps 1 through 8 until flash programming is completed and the “Flash Completed Successfully” screen displays. 10. Select Electronic Technician (ET) from button options.

NOTE If you are flash programming ECM as directed by troubleshooting, proceed to next step. If replacing an ECM, proceed to COPY CONFIGURATION TO ECM in this work package. 11. Start and run engine until operating temperature is reached and verify proper operation of all components (TM 5-2410-240-10). Check for active diagnostic codes by selecting Active Diagnostic Codes from the Diagnostics menu. END OF TASK

0017-10

0017

TM 5-2410-241-23-1

COPY CONFIGURATION TO ECM

0017

00017

CAUTION •

This procedure is for loading previously saved configuration data to the new ECM.

•

Failure to load this data may result in lowered machine performance.

1. Highlight applicable ECM, then select OK button. 2. Ensure correct ECM is highlighted. Select Copy Configuration (Figure 10, Item 2) from Service menu (Figure 10, Item 1), select ECM Replacement (Figure 10, Item 3).

Figure 10. Configuration Menu.

0017-11

0017

TM 5-2410-241-23-1

0017

COPY CONFIGURATION TO ECM – CONTINUED

00017

3. Select configuration file (Figure 11, Item 1) that was saved earlier and select open button (Figure 11, Item 2). When “The current ECM Replacement data came from:....”dialogue box (Figure 11, Item 3) displays, select OK button (Figure 11, Item 4). 4. Select Program ECM button (Figure 11, Item 5), then select ECM to be programmed and select OK button.

Figure 11. Configuration File.

0017

5. Read the Warning that comes up on the MSD screen! This configuration is for the control... message and verify that engine SN displays, then select Yes to program the ECM.

NOTE As data is loaded to ECM, the “Please wait....” message displays. The “Loading data to ECM....” progress bar displays. You may cancel process at any time by pressing Cancel button. The “Are you sure.....” dialogue box displays. Select Yes button to cancel or No button to continue configuration process. 6. Select OK button when Programming complete dialogue box displays. 7. Start and run engine until operating temperature is reached and verify proper operation of all components (TM 5-2410-241-10). Check for active diagnostic codes by selecting Active Diagnostic Codes from Diagnostics menu. 8. Once programming is complete, turn engine start switch to OFF position, shut down Electronic Technician (ET) on MSD and disconnect from diagnostic connector. 9. Install diagnostic connector cover. END OF TASK

0017-12

TM 5-2410-241-23-1

0017

FUEL INJECTOR TRIM FILE

00017

1. Connect MSD to machine (WP 0017), and select 3176C D7. 2. Turn battery disconnect switch and ignition switch to the ON position (TM 5-2410-241-10). 3. Select Service from top of ET screen, then select Calibrations. 4. Select Injector Codes Calibration from list of calibration procedures. 5. Select the injector that corresponds to the fuel injector being replaced, and select the Change button at bottom of ET screen. 6. Enter the four digit code from new fuel injector in the Change Parameter window, and select the OK button. 7. Select the Yes button on the Parameter Change dialog box to accept the changes. 8. Repeat procedure for each cylinder if more than one fuel injector is being replaced. END OF TASK END OF WORK PACKAGE

0017-13/(14 blank)

132 TM 5-2410-241-23-1

FIELD MAINTENANCE 0 0 1 8

Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41.

0018

-

CONNECTOR END VIEWS

V-C4 Engine ECM Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-6 N-C1 Engine ECM Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-7 X-C3 Powertrain ECM Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-8 X-C2 Powertrain ECM Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-9 E-C7 Dash Monitor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-10 M-I-C1 Messenger Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-10 N-C2 Engine Harness Side Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-11 NN-C1 Valve Cover Side Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-12 E-C28 Deceleration Position Sensor Connector - Dash Harness Side. . . . . . . . . . . . . . . . . . . 0018-13 Sensor Pigtail - Decelerator Sensor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-14 MA-C22 Platform Harness (Platform to Engine) Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-14 V-C1 Engine Harness (Engine to Platform) Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-15 R-C4 Throttle Switch Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-16 RW-C1 RH Console Harness Connector (Black). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-17 MA-C1 RH Platform Harness Connector (Black). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-18 Throttle Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-19 YY-C4 Arctic Kit Heater Harness to Arctic Kit Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-20 B2 Connector Arctic Kit Heater.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-20 N-C3 ECM Harness Connector at Oil Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-21 N-C11 ECM Harness Connector at Coolant Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . 0018-22 MA-C3 Platform Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-22 A-C1 Fuse Panel Wiring Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-23 N-C10 Intake Manifold Temperature Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-24 N-C9 Fuel Temperature Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-24 NC-C2 Intake Manifold Jumper to Sensor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-25 NC-C1 Intake Manifold Jumper to N-C10 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-25 N-C13 Crankshaft Position Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-26 Crankshaft Position Sensor (with Pigtail). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-27 V-C12 Engine ECM Resistor - Can/Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-28 Resistor Can/Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-29 X-C10 Powertrain ECM Resistor - Can/Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-30 Resistor Can/Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-31 MA-C14 Platform Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-32 X-C1 Steering Control Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-33 N-C4 Atmospheric Pressure Sensor Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-34 N-C5 Air Inlet Manifold Pressure Sensor Connector/Turbocharger Outlet Pressure Sensor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-34 V-C20 Turbocharger Inlet Pressure Sensor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-35 CV-C1 Crank Normal Mode Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-35 CV-C2 Crank without Injection Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-35 V-C3 Harness Connector to Crank without Injection Connector.. . . . . . . . . . . . . . . . . . . . . . . . 0018-36 N-C14 Camshaft Position Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-36

0018-1

TM 5-2410-241-23-1

Figure 42. Figure 43. Figure 44. Figure 45. Figure 46. Figure 47. Figure 48. Figure 49. Figure 50. Figure 51. Figure 52. Figure 53. Figure 54. Figure 55. Figure 56. Figure 57. Figure 58. Figure 59. Figure 60. Figure 61. Figure 62. Figure 63. Figure 64. Figure 65. Figure 66. Figure 67. Figure 68. Figure 69. Figure 70. Figure 71. Figure 72. Figure 73. Figure 74. Figure 75. Figure 76. Figure 77. Figure 78. Figure 79. Figure 80. Figure 81. Figure 82. Figure 83. Figure 84. Figure 85. Figure 86. Figure 87.

0018

Camshaft Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-37 V-C18 Engine Harness Ether Relay Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-38 X-C6 Parking Brake Switch Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-38 Parking Brake Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-39 V-C8 Transmission Oil Temperature Sensor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-39 E-C23 Instrument Panel Harness Brake Switch Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-40 KK-C1 Service Brake Switch Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-41 X-C8 FORWARD/NEUTRAL/REVERSE (FNR) Sensor Connector. . . . . . . . . . . . . . . . . . . . . . 0018-41 E-C11 Bi-directional Mode Switch Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-42 A-C3 Fuse Panel Harness Start Relay Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-42 E-C27 Dash Harness Brake Position Sensor.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-43 MA-C7 Platform Harness Connector to Transmission Jumper Harness. . . . . . . . . . . . . . . . . . 0018-44 MP-C2 Transmission Jumper Harness Connector to Platform Harness Connector.. . . . . . . . . 0018-45 MP-C1 Transmission Jumper Harness Connector to P-C1 Transmission Harness.. . . . . . . . . 0018-46 P-C1 Transmission Harness Connector to Connector MP-C1. . . . . . . . . . . . . . . . . . . . . . . . . . 0018-47 P-C2 Transmission Harness Speed Sensor #1 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-47 X-C4 Steering Harness Downshift/Upshift Switch Connector. . . . . . . . . . . . . . . . . . . . . . . . . . 0018-48 Downshift/Upshift Switch Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-48 X-C9 Harness Code Plug Connector to Steering Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-49 PW-C1 Harness Code Receptacle Connector to Steering Harness Connector X-C9. . . . . . . . 0018-50 V-C10 Engine Harness Torque Converter Output Speed Sensor Connector. . . . . . . . . . . . . . . 0018-50 Torque Converter Output Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-51 P-C8 Transmission Harness Speed Sensor #2 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-51 MA-C4 Platform Harness Parking Brake Dump Solenoid Connector.. . . . . . . . . . . . . . . . . . . . 0018-52 Parking Brake Dump Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-53 MA-C12 Platform Harness Left Brake Solenoid Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-54 Left Brake Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-55 MA-C6 Secondary Brake Dump Solenoid Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-56 Secondary Brake Dump Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-57 P-C4 Transmission Solenoid Valve #1 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-58 P-C3 Transmission Solenoid Valve #2 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-59 P-C7 Transmission Solenoid Valve #3 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-60 P-C6 Transmission Solenoid Valve #4 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-61 P-C5 Transmission Solenoid Valve #5 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-62 X-C5 Steering Harness Reverse Switch Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-63 RT-C1 Reverse Switch Connector (Pigtail). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-63 TW-C2 Fuel Tank Harness Fuel Level Sender Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-64 MA-C23 Platform Harness to Fuel Tank Harness Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . 0018-64 TW-C7 Fuel Tank Harness to Platform Harness Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-64 E-C3 Instrument Panel Harness Action Alarm Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-65 E-C25 Instrument Panel Harness Action Lamp Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-65 L-C2 Chassis Harness Hydraulic Oil Temperature Sensor Connection. . . . . . . . . . . . . . . . . . . 0018-66 L-C1 Chassis Harness to Platform Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-67 MA-C17 Platform Harness to Chassis Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-68 E-C9 Instrument Panel Harness Gauge Cluster Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-68 E-C10 Instrument Panel Harness Lamp Gear Module Connector. . . . . . . . . . . . . . . . . . . . . . . 0018-69

0018-2

TM 5-2410-241-23-1

Figure 88. Figure 89. Figure 90. Figure 91. Figure 92. Figure 93. Figure 94. Figure 95. Figure 96. Figure 97. Figure 98. Figure 99. Figure 100. Figure 101. Figure 102. Figure 103. Figure 104. Figure 105. Figure 106. Figure 107. Figure 108. Figure 109. Figure 110. Figure 111. Figure 112. Figure 113. Figure 114. Figure 115. Figure 116. Figure 117. Figure 118. Figure 119. Figure 120. Figure 121. Figure 122. Figure 123. Figure 124. Figure 125. Figure 126. Figure 127. Figure 128. Figure 129. Figure 130.

0018

V-C9 Engine Harness Torque Converter Outlet Temperature Sensor Connector. . . . . . . . . . . 0018-69 RW-C7 RH Console Harness Hydraulic Lockout Switch Connector. . . . . . . . . . . . . . . . . . . . . 0018-70 L-C4 Chassis Harness Implement Lockout Solenoid Connector. . . . . . . . . . . . . . . . . . . . . . . . 0018-71 Hydraulic Lockout Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-72 GA-C2 Left Front Cylinder Mounted Flood Lamp Harness Connector to Left Front Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-72 GC-C2 Right Front Cylinder Mounted Flood Lamp Harness Connector to Right Front Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-73 GA-C1 Left Front Flood Lamp Harness to Radiator Guard Harness Connector. . . . . . . . . . . . 0018-73 G-C2 Front Lighting Harness to Left Front Flood Lamp Harness Connector. . . . . . . . . . . . . . . 0018-73 GC-C1 Right Front Flood Lamp Harness to Radiator Guard Harness Connector. . . . . . . . . . . 0018-74 G-C3 Front Lighting Harness to Right Flood Lamp Harness Connector. . . . . . . . . . . . . . . . . . 0018-74 G-C1 Front Lighting Harness to Engine Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-75 V-C15 Engine Harness to Radiator Guard Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . 0018-75 E-C5 Instrument Panel Harness Connector to Main Light Switch. . . . . . . . . . . . . . . . . . . . . . . 0018-75 TK-C2 Left Rear Flood Lamp Harness Connector to Left ROPS Mounted Forward Facing Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-76 TJ-C2 Right Rear Flood Lamp Harness Connector to Right ROPS Mounted Forward Facing Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-76 TK-C3 Left Rear Flood Lamp Harness Connector to Fuel Tank Harness Connector.. . . . . . . . 0018-76 TJ-C3 Right Rear Flood Lamp Harness to Fuel Tank Harness Connector.. . . . . . . . . . . . . . . . 0018-77 TW-C3 Fuel Tank Harness to Left ROPS Flood Lamp Harness Connector. . . . . . . . . . . . . . . . 0018-77 TW-C5 Fuel Tank Harness to Right ROPS Flood Lamp Harness Connector.. . . . . . . . . . . . . . 0018-78 TK-C1 Left Rear Flood Lamp Harness Connector to Left Rearward Facing Flood Lamp. . . . . 0018-78 TJ-C1 Right Rear Flood Lamp Harness Connector to Right Rearward Facing Flood Lamp. . . 0018-78 E-C22 Instrument Panel Harness Connector to Rearward Facing Flood Lamp Switch. . . . . . . 0018-79 V-C16 Engine Harness Under Hoodlight Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-79 V-C17 Engine Harness Under Hoodlight Switch Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-80 E-C16 Instrument Panel Harness Connector to Cab Harness Connector. . . . . . . . . . . . . . . . . 0018-80 H-C2 Cab Harness to Instrument Panel Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-81 H-C6 Cab Harness to Headliner Harness Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-82 HA-C2 Cab Harness to Headliner Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-83 Arctic Kit Heater Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-83 YY-C3 Arctic Kit Heater Harness to Arctic Kit Heater Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . 0018-84 YY-C2 Arctic Kit Heater Diagnostic Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-84 Arctic Kit Heater Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-85 XX-C2 Arctic Kit Heater Harness Connector to Arctic Kit Heater Switch. . . . . . . . . . . . . . . . . . 0018-86 108 Blue Rear Wiper Power Supply Connector to Rear Wiper Motor Switch. . . . . . . . . . . . . . 0018-86 108 Blue Front Wiper Power Supply Connector to Front Wiper Motor Switch. . . . . . . . . . . . . . 0018-87 H-C1 Cab Harness Front Wiper Motor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-87 H-C5 Cab Harness Left Door Wiper Motor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-88 H-C4 Cab Harness Right Door Wiper Motor Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-88 HA-C4 Headliner Harness to Rear Wiper Motor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-89 YY-C1 Arctic Kit Heater Harness to Arctic Kit Heater Main Harness Connector. . . . . . . . . . . . 0018-89 XY-C4 Arctic Kit Heater Main Harness to Arctic Kit Heater Harness Connector. . . . . . . . . . . . 0018-90 XX-C1 Arctic Kit Heater Switch Harness to Arctic Kit Heater Main Harness Connector. . . . . . 0018-90 XY-C3 Arctic Kit Heater Main Harness to Arctic Kit Heater Switch Harness Connector.. . . . . . 0018-91

0018-3

TM 5-2410-241-23-1

Figure 131. Figure 132. Figure 133. Figure 134. Figure 135. Figure 136. Figure 137. Figure 138. Figure 139. Figure 140. Figure 141. Figure 142. Figure 143. Figure 144. Figure 145. Figure 146. Figure 147. Figure 148. Figure 149. Figure 150. Figure 151. Figure 152. Figure 153. Figure 154. Figure 155. Figure 156. Figure 157. Figure 158. Figure 159. Figure 160. Figure 161. Figure 162. Figure 163. Figure 164. Figure 165. Figure 166. Figure 167. Figure 168. Figure 169. Figure 170. Figure 171. Figure 172. Figure 173. Figure 174. Figure 175. Figure 176.

0018

XY-C1 Arctic Kit Heater Main Harness to Platform Harness Connector.. . . . . . . . . . . . . . . . . . 0018-91 MA-C21 Platform Harness to Arctic Kit Heater Main Harness Connector. . . . . . . . . . . . . . . . . 0018-92 H-C7 Cab Harness to Headliner Harness Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-93 HA-C1 Headliner Harness to Cab Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-94 500 Brown Front Wiper Park Supply Connector to Front Wiper Motor Switch.. . . . . . . . . . . . . 0018-94 501 Green Front Wiper Low Supply Connector to Front Wiper Motor Switch. . . . . . . . . . . . . . 0018-95 502 Orange Front Wiper High Supply Connector to Front Wiper Motor Switch.. . . . . . . . . . . . 0018-95 523 Brown Left Door Wiper Park Supply Connector to Left Door Wiper Motor Switch. . . . . . . 0018-96 524 Blue Left Door Wiper Low Supply Connector to Left Door Wiper Motor Switch. . . . . . . . . 0018-96 525 Gray Left Door Wiper High Supply Connector to Left DoorWiper Motor Switch. . . . . . . . . 0018-97 526 Yellow Right Door Wiper Park Supply Connector to Right Door Wiper Motor Switch. . . . . 0018-97 527 Green Right Door Wiper Low Supply Connector to Right Door Wiper Motor Switch. . . . . 0018-98 528 Pink Right Door Wiper High Supply Connector to Right Door Wiper Motor Switch. . . . . . 0018-98 503 Brown Rear Wiper Park Supply Connector to Rear Wiper Motor Switch. . . . . . . . . . . . . . 0018-99 504 Yellow Rear Wiper Low Supply Connector to Rear Wiper Motor Switch. . . . . . . . . . . . . . 0018-99 505 Blue Rear Wiper High Supply Connector to Rear Wiper Motor Switch.. . . . . . . . . . . . . . 0018-100 108 Blue Right Wiper Power Supply Connector to Right Door Wiper Motor Switch. . . . . . . . 0018-100 108 Blue Left Wiper Power Supply Connector to Left Door Wiper Motor Switch.. . . . . . . . . . 0018-101 108 Blue Rear Wiper Power Supply Connector to Rear Wiper Motor. . . . . . . . . . . . . . . . . . . 0018-101 506 Purple Front Washer Supply Connector to Front Washer Switch. . . . . . . . . . . . . . . . . . . 0018-102 507 White Rear Washer Supply Connector to Rear Washer Switch. . . . . . . . . . . . . . . . . . . . 0018-102 503 Orange Right Washer Supply Connector to Right Washer Switch. . . . . . . . . . . . . . . . . . 0018-103 529 White Left Washer Supply Connector to Left Washer Supply. . . . . . . . . . . . . . . . . . . . . . 0018-103 H-C8 Cab Harness Washer Bottle Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-104 HH-C1 Washer Bottle to Cab Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-104 G-C4 Front Lighting Harness Top Horn Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-105 G-C5 Front Lighting Harness Bottom Horn Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-105 MA-C13 Platform Harness to RH Console Harness Connector (Green). . . . . . . . . . . . . . . . . 0018-106 RW-C3 RH Console Harness to Platform Harness Connector (Green). . . . . . . . . . . . . . . . . . 0018-107 R-C5 RH Console Harness Connector to Horn Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-108 CH-C3 A/C Compressor Harness Connector to Compressor Clutch.. . . . . . . . . . . . . . . . . . . 0018-108 CH-C2 A/C Compressor Harness Connector to Compressor Pressure Switch. . . . . . . . . . . . 0018-109 E-C6 Instrument Panel Harness Ignition Switch Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . 0018-109 CH-C1 A/C Compressor Harness Connector to Engine Harness Connector.. . . . . . . . . . . . . 0018-110 V-C13 Engine Harness Connector to A/C Compressor Harness Connector. . . . . . . . . . . . . . 0018-110 E-C14 Instrument Panel Harness Connector to Blower Motor Harness Connector.. . . . . . . . 0018-111 EE-C8 Blower Motor Harness Connector to Instrument Panel Harness Connector. . . . . . . . 0018-112 522 White Thermostat Switch Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-113 200 Black Thermostat Switch Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-114 E-C21 Instrument Panel Harness Connector to A/C Switch. . . . . . . . . . . . . . . . . . . . . . . . . . 0018-114 E-C21 Instrument Panel Harness Connector to A/C Switch. . . . . . . . . . . . . . . . . . . . . . . . . . 0018-114 124 Green Fuse Panel Wiring Harness Blower Motor Circuit Breaker Connector. . . . . . . . . . 0018-115 112 Purple Blower Motor Circuit Breaker Supply Power Wire Point AE1. . . . . . . . . . . . . . . . 0018-116 EE-C3 Blower Motor Harness to Resistor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-117 EE-C4 Blower Motor Harness to Blower Motor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-117 Blower Motor Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-118

0018-4

TM 5-2410-241-23-1

Figure 177. Figure 178. Figure 179. Figure 180. Figure 181. Figure 182. Figure 183. Figure 184. Figure 185. Figure 186. Figure 187. Figure 188. Figure 189. Figure 190. Figure 191. Figure 192. Figure 193. Figure 194.

0018

A-C2 Fuse Panel Harness Main Power Relay Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-118 Main Power Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-119 V-C2 Engine Harness Ether Injection Solenoid Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-120 Flood Lamp Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-120 Engine Flood Lamp Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-121 Front Wiper Switch Terminal B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-121 Left Wiper Switch Terminal B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-122 Right Wiper Switch Terminal B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-122 Rear Wiper Switch Terminal B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-123 Front Wiper Motor Pigtail Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-123 Left Wiper Motor Pigtail Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-124 Right Wiper Motor Pigtail Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-124 Rear Wiper Motor Pigtail Connector.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-125 HH-C2 Front Washer Pump Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-125 HH-C3 Left Washer Pump Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-126 HH-C4 Right Washer Pump Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-126 HH-C5 Rear Washer Pump Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-127 Wiper Washer Headliner Ground Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-127

0018-5

TM 5-2410-241-23-1

Figure 1. V-C4 Engine ECM Connector.

0018-6

0018

0018

TM 5-2410-241-23-1

Figure 2. N-C1 Engine ECM Connector.

0018-7

0018

0018

TM 5-2410-241-23-1

Figure 3. X-C3 Powertrain ECM Connector.

0018-8

0018

0018

TM 5-2410-241-23-1

Figure 4. X-C2 Powertrain ECM Connector.

0018-9

0018

0018

TM 5-2410-241-23-1

Figure 5. E-C7 Dash Monitor Connector.

Figure 6. M-I-C1 Messenger Connector.

0018-10

0018

0018

0018

TM 5-2410-241-23-1

Figure 7. N-C2 Engine Harness Side Connector.

0018-11

0018

0018

TM 5-2410-241-23-1

Figure 8. NN-C1 Valve Cover Side Connector.

0018-12

0018

0018

TM 5-2410-241-23-1

Figure 9. E-C28 Deceleration Position Sensor Connector - Dash Harness Side.

0018-13

0018

0018

TM 5-2410-241-23-1

Figure 10. Sensor Pigtail - Decelerator Sensor Connector.

Figure 11. MA-C22 Platform Harness (Platform to Engine) Connector.

0018-14

0018

0018

0018

TM 5-2410-241-23-1

Figure 12. V-C1 Engine Harness (Engine to Platform) Connector.

0018-15

0018

0018

TM 5-2410-241-23-1

Figure 13. R-C4 Throttle Switch Connector.

0018-16

0018

0018

TM 5-2410-241-23-1

Figure 14. RW-C1 RH Console Harness Connector (Black).

0018-17

0018

0018

TM 5-2410-241-23-1

Figure 15. MA-C1 RH Platform Harness Connector (Black).

0018-18

0018

0018

TM 5-2410-241-23-1

Figure 16. Throttle Switch.

0018-19

0018

0018

TM 5-2410-241-23-1

Figure 17. YY-C4 Arctic Kit Heater Harness to Arctic Kit Heater.

Figure 18. B2 Connector Arctic Kit Heater.

0018-20

0018

0018

0018

TM 5-2410-241-23-1

Figure 19. N-C3 ECM Harness Connector at Oil Pressure Sensor.

0018-21

0018

0018

TM 5-2410-241-23-1

Figure 20. N-C11 ECM Harness Connector at Coolant Temperature Sensor.

Figure 21. MA-C3 Platform Harness Connector.

0018-22

0018

0018

0018

TM 5-2410-241-23-1

Figure 22. A-C1 Fuse Panel Wiring Harness Connector.

0018-23

0018

0018

TM 5-2410-241-23-1

Figure 23. N-C10 Intake Manifold Temperature Connector.

Figure 24. N-C9 Fuel Temperature Connector.

0018-24

0018

0018

0018

TM 5-2410-241-23-1

Figure 25. NC-C2 Intake Manifold Jumper to Sensor Connector.

Figure 26. NC-C1 Intake Manifold Jumper to N-C10 Connector.

0018-25

0018

0018

0018

TM 5-2410-241-23-1

Figure 27. N-C13 Crankshaft Position Connector.

0018-26

0018

0018

TM 5-2410-241-23-1

Figure 28. Crankshaft Position Sensor (with Pigtail).

0018-27

0018

0018

TM 5-2410-241-23-1

Figure 29. V-C12 Engine ECM Resistor - Can/Data Link.

0018-28

0018

0018

TM 5-2410-241-23-1

Figure 30. Resistor Can/Data Link.

0018-29

0018

0018

TM 5-2410-241-23-1

Figure 31. X-C10 Powertrain ECM Resistor - Can/Data Link.

0018-30

0018

0018

TM 5-2410-241-23-1

Figure 32. Resistor Can/Data Link.

0018-31

0018

0018

TM 5-2410-241-23-1

Figure 33. MA-C14 Platform Harness Connector.

0018-32

0018

0018

TM 5-2410-241-23-1

Figure 34. X-C1 Steering Control Harness.

0018-33

0018

0018

TM 5-2410-241-23-1

Figure 35. N-C4 Atmospheric Pressure Sensor Connector.

Figure 36. N-C5 Air Inlet Manifold Pressure Sensor Connector/Turbocharger Outlet Pressure Sensor Connector.

0018-34

0018

0018

0018

TM 5-2410-241-23-1

Figure 37. V-C20 Turbocharger Inlet Pressure Sensor Connector.

Figure 38. CV-C1 Crank Normal Mode Connector.

Figure 39. CV-C2 Crank without Injection Connector.

0018-35

0018

0018

0018

0018

TM 5-2410-241-23-1

Figure 40. V-C3 Harness Connector to Crank without Injection Connector.

Figure 41. N-C14 Camshaft Position Connector.

0018-36

0018

0018

0018

TM 5-2410-241-23-1

Figure 42. Camshaft Position Sensor.

0018-37

0018

0018

TM 5-2410-241-23-1

Figure 43. V-C18 Engine Harness Ether Relay Connector.

Figure 44. X-C6 Parking Brake Switch Connector.

0018-38

0018

0018

0018

TM 5-2410-241-23-1

Figure 45. Parking Brake Switch.

Figure 46. V-C8 Transmission Oil Temperature Sensor Connector.

0018-39

0018

0018

0018

TM 5-2410-241-23-1

Figure 47. E-C23 Instrument Panel Harness Brake Switch Connector.

0018-40

0018

0018

TM 5-2410-241-23-1

Figure 48. KK-C1 Service Brake Switch Harness Connector.

Figure 49. X-C8 FORWARD/NEUTRAL/REVERSE (FNR) Sensor Connector.

0018-41

0018

0018

0018

TM 5-2410-241-23-1

Figure 50. E-C11 Bi-directional Mode Switch Connector.

Figure 51. A-C3 Fuse Panel Harness Start Relay Connector.

0018-42

0018

0018

0018

TM 5-2410-241-23-1

Figure 52. E-C27 Dash Harness Brake Position Sensor.

0018-43

0018

0018

TM 5-2410-241-23-1

Figure 53. MA-C7 Platform Harness Connector to Transmission Jumper Harness.

0018-44

0018

0018

TM 5-2410-241-23-1

Figure 54. MP-C2 Transmission Jumper Harness Connector to Platform Harness Connector.

0018-45

0018

0018

TM 5-2410-241-23-1

Figure 55. MP-C1 Transmission Jumper Harness Connector to P-C1 Transmission Harness.

0018-46

0018

0018

TM 5-2410-241-23-1

Figure 56. P-C1 Transmission Harness Connector to Connector MP-C1.

Figure 57. P-C2 Transmission Harness Speed Sensor #1 Connector.

0018-47

0018

0018

0018

TM 5-2410-241-23-1

Figure 58. X-C4 Steering Harness Downshift/Upshift Switch Connector.

Figure 59. Downshift/Upshift Switch Connector.

0018-48

0018

0018

0018

TM 5-2410-241-23-1

Figure 60. X-C9 Harness Code Plug Connector to Steering Harness.

0018-49

0018

0018

TM 5-2410-241-23-1

Figure 61. PW-C1 Harness Code Receptacle Connector to Steering Harness Connector X-C9.

Figure 62. V-C10 Engine Harness Torque Converter Output Speed Sensor Connector.

0018-50

0018

0018

0018

TM 5-2410-241-23-1

Figure 63. Torque Converter Output Speed Sensor.

Figure 64. P-C8 Transmission Harness Speed Sensor #2 Connector.

0018-51

0018

0018

0018

TM 5-2410-241-23-1

Figure 65. MA-C4 Platform Harness Parking Brake Dump Solenoid Connector.

0018-52

0018

0018

TM 5-2410-241-23-1

Figure 66. Parking Brake Dump Solenoid.

0018-53

0018

0018

TM 5-2410-241-23-1

Figure 67. MA-C12 Platform Harness Left Brake Solenoid Connector.

0018-54

0018

0018

TM 5-2410-241-23-1

Figure 68. Left Brake Solenoid.

0018-55

0018

0018

TM 5-2410-241-23-1

Figure 69. MA-C6 Secondary Brake Dump Solenoid Connector.

0018-56

0018

0018

TM 5-2410-241-23-1

Figure 70. Secondary Brake Dump Solenoid.

0018-57

0018

0018

TM 5-2410-241-23-1

Figure 71. P-C4 Transmission Solenoid Valve #1 Connector.

0018-58

0018

0018

TM 5-2410-241-23-1

Figure 72. P-C3 Transmission Solenoid Valve #2 Connector.

0018-59

0018

0018

TM 5-2410-241-23-1

Figure 73. P-C7 Transmission Solenoid Valve #3 Connector.

0018-60

0018

0018

TM 5-2410-241-23-1

Figure 74. P-C6 Transmission Solenoid Valve #4 Connector.

0018-61

0018

0018

TM 5-2410-241-23-1

Figure 75. P-C5 Transmission Solenoid Valve #5 Connector.

0018-62

0018

0018

TM 5-2410-241-23-1

Figure 76. X-C5 Steering Harness Reverse Switch Connector.

Figure 77. RT-C1 Reverse Switch Connector (Pigtail).

0018-63

0018

0018

0018

TM 5-2410-241-23-1

Figure 78. TW-C2 Fuel Tank Harness Fuel Level Sender Connector.

Figure 79. MA-C23 Platform Harness to Fuel Tank Harness Connector.

Figure 80. TW-C7 Fuel Tank Harness to Platform Harness Connector.

0018-64

0018

0018

0018

0018

TM 5-2410-241-23-1

Figure 81. E-C3 Instrument Panel Harness Action Alarm Connector.

Figure 82. E-C25 Instrument Panel Harness Action Lamp Connector.

0018-65

0018

0018

0018

TM 5-2410-241-23-1

Figure 83. L-C2 Chassis Harness Hydraulic Oil Temperature Sensor Connection.

0018-66

0018

0018

TM 5-2410-241-23-1

Figure 84. L-C1 Chassis Harness to Platform Harness Connector.

0018-67

0018

0018

TM 5-2410-241-23-1

Figure 85. MA-C17 Platform Harness to Chassis Harness Connector.

Figure 86. E-C9 Instrument Panel Harness Gauge Cluster Connector.

0018-68

0018

0018

0018

TM 5-2410-241-23-1

Figure 87. E-C10 Instrument Panel Harness Lamp Gear Module Connector.

Figure 88. V-C9 Engine Harness Torque Converter Outlet Temperature Sensor Connector.

0018-69

0018

0018

0018

TM 5-2410-241-23-1

Figure 89. RW-C7 RH Console Harness Hydraulic Lockout Switch Connector.

0018-70

0018

0018

TM 5-2410-241-23-1

Figure 90. L-C4 Chassis Harness Implement Lockout Solenoid Connector.

0018-71

0018

0018

TM 5-2410-241-23-1

0018

Figure 91. Hydraulic Lockout Switch.

Figure 92. GA-C2 Left Front Cylinder Mounted Flood Lamp Harness Connector to Left Front Flood Lamp.

0018-72

0018

0018

TM 5-2410-241-23-1

Figure 93. GC-C2 Right Front Cylinder Mounted Flood Lamp Harness Connector to Right Front Flood Lamp.

Figure 94. GA-C1 Left Front Flood Lamp Harness to Radiator Guard Harness Connector.

Figure 95. G-C2 Front Lighting Harness to Left Front Flood Lamp Harness Connector.

0018-73

0018

0018

0018

0018

TM 5-2410-241-23-1

Figure 96. GC-C1 Right Front Flood Lamp Harness to Radiator Guard Harness Connector.

Figure 97. G-C3 Front Lighting Harness to Right Flood Lamp Harness Connector.

0018-74

0018

0018

0018

TM 5-2410-241-23-1

Figure 98. G-C1 Front Lighting Harness to Engine Harness Connector.

Figure 99. V-C15 Engine Harness to Radiator Guard Harness Connector.

Figure 100. E-C5 Instrument Panel Harness Connector to Main Light Switch.

0018-75

0018

0018

0018

0018

TM 5-2410-241-23-1

Figure 101. TK-C2 Left Rear Flood Lamp Harness Connector to Left ROPS Mounted Forward Facing Flood Lamp.

Figure 102. TJ-C2 Right Rear Flood Lamp Harness Connector to Right ROPS Mounted Forward Facing Flood Lamp.

Figure 103. TK-C3 Left Rear Flood Lamp Harness Connector to Fuel Tank Harness Connector.

0018-76

0018

0018

0018

0018

TM 5-2410-241-23-1

Figure 104. TJ-C3 Right Rear Flood Lamp Harness to Fuel Tank Harness Connector.

Figure 105. TW-C3 Fuel Tank Harness to Left ROPS Flood Lamp Harness Connector.

0018-77

0018

0018

0018

TM 5-2410-241-23-1

0018

Figure 106. TW-C5 Fuel Tank Harness to Right ROPS Flood Lamp Harness Connector.

Figure 107. TK-C1 Left Rear Flood Lamp Harness Connector to Left Rearward Facing Flood Lamp.

Figure 108. TJ-C1 Right Rear Flood Lamp Harness Connector to Right Rearward Facing Flood Lamp.

0018-78

0018

0018

0018

TM 5-2410-241-23-1

0018

Figure 109. E-C22 Instrument Panel Harness Connector to Rearward Facing Flood Lamp Switch.

Figure 110. V-C16 Engine Harness Under Hoodlight Connector.

0018-79

0018

0018

TM 5-2410-241-23-1

Figure 111. V-C17 Engine Harness Under Hoodlight Switch Connector.

Figure 112. E-C16 Instrument Panel Harness Connector to Cab Harness Connector.

0018-80

0018

0018

0018

TM 5-2410-241-23-1

Figure 113. H-C2 Cab Harness to Instrument Panel Harness Connector.

0018-81

0018

0018

TM 5-2410-241-23-1

Figure 114. H-C6 Cab Harness to Headliner Harness Connector.

0018-82

0018

0018

TM 5-2410-241-23-1

Figure 115. HA-C2 Cab Harness to Headliner Harness Connector.

Figure 116. Arctic Kit Heater Fuel Pump.

0018-83

0018

0018

0018

TM 5-2410-241-23-1

Figure 117. YY-C3 Arctic Kit Heater Harness to Arctic Kit Heater Fuel Pump.

Figure 118. YY-C2 Arctic Kit Heater Diagnostic Connector.

0018-84

0018

0018

0018

TM 5-2410-241-23-1

Figure 119. Arctic Kit Heater Switch.

0018-85

0018

0018

TM 5-2410-241-23-1

Figure 120. XX-C2 Arctic Kit Heater Harness Connector to Arctic Kit Heater Switch.

Figure 121. 108 Blue Rear Wiper Power Supply Connector to Rear Wiper Motor Switch.

0018-86

0018

0018

0018

TM 5-2410-241-23-1

Figure 122. 108 Blue Front Wiper Power Supply Connector to Front Wiper Motor Switch.

Figure 123. H-C1 Cab Harness Front Wiper Motor Connector.

0018-87

0018

0018

0018

TM 5-2410-241-23-1

Figure 124. H-C5 Cab Harness Left Door Wiper Motor Connector.

Figure 125. H-C4 Cab Harness Right Door Wiper Motor Connector.

0018-88

0018

0018

0018

TM 5-2410-241-23-1

0018

Figure 126. HA-C4 Headliner Harness to Rear Wiper Motor Connector.

Figure 127. YY-C1 Arctic Kit Heater Harness to Arctic Kit Heater Main Harness Connector.

0018-89

0018

0018

TM 5-2410-241-23-1

0018

Figure 128. XY-C4 Arctic Kit Heater Main Harness to Arctic Kit Heater Harness Connector.

Figure 129. XX-C1 Arctic Kit Heater Switch Harness to Arctic Kit Heater Main Harness Connector.

0018-90

0018

0018

TM 5-2410-241-23-1

0018

Figure 130. XY-C3 Arctic Kit Heater Main Harness to Arctic Kit Heater Switch Harness Connector.

Figure 131. XY-C1 Arctic Kit Heater Main Harness to Platform Harness Connector.

0018-91

0018

0018

TM 5-2410-241-23-1

Figure 132. MA-C21 Platform Harness to Arctic Kit Heater Main Harness Connector.

0018-92

0018

0018

TM 5-2410-241-23-1

Figure 133. H-C7 Cab Harness to Headliner Harness Connector.

0018-93

0018

0018

TM 5-2410-241-23-1

Figure 134. HA-C1 Headliner Harness to Cab Harness Connector.

Figure 135. 500 Brown Front Wiper Park Supply Connector to Front Wiper Motor Switch.

0018-94

0018

0018

0018

TM 5-2410-241-23-1

Figure 136. 501 Green Front Wiper Low Supply Connector to Front Wiper Motor Switch.

Figure 137. 502 Orange Front Wiper High Supply Connector to Front Wiper Motor Switch.

0018-95

0018

0018

0018

TM 5-2410-241-23-1

0018

Figure 138. 523 Brown Left Door Wiper Park Supply Connector to Left Door Wiper Motor Switch.

Figure 139. 524 Blue Left Door Wiper Low Supply Connector to Left Door Wiper Motor Switch.

0018-96

0018

0018

TM 5-2410-241-23-1

0018

Figure 140. 525 Gray Left Door Wiper High Supply Connector to Left DoorWiper Motor Switch.

Figure 141. 526 Yellow Right Door Wiper Park Supply Connector to Right Door Wiper Motor Switch.

0018-97

0018

0018

TM 5-2410-241-23-1

0018

Figure 142. 527 Green Right Door Wiper Low Supply Connector to Right Door Wiper Motor Switch.

Figure 143. 528 Pink Right Door Wiper High Supply Connector to Right Door Wiper Motor Switch.

0018-98

0018

0018

TM 5-2410-241-23-1

Figure 144. 503 Brown Rear Wiper Park Supply Connector to Rear Wiper Motor Switch.

Figure 145. 504 Yellow Rear Wiper Low Supply Connector to Rear Wiper Motor Switch.

0018-99

0018

0018

0018

TM 5-2410-241-23-1

Figure 146. 505 Blue Rear Wiper High Supply Connector to Rear Wiper Motor Switch.

Figure 147. 108 Blue Right Wiper Power Supply Connector to Right Door Wiper Motor Switch.

0018-100

0018

0018

0018

TM 5-2410-241-23-1

Figure 148. 108 Blue Left Wiper Power Supply Connector to Left Door Wiper Motor Switch.

Figure 149. 108 Blue Rear Wiper Power Supply Connector to Rear Wiper Motor.

0018-101

0018

0018

0018

TM 5-2410-241-23-1

Figure 150. 506 Purple Front Washer Supply Connector to Front Washer Switch.

Figure 151. 507 White Rear Washer Supply Connector to Rear Washer Switch.

0018-102

0018

0018

0018

TM 5-2410-241-23-1

Figure 152. 503 Orange Right Washer Supply Connector to Right Washer Switch.

Figure 153. 529 White Left Washer Supply Connector to Left Washer Supply.

0018-103

0018

0018

0018

TM 5-2410-241-23-1

Figure 154. H-C8 Cab Harness Washer Bottle Connector.

Figure 155. HH-C1 Washer Bottle to Cab Harness Connector.

0018-104

0018

0018

0018

TM 5-2410-241-23-1

Figure 156. G-C4 Front Lighting Harness Top Horn Connector.

Figure 157. G-C5 Front Lighting Harness Bottom Horn Connector.

0018-105

0018

0018

0018

TM 5-2410-241-23-1

Figure 158. MA-C13 Platform Harness to RH Console Harness Connector (Green).

0018-106

0018

0018

TM 5-2410-241-23-1

Figure 159. RW-C3 RH Console Harness to Platform Harness Connector (Green).

0018-107

0018

0018

TM 5-2410-241-23-1

Figure 160. R-C5 RH Console Harness Connector to Horn Switch.

Figure 161. CH-C3 A/C Compressor Harness Connector to Compressor Clutch.

0018-108

0018

0018

0018

TM 5-2410-241-23-1

Figure 162. CH-C2 A/C Compressor Harness Connector to Compressor Pressure Switch.

Figure 163. E-C6 Instrument Panel Harness Ignition Switch Connector.

0018-109

0018

0018

0018

TM 5-2410-241-23-1

Figure 164. CH-C1 A/C Compressor Harness Connector to Engine Harness Connector.

Figure 165. V-C13 Engine Harness Connector to A/C Compressor Harness Connector.

0018-110

0018

0018

0018

TM 5-2410-241-23-1

Figure 166. E-C14 Instrument Panel Harness Connector to Blower Motor Harness Connector.

0018-111

0018

0018

TM 5-2410-241-23-1

Figure 167. EE-C8 Blower Motor Harness Connector to Instrument Panel Harness Connector.

0018-112

0018

0018

TM 5-2410-241-23-1

Figure 168. 522 White Thermostat Switch Connector.

0018-113

0018

0018

TM 5-2410-241-23-1

Figure 169. 200 Black Thermostat Switch Connector.

Figure 170. E-C21 Instrument Panel Harness Connector to A/C Switch.

0018-114

0018

0018

0018

TM 5-2410-241-23-1

0018

Figure 171. E-C2 Instrument Panel Harness Connector to Blower Motor Speed Switch Connector.

Figure 172. 124 Green Fuse Panel Wiring Harness Blower Motor Circuit Breaker Connector.

0018-115

0018

0018

TM 5-2410-241-23-1

Figure 173. 112 Purple Blower Motor Circuit Breaker Supply Power Wire Point AE1.

0018-116

0018

0018

TM 5-2410-241-23-1

Figure 174. EE-C3 Blower Motor Harness to Resistor Connector.

Figure 175. EE-C4 Blower Motor Harness to Blower Motor Connector.

0018-117

0018

0018

0018

TM 5-2410-241-23-1

Figure 176. Blower Motor Resistor.

Figure 177. A-C2 Fuse Panel Harness Main Power Relay Connector.

0018-118

0018

0018

0018

TM 5-2410-241-23-1

Figure 178. Main Power Relay.

0018-119

0018

0018

TM 5-2410-241-23-1

Figure 179. V-C2 Engine Harness Ether Injection Solenoid Connector.

Figure 180. Flood Lamp Wiring.

0018-120

0018

0018

0018

TM 5-2410-241-23-1

Figure 181. Engine Flood Lamp Wiring.

Figure 182. Front Wiper Switch Terminal B.

0018-121

0018

0018

0018

TM 5-2410-241-23-1

Figure 183. Left Wiper Switch Terminal B.

Figure 184. Right Wiper Switch Terminal B.

0018-122

0018

0018

0018

TM 5-2410-241-23-1

Figure 185. Rear Wiper Switch Terminal B.

Figure 186. Front Wiper Motor Pigtail Connector.

0018-123

0018

0018

0018

TM 5-2410-241-23-1

Figure 187. Left Wiper Motor Pigtail Connector.

Figure 188. Right Wiper Motor Pigtail Connector.

0018-124

0018

0018

0018

TM 5-2410-241-23-1

Figure 189. Rear Wiper Motor Pigtail Connector.

Figure 190. HH-C2 Front Washer Pump Connector.

0018-125

0018

0018

0018

TM 5-2410-241-23-1

Figure 191. HH-C3 Left Washer Pump Connector.

Figure 192. HH-C4 Right Washer Pump Connector.

0018-126

0018

0018

0018

TM 5-2410-241-23-1

Figure 193. HH-C5 Rear Washer Pump Connector.

Figure 194. Wiper Washer Headliner Ground Stud.

0018-127

0018

0018

0018

TM 5-2410-241-23-1

CONNECTOR END INDEX

0018

00018

A-C1 Fuse Panel Wiring Harness Connector - Figure 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-23 A-C2 Fuse Panel Harness Main Power Relay Connector - Figure 177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-118 A-C3 Fuse Panel Harness Start Relay Connector - Figure 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-42 B2 Connector Arctic Kit Heater - Figure 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-20 CH-C1 A/C Compressor Harness Connector to Engine Harness Connector - Figure 164 . . . . . . . . . . . . . 0018-110 CH-C2 A/C Compressor Harness Connector to Compressor Pressure Switch - Figure 162 . . . . . . . . . . . 0018-109 CH-C3 A/C Compressor Harness Connector to Compressor Clutch - Figure 161 . . . . . . . . . . . . . . . . . . . 0018-108 CV-C1 Crank Normal Mode Connector - Figure 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-35 CV-C2 Crank without Injection Connector - Figure 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-35 E-C10 Instrument Panel Harness Lamp Gear Module Connector - Figure 87 . . . . . . . . . . . . . . . . . . . . . . . 0018-69 E-C11 Bi-directional Mode Switch Connector - Figure 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-42 E-C14 Instrument Panel Harness Connector to Blower Motor Harness Connector - Figure 166 . . . . . . . . 0018-111 E-C16 Instrument Panel Harness Connector to Cab Harness Connector - Figure 112. . . . . . . . . . . . . . . . . 0018-80 E-C2 Instrument Panel Harness Connector to Blower Motor Speed Switch Connector - Figure 171 . . . . . 0018-115 E-C21 Instrument Panel Harness Connector to A/C Switch - Figure 170 . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-114 E-C22 Instrument Panel Harness Connector to Rearward Facing Flood Lamp Switch - Figure 109 . . . . . . 0018-79 E-C23 Instrument Panel Harness Brake Switch Connector - Figure 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-40 E-C25 Instrument Panel Harness Action Lamp Connector - Figure 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-65 E-C27 Dash Harness Brake Position Sensor - Figure 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-43 E-C28 Decelerator Position Sensor Connector Dash Harness Side - Figure 9 . . . . . . . . . . . . . . . . . . . . . . 0018-13 E-C3 Instrument Panel Harness Action Alarm Connector - Figure 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-65 E-C5 Instrument Panel Harness Connector to Main Light Switch - Figure 100 . . . . . . . . . . . . . . . . . . . . . . . 0018-75 E-C6 Instrument Panel Harness Ignition Switch Connector - Figure 163 . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-109 E-C7 Dash Monitor Connector - Figure 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-10 E-C9 Instrument Panel Harness Gauge Cluster Connector - Figure 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-68 EE-C3 Blower Motor Harness to Resistor Connector - Figure 174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-117 EE-C4 Blower Motor Harness to Blower Motor Connector - Figure 175 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-117 EE-C8 Blower Motor Harness Connector to Instrument Panel Harness Connector - Figure 167 . . . . . . . . 0018-112 GA-C1 Left Front Flood Lamp Harness to Radiator Guard Harness Connector - Figure 94 . . . . . . . . . . . . 0018-73 GA-C2 Left Front Cylinder Mounted Flood Lamp Harness Connector to Left Front Flood Lamp - Figure 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-72 G-C1 Front Lighting Harness to Engine Harness Connector - Figure 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-75 G-C2 Front Lighting Harness to Left Front Flood Lamp Harness Connector - Figure 95 . . . . . . . . . . . . . . . 0018-73 G-C3 Front Lighting Harness to Right Flood Lamp Harness Connector - Figure 97 . . . . . . . . . . . . . . . . . . . 0018-74 G-C4 Front Lighting Harness Top Horn Connector - Figure 156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-105 G-C5 Front Lighting Harness Bottom Horn Connector - Figure 157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-105 GC-C1 Right Front Flood Lamp Harness to Radiator Guard Harness Connector - Figure 96 . . . . . . . . . . 0018-74 GC-C2 Right Front Cylinder Mounted Flood Lamp Harness Connector to Right Front Flood Lamp - Figure 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-73 HA-C1 Headliner Harness to Cab Harness Connector - Figure 134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-94

0018-128

TM 5-2410-241-23-1

0018

HA-C2 Cab Harness to Headliner Harness Connector - Figure 115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-81 HA-C4 Headliner Harness to Rear Wiper Motor Connector - Figure 126 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-89 H-C1 Cab Harness Front Wiper Motor Connector - Figure 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-87 H-C2 Cab Harness to Instrument Panel Harness Connector - Figure 113 . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-81 H-C4 Cab Harness Right Door Wiper Motor Connector - Figure 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-88 H-C5 Cab Harness Left Door Wiper Motor Connector - Figure 124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-88 H-C6 Cab Harness to Headliner Harness Connector - Figure 114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-82 H-C7 Cab Harness to Headliner Harness Connector - Figure 133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-93 H-C8 Cab Harness Washer Bottle Connector - Figure 154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-104 HH-C1 Washer Bottle to Cab Harness Connector - Figure 155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-104 HH -C2 Front Washer Pump Connector - Figure 190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-125 HH-C3 Left Washer Pump Connector - Figure 191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-126 HH-C4 Right Washer Pump Connector - Figure 192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-126 HH-C5 Rear Washer Pump Connector - Figure 193 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-127 KK-C1 Service Brake Switch Harness Connector - Figure 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-41 L-C1 Chassis Harness to Platform Harness Connector - Figure 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-67 L-C2 Chassis Harness Hydraulic Oil Temperature Sensor Connector - Figure 83 . . . . . . . . . . . . . . . . . . . . 0018-66 L-C4 Chassis Harness Implement Lockout Solenoid Connector - Figure 90. . . . . . . . . . . . . . . . . . . . . . . . . 0018-71 MA-C1 RH Platform Harness Connector (Black) - Figure 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-18 MA-C12 Platform Harness Left Brake Solenoid Connector - Figure 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-54 MA-C13 Platform Harness to RH Console Harness Connector (Green) - Figure 158 . . . . . . . . . . . . . . . . . 0018-106 MA-C14 Platform Harness Connector - Figure 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-32 MA-C17 Platform Harness to Chassis Harness Connector - Figure 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-68 MA-C21 Platform Harness to Arctic Kit Heater Main Harness Connector - Figure 132 . . . . . . . . . . . . . . . . . 0018-92 MA-C22 Platform Harness (Platform to Engine) Connector - Figure 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-14 MA-C23 Platform Harness to Fuel Tank Harness Connector - Figure 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-64 MA-C3 Platform Harness Connector - Figure 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-22 MA-C4 Platform Harness Parking Brake Dump Solenoid Connector - Figure 65 . . . . . . . . . . . . . . . . . . . . . 0018-52 MA-C6 Secondary Brake Dump Solenoid Connector - Figure 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-56 MA-C7 Platform Harness Connector to Transmission Jumper Harness - Figure 53 . . . . . . . . . . . . . . . . . . . 0018-44 M-I-C1 Messenger Connector - Figure 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-10 MP-C1 Transmission Jumper Harness Connector to P-C1 Transmission Harness - Figure 55 . . . . . . . . . . 0018-46 MP-C2 Transmission Jumper Harness Connector to Platform Harness Connector - Figure 54 . . . . . . . . . . 0018-45 N-C1 Engine ECM Connector - Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-7 N-C10 Intake Manifold Temperature Connector - Figure 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-24 N-C11 ECM Harness Connector at Coolant Temperature Sensor - Figure 20. . . . . . . . . . . . . . . . . . . . . . . . 0018-22 N-C13 Crankshaft Position Connector - Figure 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-26 N-C14 Camshaft Position Connector - Figure 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-36 N-C2 Engine Harness Side Connector - Figure 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-11 N-C3 ECM Harness Connector at Oil Pressure Sensor - Figure 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-21

0018-129

TM 5-2410-241-23-1

0018

N-C4 Atmospheric Pressure Sensor Connector - Figure 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-34 N-C5 Air Inlet Manifold Pressure Sensor Connector/ Turbocharger Outlet Pressure Sensor Connector - Figure 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-34 N-C9 Fuel Temperature Connector - Figure 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-24 NC-C1 Intake Manifold Jumper to N-C10 Connector - Figure 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-25 NC-C2 Intake Manifold Jumper to Sensor Connector - Figure 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-25 NN -C1 Valve Cover Side Connector - Figure 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-12 P-C1 Transmission Harness Connector to Connector MP-C1 - Figure 56 . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-47 P-C2 Transmission Harness Speed Sensor #1 Connector - Figure 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-47 P-C3 Transmission Solenoid Valve #2 Connector - Figure 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-59 P-C4 Transmission Solenoid Valve #1 Connector - Figure 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-58 P-C5 Transmission Solenoid Valve #5 Connector - Figure 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-62 P-C6 Transmission Solenoid Valve #4 Connector - Figure 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-61 P-C7 Transmission Solenoid Valve #3 Connector - Figure 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-60 P-C8 Transmission Harness Speed Sensor #2 Connector - Figure 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-51 PW-C1 Harness Code Receptacle Connector to Steering Harness Connector X C9 - Figure 61 . . . . . . . . . 0018-50 R-C4 Throttle Switch Connector - Figure 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-16 R-C5 RH Console Harness Connector to Horn Switch - Figure 160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-108 RT-C1 Reverse Switch Connector (Pigtail) - Figure 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-63 RW-C1 RH Console Harness Connector (Black) - Figure 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-17 RW-C3 RH Console Harness to Platform Harness Connector (Green) - Figure 159 . . . . . . . . . . . . . . . . . 0018-107 RW-C7 RH Console Harness Hydraulic Lockout Switch Connector - Figure 89 . . . . . . . . . . . . . . . . . . . . . . 0018-70 TJ-C1 Right Rear Flood Lamp Harness Connector to Right Rearward Facing Flood Lamp - Figure 108. . . 0018-78 TJ-C2 Right Rear Flood Lamp Harness Connector to Right ROPS Mounted Forward Facing Flood Lamp - Figure 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-76 TJ-C3 Right Rear Flood Lamp Harness to Fuel Tank Harness Connector - Figure 104 . . . . . . . . . . . . . . . . 0018-77 TK-C1 Left Rear Flood Lamp Harness Connector to Left Rearward Facing Flood Lamp - Figure 107 . . . . . 0018-78 TK-C2 Left Rear Flood Lamp Harness Connector to Left ROPS Mounted Forward Facing Flood Lamp - Figure 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-76 TK-C3 Left Rear Flood Lamp Harness Connector to Fuel Tank Harness Connector - Figure 103 . . . . . . . . 0018-76 TW-C2 Fuel Tank Harness Fuel Level Sender Connector - Figure 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-64 TW-C3 Fuel Tank Harness to Left ROPS Flood Lamp Harness Connector - Figure 105 . . . . . . . . . . . . . . . 0018-77 TW-C5 Fuel Tank Harness to Right ROPS Flood Lamp Harness Connector - Figure 106 . . . . . . . . . . . . . . 0018-78 TW-C7 Fuel Tank Harness to Platform Harness Connector - Figure 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-64 V-C1 Engine Harness (Engine to Platform) Connector - Figure 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-15 V-C10 Engine Harness Torque Converter Output Speed Sensor Connector - Figure 62 . . . . . . . . . . . . . . . 0018-50 V-C12 Engine ECM Resistor Can/Data Link - Figure 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-28 V-C13 Engine Harness Connector to A/C Compressor Harness Connector - Figure 165. . . . . . . . . . . . . . 0018-110 V-C15 Engine harness to Radiator Guard Harness Connector - Figure 99 . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-75 V-C16 Engine Harness Under Hoodlight Connector - Figure 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-79 V-C17 Engine Harness Under Hoodlight Switch Connector - Figure 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-80

0018-130

TM 5-2410-241-23-1

0018

V-C18 Engine Harness Ether Relay Connector - Figure 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-38 V-C2 Engine Harness Ether Injection Solenoid Connector - Figure 179 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-120 V-C20 Turbocharger Inlet Pressure Sensor Connector - Figure 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-35 V-C3 Harness Connector to Crank without Injection Connector - Figure 40 . . . . . . . . . . . . . . . . . . . . . . . . . 0018-36 V-C4 Engine ECM Connector - Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-6 V-C8 Transmission Oil Temperature Sensor Connector - Figure 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-39 V-C9 Engine Harness Torque Converter Outlet Temperature Sensor Connector - Figure 88 . . . . . . . . . . . . 0018-69 X-C1 Steering Control Harness - Figure 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-33 X-C10 Powertrain ECM Resistor Can/Data Link - Figure 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-30 X-C2 Powertrain ECM Connector - Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-9 X-C3 Powertrain ECM Connector - Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-8 X-C4 Steering Harness Downshift/Upshift Switch Connector - Figure 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-48 X-C5 Steering Harness Reverse Switch Connector - Figure 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-63 X-C6 Parking Brake Switch Connector - Figure 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-38 X-C8 FORWARD/NEUTRAL/REVERSE (FNR) Sensor Connector - Figure 49 . . . . . . . . . . . . . . . . . . . . . . 0018-41 X-C9 Harness Code Plug Connector to Steering Harness - Figure 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-49 XX-C1 Arctic Kit Heater Switch Harness to Arctic Kit Heater Main Harness Connector - Figure 129 . . . . . . 0018-90 XX-C2 Arctic Kit Heater Harness Connector to Arctic Kit Heater Switch - Figure 120. . . . . . . . . . . . . . . . . . 0018-86 XY-C1 Arctic Kit Heater Main Harness to Platform Harness Connector - Figure 131 . . . . . . . . . . . . . . . . . . 0018-91 XY-C3 Arctic Kit Heater Main Harness to Arctic Kit Heater Switch Harness Connector - Figure 130 . . . . . . 0018-91 XY-C4 Arctic Kit Heater Main Harness to Arctic Kit Heater Harness Connector - Figure 128 . . . . . . . . . . . . 0018-90 YY-C1 Arctic Kit Heater Harness to Arctic Kit Main Harness Connector - Figure 127 . . . . . . . . . . . . . . . . . . 0018-89 YY-C2 Arctic Kit Heater Diagnostic Connector - Figure 118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-84 YY-C3 Arctic Kit Heater Harness to Arctic Kit Heater Fuel Pump - Figure 117 . . . . . . . . . . . . . . . . . . . . . . . 0018-84 YY-C4 Arctic Kit Heater Harness to Arctic Kit Heater - Figure 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-20 Arctic Kit Heater Fuel Pump - Figure 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-83 Arctic Kit Heater Switch - Figure 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-85 Blower Motor Resistor - Figure 176 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-118 Camshaft Position Sensor - Figure 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-37 Crankshaft Position Sensor (with Pigtail) - Figure 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-27 Downshift/Upshift Switch Connector - Figure 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-48 Engine Flood Lamp Wiring - Figure 181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-121 Flood Lamp Wiring - Figure 180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-120 Front Wiper Motor Pigtail Connector - Figure 186 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-123 Front Wiper Switch Terminal B - Figure 182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-121 Hydraulic Lockout Switch - Figure 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-72 Left Brake Solenoid - Figure 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-55 Left Wiper Motor Pigtail Connector - Figure 187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-124 Left Wiper Switch Terminal B - Figure 183. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-122 Main Power Relay - Figure 178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-119

0018-131

TM 5-2410-241-23-1

0018

Parking Brake Dump Solenoid - Figure 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-53 Parking Brake Switch - Figure 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-39 Rear Wiper Motor Pigtail Connector - Figure 189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-125 Rear Wiper Switch Terminal B - Figure 185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-123 Resistor Can/Data Link - Figure 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-29 Resistor Can/Data Link - Figure 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-31 Right Wiper Motor Pigtail Connector - Figure 188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-124 Right Wiper Switch Terminal B - Figure 184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-122 Secondary Brake Dump Solenoid - Figure 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-57 Sensor Pigtail Decelerator Sensor Connector - Figure 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-14 Throttle Switch - Figure 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-19 Torque Converter Output Speed Sensor - Figure 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-51 Wiper Washer Headliner Ground Stud - Figure 194 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-127 108 Blue Front Wiper Power Supply Connector to Front Wiper Motor Switch - Figure 122 . . . . . . . . . . . . . 0018-87 108 Blue Left Wiper Power Supply Connector to Left Door Wiper Motor Switch - Figure 148 . . . . . . . . . . 0018-101 108 Blue Rear Wiper Power Supply Connector to Rear Wiper Motor - Figure 149 . . . . . . . . . . . . . . . . . . . 0018-101 108 Blue Rear Wiper Power Supply Connector to Rear Wiper Motor Switch - Figure 121 . . . . . . . . . . . . . . 0018-86 108 Blue Right Wiper Power Supply Connector to Right Door Wiper Motor Switch - Figure 147 . . . . . . . . 0018-100 112 Purple Blower Motor Circuit Breaker Supply Power Wire Point AE1 - Figure 173 . . . . . . . . . . . . . . . . 0018-116 124 Green Fuse Panel Wire Harness Blower Motor Circuit Breaker Connector - Figure 172 . . . . . . . . . . . 0018-115 200 Black Thermostat Switch Connector - Figure 169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-114 500 Brown Front Wiper Park Supply Connector to Front Wiper Motor Switch - Figure 135 . . . . . . . . . . . . . 0018-94 501 Green Front Wiper Low Supply Connector to Front Wiper Motor Switch - Figure 136 . . . . . . . . . . . . . . 0018-95 502 Orange Front Wiper High Supply Connector to Front Wiper Motor Switch - Figure 137 . . . . . . . . . . . . 0018-95 503 Brown Rear Wiper Park Supply Connector to Rear Wiper Motor Switch - Figure 144 . . . . . . . . . . . . . . 0018-99 503 Orange Right Washer Supply Connector to Right Washer Switch - Figure 152 . . . . . . . . . . . . . . . . . . 0018-103 504 Yellow Rear Wiper Low Supply Connector to Rear Wiper Motor Switch - Figure 145 . . . . . . . . . . . . . . 0018-99 505 Blue Rear Wiper High Supply Connector to Rear Wiper Motor Switch - Figure 146 . . . . . . . . . . . . . . 0018-100 506 Purple Front Washer Supply Connector to Front Washer Switch - Figure 150. . . . . . . . . . . . . . . . . . . 0018-102 507 White Rear Washer Supply Connector to Rear Washer Switch - Figure 151 . . . . . . . . . . . . . . . . . . . . 0018-102 522 White Thermostat Switch Connector - Figure 168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018-113 523 Brown Left Door Wiper Park Supply Connector to Left Door Wiper Motor Switch - Figure 138 . . . . . . . 0018-96 524 Blue Left Door Wiper Low Supply Connector to Left Door Wiper Motor Switch - Figure 139 . . . . . . . . . 0018-96 525 Gray Left Door Wiper High Supply Connector to Left Wiper Door Motor Switch - Figure 140 . . . . . . . . 0018-97 526 Yellow Right Door Wiper Park Supply Connector to Right Door Wiper Motor Switch - Figure 141 . . . . 0018-97 527 Green Right Door Wiper Low Supply Connector to Right Door Wiper Motor Switch - Figure 142 . . . . . 0018-98 528 Pink Right Door Wiper High Supply Connector to Right Door Wiper Motor Switch - Figure 143 . . . . . . 0018-98 529 White Left Washer Supply Connector to Left Washer Supply - Figure 153 . . . . . . . . . . . . . . . . . . . . . 0018-103 END OF WORK PACKAGE

0018-132

96 TM 5-2410-241-23-1

0019

FIELD MAINTENANCE 0 0 1

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ENGINE TROUBLESHOOTING PROCEDURES

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Adapter Kit, Test (WP 0302, Item 5) Test Set, Electronic (MSD) (WP 0302, Item 62) Materials/Parts Rag, Wiping (WP 0303, Item 24) References WP 0013 WP 0016 WP 0017 WP 0018 WP 0019 WP 0023 WP 0024 WP 0025 WP 0026 WP 0027 WP 0028 WP 0029 WP 0030 WP 0031 WP 0042 WP 0046 WP 0047 WP 0048 WP 0054 WP 0055 WP 0056 WP 0057

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WP 0299 Equipment Condition Machine parked (TM 5-2410-241-10)

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GENERAL

00019

This work package contains troubleshooting information for the D7R Dozer. Each malfunction or symptom listed is followed by the possible cause(s) and suggested remedy or remedies. This work package should be used as an aid in the isolation and correction of system problems. 00019

0019-1

TM 5-2410-241-23-1

0019

Table 1. Engine Troubleshooting Procedures. MALFUNCTION 1. Alternator (Charging Problem)

2. Coolant in Engine Oil

TEST OR INSPECTION

CORRECTIVE ACTION

1. Inspect alternator drive belt and pulleys. Refer to Drive Belt and Pulley Inspection (WP 0098).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If alternator drive belt and pulleys are OK, proceed to step 2.

2. Check charging circuit (WP 0028).

1. Verify correct operation of machine (TM 5-2410-241-10).

1. Inspect engine water pump for coolant leakage. Refer to Engine Water Pump Inspection (WP 0026).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If engine water pump is OK, proceed to step 2.

2. Inspect aftercooler water pump for coolant leakage. Refer to Aftercooler Water Pump Inspection (WP 0026).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If aftercooler water pump is OK, proceed to step 3.

3. Inspect cylinder head and gasket. Refer to Cylinder Head and Gasket Inspection (WP 0025).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If cylinder head and gasket are OK, proceed to step 4.

4. Replace engine. Refer to Engine Replacement (WP 0057). 3. Engine Cranks but Will Not Start

1. Visually inspect fluid levels of engine (fuel, oil and coolant) in accordance with TM 5-2410241-10.

1. If fluids are low, add fluid as necessary (TM 5-2410-241-10). 2. If fluid levels are OK, proceed to step 2.

2. Connect MSD (WP 0016). Check for Diagnostic Codes or Event Codes (WP 0013).

1. If codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no codes are present, proceed to step 3.

3. Check if ECM is energizing the injector solenoids. Refer to Injector Solenoid Test (WP 0025).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If injector solenoids are OK, proceed to step 4.

4. Perform Fuel Quality Test (WP 0025).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If fuel quality is OK, proceed to step 5.

0019-2

0019

TM 5-2410-241-23-1

0019

Table 1. Engine Troubleshooting Procedures - Continued. MALFUNCTION 3. Engine Cranks But Will Not Start - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

5. Ensure fuel system is primed. Refer to Priming Fuel System (WP 0025).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If fuel system is OK, proceed to step 6.

6. Inspect for restricted fuel lines. (WP 0025).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If fuel system is OK, proceed to step 7.

7. Check fuel pressure (WP 0025).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If fuel pressure is OK, proceed to step 8.

8. If temperature is below 32°F (0°C) inspect ether injection system (WP 0031).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If either injection system is OK, replace engine (WP 0057).

0019-3

0019

TM 5-2410-241-23-1

0019

Table 1. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

0019

CORRECTIVE ACTION

4. Oil in Cooling System

WARNING

Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. Radiator and all lines to heaters or engine contain hot coolant or steam. Any contact can cause severe burns. Allow engine and coolant to cool before slowly removing filler cap to relieve cooling system pressure. Engine must be stopped and radiator cap is cool enough to touch with your bare hand. Failure to follow this warning may result in injury or death to personnel. 1. Inspect transmission oil cooler for leakage. a. Open door (Figure 1, Item 2) and remove radiator cap (Figure 1, Item 1).

1. If fluid is brown and milky, replace transmission cooler (WP 0042). 2. If fluid is black and milky, proceed to step 2.

b. Inspect fluid in coolant tank.

Figure 1. Radiator Cap. 2. Start engine and inspect for air bubbles in radiator tank.

0019-4

019

1. If air bubbles are found, replace head gasket (WP 0108). 2. If no air bubbles are found, replace engine oil cooler (WP 0084).

TM 5-2410-241-23-1

0019

Table 1. Engine Troubleshooting Procedures - Continued. MALFUNCTION 5. Engine Vibration

6. Engine Will Not Crank

7. Excessive Engine Oil Consumption

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016). Check for Diagnostic Codes or Event Codes (WP 0013)

1. If codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no codes are present, proceed to step 2.

2. Inspect engine vibration damper. Refer to Vibration Damper Inspection (WP 0023).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If vibration damper is OK, proceed to step 3.

3. Inspect engine mounts for looseness, cracks, or damage. Refer to Engine Mount Inspection (WP 0046).

1. If engine mounts are loose, cracked or damaged tighten or replace engine mounts (WP 0046). 2. If engine mounts OK, proceed to step 4.

4. Inspect engine support for looseness, cracks, or damage. Refer to Engine Support Inspection (WP 0047).

1. If engine support is loose, cracked, or damaged, tighten or replace engine support (WP 0047). 2. If engine support is OK, proceed to step 5.

5. Inspect trunnion assembly for looseness, cracks, or damage: Refer to Trunnion Inspection (WP 0048).

1. If trunnion assembly is loose, cracked, or damaged, tighten or replace trunnion (WP 0048). 2. If problem is not found, verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Check for Diagnostic Codes or Event Codes (WP 0013)

1. If codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no codes are present, proceed to step 2.

2. Perform Starting System Tests (WP 0031).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If starting system OK, verify correct operation of machine (TM 5-2410-241-10).

1. Inspect for engine oil leaks on outside of engine (WP 0024).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If outside engine oil leaks are not found, proceed to step 2.

0019-5

0019

TM 5-2410-241-23-1

0019

Table 1. Engine Troubleshooting Procedures - Continued. MALFUNCTION 7. Excessive Engine Oil Consumption Continued

TEST OR INSPECTION 2. Inspect turbocharger for internal leakage. Refer to Turbocharger Inspection (WP 0027).

CORRECTIVE ACTION 1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If turbocharger is OK, proceed to step 3.

3. Replace engine (WP 0057). 8. Low Power/ Poor or No Response to Throttle

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no codes are present, proceed to step 2.

2. Test injector solenoids. Refer to Injector solenoid test (WP 0025).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If injector solenoids are OK, proceed to step 3.

3. Test cylinder performance. Refer to cylinder cutout test (WP 0025).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If no failure is shown, proceed to step 4.

4. Inspect air inlet and exhaust system for damage. Refer to Air inlet and Exhaust Inspection (WP 0027).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If air inlet and exhaust system are OK, proceed to step 5.

5. Perform turbocharger inspection (WP 0027).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If turbocharger is OK, proceed to step 6.

6. Inspect fuel system for restriction or damage. Refer to Fuel System Inspection (WP 0025).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If fuel system is OK, proceed to step 7.

7. Check fuel pressure. Refer to Fuel System Inspection (WP 0025).

1. If problem is found, verify correct operation of machine (TM 5-2410-241-10). 2. If fuel pressure is OK, replace engine (WP 0057).

0019-6

0019

TM 5-2410-241-23-1

0019

00019

Table 2. Engine Troubleshooting Procedures. MALFUNCTION 1-11 Cylinder #1 Injector Fault

TEST OR INSPECTION

CORRECTIVE ACTION

CAUTION Electrical shock hazard. Electronic unit injector system uses 67-73 Volts. Failure to follow this warning may result in injury to personnel.

NOTE Fuel injectors are an electro-mechanical device. High-pressure fuel is continuously available to each injector. The engine Electronic Control Module (ECM) determines the correct time and duration to activate each injector. 1. Connect MSD (WP 0016). 2. Start engine (TM 5-2410-241-10). On MSD, select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, proceed to step 3.

3. Perform Injector Solenoid Test (WP 0025).

1. If “OK” displayed, problem does not exist with injector at this time. Resume normal operation. 2. If “OPEN” displayed, proceed to step 4. 3. If “SHORT” displayed, proceed to step 14.

4. Disconnect engine harness connector N-C2 (WP 0018, Figure 7) from valve cover side connector NN-C1 (WP 0018, Figure 8). 5. Install jumper wire in pins 1 and 12 on engine harness connector N-C2 (WP 0018, Figure 7).

NOTE Other diagnostic codes will set during this test. Ignore other codes. 6. Perform Injector Solenoid Test (WP 0025).

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0019-7

1. If “OPEN” displayed, proceed to step 7. 2. If “SHORT” displayed, proceed to step 10.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 1-11 Cylinder #1 Injector Fault - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

8. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from engine ECM (WP 0101). 9. Using digital multimeter (WP 0296), test for continuity between pins 38 and 44 on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace engine ECM (WP 0101). Remove jumper wire from pins 1 and 12 on engine harness connector N-C2 (WP 0018, Figure 7) and connect engine harness connector N-C2 (WP 0018 Figure 7) on valve cover side connector NN-C1 (WP 0018, Figure 8). 2. If continuity is not found, replace engine main wiring harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

10. Remove jumper wire from pins 1 and 12 on engine harness connector N-C2 (WP 0018, Figure 7) and connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NN-C1 (WP 0018, Figure 8). 11. Remove valve cover (WP 0106). 12. Install jumper wire between nuts (Figure 2, Item 2).

Figure 2. Cylinder #1 Injector Fault Code.

0019-8

019

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 1-11 Cylinder #1 Injector Fault - Continued

TEST OR INSPECTION 13. Perform Injector Solenoid Test (WP 0025).

CORRECTIVE ACTION 1. If “OPEN” displayed, replace injector wiring harness (WP 0106). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace fuel injector (WP 0069). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

14. Disconnect engine harness connector N-C2 (WP 0018, Figure 7) from valve cover side connector NN-C1 (WP 0018, Figure 8) (WP 0105). 15. Perform Injector Solenoid Test (WP 0025).

1. If “OPEN” displayed, proceed to step18. 2. If “SHORT” displayed, proceed to step 16.

16. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from engine ECM (WP 0101). 17. Perform Injector Solenoid Test (WP 0025).

18. Connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NN-C1 (WP 0018, Figure 8). 19. Remove valve cover (WP 0106), and disconnect injector wire (Figure 2, Item 1).

0019-9

1. If “OPEN” displayed, replace engine main wiring harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 1-11 Cylinder #1 Injector Fault - Continued

2-11 Cylinder #2 Injector Fault

TEST OR INSPECTION

CORRECTIVE ACTION

20. Perform Injector Solenoid Test (WP 0025).

1. If “OPEN” displayed, replace fuel injector (WP 0069). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace injector wiring harness (WP 0106). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

WARNING Electrical shock hazard. Electronic unit injector system uses 67-73 Volts. Failure to follow this warning may result in injury to personnel.

NOTE The fuel injectors are an electro-mechanical device. High-pressure fuel is continuously available to each injector. The engine Electronic Control Module (ECM) determines the correct time and duration to activate each injector. 1. Connect MSD (WP 0016). 2. Start engine (TM 5-2410-241-10). On MSD, select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, proceed to step 3.

3. Perform Injector Solenoid Test (WP 0025).

1. If “OK” displayed, problem does not exist with injector at this time. Resume normal operation. 2. If “OPEN” displayed, proceed to step 4. 3. If “SHORT” displayed, proceed to step 14.

4. Disconnect engine harness connector N-C2 (WP 0018, Figure 7) from valve cover side connector NN-C1 (WP 0018, Figure 8). 5. Install jumper wire in pins 2 and 12 on engine harness connector N-C2 (WP 0018, Figure 7).

0019-10

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 2-11 Cylinder #2 Injector Fault - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

NOTE Other diagnostic codes will set during this test. Ignore other codes. 6. Perform Injector Solenoid Test (WP 0025).

1. If “OPEN” displayed, proceed to step 7. 2. If “SHORT” displayed, proceed to step 10.

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from engine ECM (WP 0101). 9. Using digital multimeter (WP 0296), test for continuity between pins 37 and 44 on engine ECM connector N-C1 (WP 0018, Figure 2).

10. Remove jumper wire from pins 2 and 12 on engine harness connector N-C2 (WP 0018, Figure 7) and connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NN-C1 (WP 0018, Figure 8). 11. Remove valve cover (WP 0106).

0019-11

1. If continuity is found, replace engine ECM (WP 0101). Remove jumper wire from pins 2 and 12 on engine harness connector N-C2 (WP 0018, Figure 7) and connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NN-C1 (WP 0018, Figure 8). 2. If continuity is not found, replace engine main wiring harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 2 -11 Cylinder #2 Injector Fault - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

12. Install jumper wire between nuts (Figure 3, Item 1).

Figure 3. Cylinder #2 Injector Fault Code. 13. Perform Injector Solenoid Test (WP 0025).

019

1. If “OPEN” displayed, replace injector wiring harness (WP 0106). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace fuel injector (WP 0069). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

14. Disconnect engine harness connector N-C2 (WP 0018, Figure 7) from valve cover side connector NN-C1 (WP 0018, Figure 8). 15. Perform Injector Solenoid Test. (WP 0025).

16. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from engine ECM (WP 0101).

0019-12

1. If “OPEN” displayed, proceed to step18. 2. If “SHORT” displayed, proceed to step 16.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 2 -11 Cylinder #2 Injector Fault - Continued

TEST OR INSPECTION 17. Perform Injector Solenoid Test (WP 0025).

CORRECTIVE ACTION 1. If “OPEN” displayed, replace engine main wiring harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

18. Connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NN-C1 (WP 0018, Figure 8). 19. Remove valve cover (WP 0106), and disconnect injector wire (Figure 3, Item 2). 20. Perform Injector Solenoid Test (WP 0025).

0019-13

1. If “OPEN” displayed, replace fuel injector (WP 0069). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace injector wiring harness (WP 0106). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

WARNING

3-11 Cylinder #3 Injector Fault

Electrical shock hazard. Electronic unit injector system uses 67-73 Volts. Failure to follow this warning may result in injury to personnel.

NOTE Fuel injectors are an electro-mechanical device. High-pressure fuel is continuously available to each injector. The engine Electronic Control Module (ECM) determines correct time and duration to activate each injector. 1. Connect MSD (WP 0016). 2. Start engine (TM 5-2410-241-10). On MSD, select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, proceed to step 3.

3. Perform Injector Solenoid Test (WP 0025).

1. If “OK” displayed, problem does not exist with injector at this time. Resume normal operation. 2. If “OPEN” displayed, proceed to step 4. 3. If “SHORT” displayed, proceed to step 14.

4. Disconnect engine harness connector N-C2 (WP 0018, Figure 7) from valve cover side connector NN-C1 (WP 0018, Figure 8). 5. Install jumper wire in pins 3 and 10 on engine harness connector N-C2 (WP 0018, Figure 7).

NOTE Other diagnostic codes will set during this test. Ignore other codes. 6. Perform Injector Solenoid Test (WP 0025).

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from engine ECM (WP 0101).

0019-14

1. If “OPEN” displayed, proceed to step 7. 2. If “SHORT” displayed, proceed to step 10.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 3-11 Cylinder #3 Injector Fault - Continued

TEST OR INSPECTION 9. Using digital multimeter (WP 0296), test for continuity between pins 38 and 45 on engine ECM connector N-C1 (WP 0018, Figure 2).

CORRECTIVE ACTION 1. If continuity is found, replace engine ECM (WP 0101). Remove jumper wire from pins 3 and 10 on engine harness connector N-C2 (WP 0018, Figure 7) and connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NN-C1 (WP 0018, Figure 8). 2. If continuity is not found, replace engine main wiring harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

10. Remove jumper wire from pins 3 and 10 on engine harness connector N-C2 (WP 0018, Figure 7) and connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NN-C1 (WP 0018, Figure 8). 11. Remove valve cover (WP 0106). 12. Install jumper wire between nuts (Figure 4, Item 2). 13. Perform Injector Solenoid Test (WP 0025).

1. If “OPEN” displayed, replace injector wiring harness (WP 0106). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace Fuel Injector (WP 0069). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

14. Disconnect engine harness connector N-C2 (WP 0018, Figure 7) from valve cover side connector NN-C1 (WP 0018, Figure 8). 15. Perform Injector Solenoid Test (WP 0025).

16. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from engine ECM (WP 0101).

0019-15

1. If “OPEN” displayed, proceed to step18. 2. If “SHORT” displayed, proceed to step 16.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 3-11 Cylinder #3 Injector Fault - Continued

TEST OR INSPECTION 17. Perform Injector Solenoid Test (WP 0025).

CORRECTIVE ACTION 1. If “OPEN” displayed, replace engine main wiring harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

18. Connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NN-C1 (WP 0018, Figure 8). 19. Remove valve cover (WP 0106), and disconnect injector wire (Figure 4, Item 1).

Figure 4. Cylinder #3 Injector Fault Code.

0019-16

019

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 3-11 Cylinder #3 Injector Fault - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

20. Perform Injector Solenoid Test (WP 0025).

1. If “OPEN” displayed, replace fuel injector (WP 0069). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace injector wiring harness (WP 0106). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

WARNING

4-11 Cylinder #4 Injector Fault

Electrical shock hazard. Electronic unit injector system uses 67-73 Volts. Failure to follow this warning may result in injury to personnel.

NOTE Fuel injectors are an electro-mechanical device. High-pressure fuel is continuously available to each injector. The engine Electronic Control Module (ECM) determines the correct time and duration to activate each injector. 1. Connect MSD (WP 0016). 2. Start engine (TM 5-2410-241-10). On MSD, select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, proceed to step 3.

3. Perform Injector Solenoid Test (WP 0025).

1. If “OK” displayed, problem does not exist with the injector at this time. Resume normal operation. 2. If “OPEN” displayed, proceed to step 4. 3. If “SHORT” displayed, proceed to step 14.

4. Disconnect engine harness connector N-C2 (WP 0018, Figure 7) from valve cover side connector NN-C1 (WP 0018, Figure 8). 5. Install jumper wire in pins 4 and 10 on engine harness connector N-C2 (WP 0018, Figure 7).

0019-17

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 4-11 Cylinder #4 Injector Fault - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

NOTE Other diagnostic codes will set during this test. Ignore other codes. 6. Perform Injector Solenoid Test (WP 0025).

1. If “OPEN” displayed, proceed to step 7. 2. If “SHORT” displayed, proceed to step 10.

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from engine ECM (WP 0101). 9. Using digital multimeter (WP 0296), test for continuity between pins 39 and 45 on engine ECM connector N-C1 (WP 0018, Figure 2).

If continuity is found replace engine ECM (WP 0101). Remove jumper wire from pins 4 and 10 on engine harness connector N-C2 (WP 0018, Figure 7) and connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NN-C1 (WP 0018, Figure 8). If continuity is not found, replace engine main wiring harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

10. Remove jumper wire from pins 4 and 10 on engine harness connector N-C2 (WP 0018, Figure 7) and connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NN-C1(WP 0018, Figure 8). 11. Remove valve cover (WP 0106).

0019-18

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 4-11 Cylinder #4 Injector Fault - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

12. Install jumper wire between nuts (Figure 5, Item 1).

Figure 5. Cylinder #4 Injector Fault Code. 13. Perform Injector Solenoid Test (WP 0025).

019

1. If “OPEN” displayed, replace injector wiring harness (WP 0106). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace fuel injector (WP 0069). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

14. Disconnect engine harness connector N-C2 (WP 0018, Figure 7) from valve cover side connector NN-C1 (WP 0018, Figure 8). 15. Perform Injector Solenoid Test (WP 0019).

16. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from engine ECM (WP 0101).

0019-19

1. If “OPEN” displayed, proceed to step 18. 2. If “SHORT” displayed, proceed to step 16.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 4-11 Cylinder #4 Injector Fault - Continued

TEST OR INSPECTION 17. Perform Injector Solenoid Test (WP 0025).

CORRECTIVE ACTION 1. If “OPEN” displayed, replace engine main wiring harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

18. Connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NN-C1 (WP 0018, Figure 8). 19. Remove valve cover (WP 0106), and disconnect injector wire (Figure 5, Item 2). 20. Perform Injector Solenoid Test (WP 0025).

0019-20

1. If “OPEN” displayed, replace fuel injector (WP 0069). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace injector wiring harness (WP 0106). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

WARNING

5-11 Cylinder #5 Injector Fault

Electrical shock hazard. Electronic unit injector system uses 67-73 Volts. Failure to follow this warning may result in injury to personnel.

NOTE The fuel injectors are an electro-mechanical device. High-pressure fuel is continuously available to each injector. The engine Electronic Control Module (ECM) determines the correct time and duration to activate each injector. 1. Connect MSD (WP 0016). 2. Start engine (TM 5-2410-241-10). On MSD, select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, proceed to step 3.

3. Perform Injector Solenoid Test (WP 0025).

1. If “OK” displayed, problem does not exist with the injector at this time. Resume normal operation. 2. If “OPEN” displayed, proceed to step 4. 3. If “SHORT” displayed, proceed to step 14.

4. Disconnect engine harness connector N-C2 (WP 0018, Figure 7) from valve cover side connector NN-C1 (WP 0018, Figure 8). 5. Install jumper wire in pins 5 and 8 on engine harness connector N-C2 (WP 0018, Figure 7).

0019-21

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 5-11 Cylinder #5 Injector Fault - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

NOTE Other diagnostic codes will set during this test. Ignore other codes. 6. Perform Injector Solenoid Test (WP 0025).

1. If “OPEN” displayed, proceed to step 7. 2. If “SHORT” displayed, proceed to step 10.

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from engine ECM (WP 0101). 9. Using digital multimeter (WP 0296), test for continuity between pins 54 and 46 on engine ECM connector N-C1 (WP 0018, Figure 2).

10. Remove jumper wire from pins 5 and 8 on engine harness connector N-C2 (WP 0018, Figure 7) and connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NNC1 (WP 0018, Figure 8). 11. Remove valve cover (WP 0106).

0019-22

1. If continuity is found replace engine ECM (WP 0101). Remove jumper wire from pins 5 and 8 on engine harness connector N-C2 (WP 0018, Figure 7) and connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NN-C1 (WP 0018, Figure 8). 2. If continuity is not found replace engine main wiring harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 5-11 Cylinder #5 Injector Fault - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

12. Install jumper wire between nuts. (Figure 6, Item 2).

Figure 6. Cylinder #5 Injector Fault Code. 13. Perform Injector Solenoid Test (WP 0025).

019

1. If “OPEN” displayed, replace injector wiring harness (WP 0106). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace fuel injector (WP 0069). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

14. Disconnect engine harness connector N-C2 (WP 0018, Figure 7) from valve cover side connector NN-C1 (WP 0018, Figure 8). 15. Perform Injector Solenoid Test (WP 0025).

16. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from engine ECM (WP 0101).

0019-23

1. If “OPEN” displayed, proceed to step18. 2. If “SHORT” displayed, proceed to step 16.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 5-11 Cylinder #5 Injector Fault - Continued

TEST OR INSPECTION 17. Perform Injector Solenoid Test (WP 0025).

CORRECTIVE ACTION 1. If “OPEN” displayed, replace engine main wiring harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

18. Connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NNC1 (WP 0018, Figure 8). 19. Remove valve cover (WP 0106), and disconnect injector wire (Figure 6, Item 1). 20. Perform Injector Solenoid Test (WP 0025).

0019-24

1. If “OPEN” displayed, replace fuel injector (WP 0069). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace injector wiring harness (WP 0106). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

WARNING

6-11 Cylinder #6 Injector Fault

Electrical shock hazard. Electronic unit injector system uses 67-73 Volts. Failure to follow this warning may result in injury to personnel.

NOTE Fuel injectors are an electro-mechanical device. High-pressure fuel is continuously available to each injector. The engine Electronic Control Module (ECM) determines the correct time and duration to activate each injector. 1. Connect MSD (WP 0016). 2. Start engine (TM 5-2410-241-10). On MSD, select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, proceed to step 3.

3. Perform Injector Solenoid Test (WP 0025).

1. If “OK” displayed, problem does not exist with the injector at this time. Resume normal operation. 2. If “OPEN” displayed, proceed to step 4. 3. If “SHORT” displayed, proceed to step 14.

4. Disconnect engine harness connector N-C2 (WP 0018, Figure 7) from valve cover side connector NN-C1 (WP 0018, Figure 8). 5. Install jumper wire in pins 6 and 8 on engine harness connector N-C2 (WP 0018, Figure 7).

0019-25

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 6-11 Cylinder #6 Injector Fault - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

NOTE Other diagnostic codes will set during this test. Ignore other codes. 6. Perform Injector Solenoid Test (WP 0025).

1. If “OPEN” displayed, proceed to step 7. 2. If “SHORT” displayed, proceed to step 10.

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from engine ECM (WP 0101). 9. Using digital multimeter (WP 0296), test for continuity between pins 55 and 46 on engine ECM connector N-C1 (WP 0018, Figure 2).

10. Remove jumper wire from pins 6 and 8 on engine harness connector N-C2 (WP 0018, Figure 7) and connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NN-C1 (WP 0018, Figure 8). 11. Remove valve cover (WP 0106).

0019-26

1. If continuity is found, replace engine ECM (WP 0101). Remove jumper wire from pins 6 and 8 on engine harness connector N-C2 (WP 0018, Figure 7) and connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NN-C1 (WP 0018, Figure 8). 2. If continuity is not found, replace engine main wiring harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 6-11 Cylinder #6 Injector Fault - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

12. Install jumper wire between nuts. (Figure 7, Item 1).

Figure 7. Cylinder # 6 Injector Fault Code. 13. Perform Injector Solenoid Test (WP 0025).

019

1. If “OPEN” displayed, replace injector wiring harness (WP 0106). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace fuel injector (WP 0069). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

14. Disconnect engine harness connector N-C2 (WP 0018, Figure 7) from valve cover side connector NN-C1 (WP 0018, Figure 8). 15. Perform Injector Solenoid Test (WP 0025).

16. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from engine ECM (WP 0101).

0019-27

1. If “OPEN” displayed, proceed to step 18. 2. If “SHORT” displayed, proceed to step 16.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 6-11 Cylinder #6 Injector Fault - Continued

TEST OR INSPECTION 17. Perform Injector Solenoid Test (WP 0025).

CORRECTIVE ACTION 1. If “OPEN” displayed, replace engine main wiring harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

18. Connect engine harness connector N-C2 (WP 0018, Figure 7) on valve cover side connector NNC1 (WP 0018, Figure 8). 19. Remove valve cover (WP 0106), and disconnect injector wire (WP 0105) (Figure 7, Item 2).

41-3 8 Volt DC Supply Short to +Batt

20. Perform Injector Solenoid Test (WP 0025).

1. If “OPEN” displayed, replace fuel injector (WP 0069). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If “SHORT” displayed, replace injector wiring harness (WP 0106). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 41-3 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect decelerator position sensor connector E-C28 (WP 0018, Figure 9) from decelerator position sensor (WP 0258). 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0019-28

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 41-3 8 Volt DC Supply Short to +Batt - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

5. Using digital multimeter 1. If voltage of 7.6 - 8.4 Volts is (WP 0296), measure for voltage found, replace decelerator pedal between pins A and B on decelersensor (WP 0258). Ensure all ator position sensor connector harness connectors are reconE-C28 (WP 0018, Figure 9). nected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 7.6 - 8.4 Volts is not found, proceed to step 6. 6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Disconnect platform harness connector MA-C22 (WP 0018, Figure 11) from engine harness connector V-C1 (WP 0018, Figure 12). 8. Using digital multimeter (WP 0296), test for continuity between pin 19 on platform harness connector MA-C22 (WP 0018, Figure 11) and pin A on decelerator position sensor connector E-C28 (WP 0018, Figure 9).

1. If continuity is found, proceed to step 9. 2. If continuity is not found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

9. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from engine ECM (WP 0101).

41-4 8 Volt DC Short to Ground

10. Using digital multimeter (WP 0296), test for continuity between pin 19 on engine harness connector V-C1 (WP 0018, Figure 12) and pin 4 engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 41-4 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0019-29

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 41-4 8 Volt DC Short to Ground - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

3. Disconnect decelerator position sensor connector E-C28 (WP 0018, Figure 9) from decelerator position sensor (WP 0258). 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Using digital multimeter 1. If voltage of 7.6 - 8.4 Volts is (WP 0296), measure for voltage found, replace decelerator pedal between pins A and B on decelersensor (WP 0258). Ensure all ator position sensor connector harness connectors are reconE-C28 (WP 0018, Figure 9). nected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 7.6 - 8.4 Volts is not found, proceed to step 6. 6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Disconnect platform harness connector MA-C22 (WP 0018, Figure 11) from engine harness connector V-C1 (WP 0018, Figure 12) (WP 0055). 8. Using digital multimeter (WP 0296), test for continuity between pin 19 on platform harness connector MA-C22 (WP 0018, Figure 11) and all other pins on platform harness connector MA-C22 (WP 0018, Figure 11) and ground.

1. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 9.

9. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from engine ECM (WP 0101). 10. Using a digital multimeter 1. If continuity is found, replace (WP 0296), test for continuity engine harness (WP 0055). between pin 19 on engine harEnsure all harness connectors ness connector V-C1 are reconnected. Verify correct (WP 0018, Figure 12) and all operation of machine other pins on engine harness con(TM 5-2410-241-10). nector V-C1 (WP 0018, Figure 12) 2. If continuity is not found replace and ground. engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0019-30

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 91-2 Incorrect Throttle Switch Inputs

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 91-2 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove four screws (Figure 8, Item 1) and switch (Figure 8, Item 3) from switch pod (Figure 8, Item 2).

Figure 8. Throttle Switch.

0019-31

019

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 91-2 Incorrect Throttle Switch Inputs Continued

TEST OR INSPECTION

CORRECTIVE ACTION

4. Disconnect throttle switch connector RW-C4 (WP 0018, Figure 13) (Figure 9, Item 1) from throttle switch (WP 0018, Figure 16) (Figure 9, Item 2).

Figure 9. Throttle Switch Connector.

019

5. Hold the throttle switch in the LOW (tortoise) position (TM 5-2410-241-10). 6. Using digital multimeter (WP 0296), test for continuity between pin 1 and pin 2 on the throttle switch (WP 0018, Figure 16).

1. If continuity is found, proceed to step 7. 2. If continuity is not found, replace throttle switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

7. Hold the throttle switch in the LOW (tortoise) position (TM 5-2410-241-10). 8. Using digital multimeter (WP 0296), test for continuity between pin 4 and pin 5 on the throttle switch (WP 0018, Figure 16).

0019-32

1. If continuity is found, proceed to step 9. 2. If continuity is not found, replace throttle switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 91-2 Incorrect Throttle Switch Inputs Continued

TEST OR INSPECTION

CORRECTIVE ACTION

9. Hold the throttle switch in the LOW (tortoise) position (TM 5-2410-241-10). 10. Using digital multimeter (WP 0296), test for continuity between pin 3 and pin 2 on throttle switch (WP 0018, Figure 16).

1. If continuity is found, replace throttle switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 11.

11. Hold throttle switch in the LOW (tortoise) position. 12. Using digital multimeter (WP 0296), test for continuity between pin 6 and pin 2 on throttle switch (WP 0018, Figure 16).

1. If continuity is found, replace throttle switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 13.

13. Hold throttle switch in HIGH (rabbit) position (TM 5-2410-241-10). 14. Using digital multimeter (WP 0296), test for continuity between pin 6 and pin 2 on the throttle switch (WP 0018, Figure 16).

1. If continuity is not found, proceed to step 15. 2. If continuity is found, replace throttle switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

15. Hold throttle switch in HIGH (rabbit) position (TM 5-2410-241-10). 16. Using a digital multimeter (WP 0296), test for continuity between pin 3 and pin 2 on the throttle switch (WP 0018, Figure 16).

17. Hold throttle switch in the HIGH (rabbit) position (TM 5-2410-24110).

0019-33

1. If continuity is found, proceed to step 17. 2. If continuity is not found, replace throttle switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 91-2 Incorrect Throttle Switch Inputs Continued

TEST OR INSPECTION 18. Using digital multimeter (WP 0296), test for continuity between pin 1 and pin 5 on the throttle switch (WP 0018, Figure 16).

CORRECTIVE ACTION 1. If continuity is found, replace throttle switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 19.

19. Hold throttle switch in HIGH (rabbit) position (TM 5-2410-241-10). 20. Using digital multimeter (WP 0296), test for continuity between pin 4 and pin 5 on throttle switch (WP 0018, Figure 16).

1. If continuity is found, replace throttle switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 21

21. Allow throttle switch to return to neutral position (TM 5-2410-24110). 22. Using digital multimeter (WP 0296), test for continuity between pin 1 and pin 5 on the throttle switch (WP 0018, Figure 16).

1. If continuity is found, replace throttle switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 23.

23. With throttle switch in neutral position (TM 5-2410-241-10). 24. Using digital multimeter (WP 0296), test for continuity between pin 6 and pin 2 on the throttle switch (WP 0018, Figure 16).

1. If continuity is found, replace throttle switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 25.

25. With throttle switch in neutral position (TM 5-2410-241-10). 26. Using digital multimeter (WP 0296), test for continuity between pin 4 and pin 5 on the throttle switch (WP 0018, Figure 16).

27. With throttle switch in neutral position (TM 5-2410-241-10).

0019-34

1. If continuity is found, proceed to step 27. 2. If continuity is not found, replace throttle switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 91-2 Incorrect Throttle Switch Inputs Continued

TEST OR INSPECTION 28. Using digital multimeter (WP 0296), test for continuity between pin 3 and pin 2 on the throttle switch (WP 0018, Figure 16).

CORRECTIVE ACTION 1. If continuity is found, proceed to step 29. 2. If continuity is not found, replace throttle switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

29. Remove upper right access panel (WP 0179). 30. Disconnect right hand console harness connector RW-C1 (WP 0018, Figure 14) from right hand console platform harness connector MA-C1 (WP 0018, Figure 15). 31. Using digital multimeter (WP 0296), test for continuity between pin 1 on right hand console harness connector RW-C1 (WP 0018, Figure 14) and pin 1 on throttle switch connector RWC4 (WP 0018, Figure 13).

1. If continuity is found, proceed to step 32. 2. If continuity is not found, replace right cab switch panel harness assembly (WP 0179). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

32. Using digital multimeter (WP 0296), test for continuity between pin 2 on right hand console harness connector RW-C1 (WP 0018, Figure 14) and pin 4 on throttle switch connector RWC4 (WP 0018, Figure 13).

1. If continuity is found, proceed to step 33. 2. If continuity is not found, replace right cab switch panel harness assembly (WP 0179). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

33. Using digital multimeter (WP 0296), test for continuity between pin 3 on right hand console harness connector RW-C1 (WP 0018, Figure 14) and pin 6 on throttle switch connector RWC4 (WP 0018, Figure 13).

1. If continuity is found, proceed to step 34. 2. If continuity is not found, replace right cab switch panel harness assembly (WP 0179). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

34. Using digital multimeter (WP 0296), test for continuity between pin 4 on right hand console harness connector RW-C1 (WP 0018, Figure 14) and pin 3 on throttle switch connector RWC4 (WP 0018, Figure 13).

1. If continuity is found, proceed to step 35. 2. If continuity is not found, replace right cab switch panel harness assembly (WP 0179). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0019-35

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 91-2 Incorrect Throttle Switch Inputs Continued

TEST OR INSPECTION

CORRECTIVE ACTION

35. Using digital multimeter (WP 0296), test for continuity between pin 5 on right hand console harness connector RW-C1 (WP 0018, Figure 14) and pin 2 on throttle switch connector RWC4 (WP 0018, Figure 13).

1. If continuity is found, proceed to step 36. 2. If continuity is not found, replace right cab switch panel harness assembly (WP 0179). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

36. Using digital multimeter (WP 0296), test for continuity between pin 5 on right hand console harness connector RW-C1 (WP 0018, Figure 14) and pin 5 on throttle switch connector RWC4 (WP 0018, Figure 13).

1. If continuity is found, proceed to step 37. 2. If continuity is not found, replace right cab switch panel harness assembly (WP 0179). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

37. Disconnect platform harness connector MA-C22 (WP 0018, Figure 11) from engine harness connector V-C1 (WP 0018, Figure 12). 38. Using digital multimeter (WP 0296), test for continuity between pin 13 on platform harness connector MA-C22 (WP 0018, Figure 11) and pin 1 on right hand console platform harness connector MA-C1 (WP 0018, Figure 15).

1. If continuity is found, proceed to step 39. 2. If continuity is not found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

39. Using digital multimeter (WP 0296), test for continuity between pin 14 on platform harness connector MA-C22 (WP 0018, Figure 11) and pin 2 on right hand console platform harness connector MA-C1 (WP 0018, Figure 15).

1. If continuity is found, proceed to step 40. 2. If continuity is not found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

40. Using digital multimeter (WP 0296), test for continuity between pin 15 on platform harness connector MA-C22 (WP 0018, Figure 11) and pin 3 on right hand console platform harness connector MA-C1 (WP 0018, Figure 15).

1. If continuity is found, proceed to step 41. 2. If continuity is not found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0019-36

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 91-2 Incorrect Throttle Switch Inputs Continued

TEST OR INSPECTION

CORRECTIVE ACTION

41. Using digital multimeter (WP 0296), test for continuity between pin 16 on platform harness connector MA-C22 (WP 0018, Figure 11) and pin 4 on right hand console platform harness connector MA-C1 (WP 0018, Figure 15).

1. If continuity is found, proceed to step 42. 2. If continuity is not found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

42. Using digital multimeter (WP 0296), test for continuity between pin 10 on platform harness connector MA-C22 (WP 0018, Figure 11) and pin 5 on right hand console platform harness connector MA-C1 (WP 0018, Figure 15).

1. If continuity is found, proceed to step 43. 2. If continuity is not found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

43. Disconnect engine ECM connector V-C4 (WP 0018, Figure 2) from ECM. 44. Using digital multimeter (WP 0296), test for continuity between pin 13 on engine harness connector V-C1 (WP 0018, Figure 12) and pin 22 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 45.

45. Using digital multimeter (WP 0296), test for continuity between pin 14 on engine harness connector V-C1 (WP 0018, Figure 12) and pin 23 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 46. 2. If continuity is not found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

46. Using digital multimeter (WP 0296), test for continuity between pin 15 on engine harness connector V-C1 (WP 0018, Figure 12) and pin 40 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found proceed to step 47. 2. If continuity is not found replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0019-37

2. If continuity is not found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 91-2 Incorrect Throttle Switch Inputs Continued

100-3 Engine Oil Pressure Open/Short to +Batt

TEST OR INSPECTION

CORRECTIVE ACTION

47. Using digital multimeter (WP 0296), test for continuity between pin 16 on engine harness connector V-C1 (WP 0018, Figure 12) and pin 41 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 48. 2. If continuity is not found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

48. Using digital multimeter (WP 0296), test for continuity between pin 10 on engine harness connector V-C1 (WP 0018, Figure 12) and pin 61, 63, and 65 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 49. 2. If continuity is not found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

49. Using digital multimeter (WP 0296), test for continuity between pin 10 on engine harness connector V-C1 (WP 0018, Figure 12) and pin 63 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 50. 2. If continuity is not found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

50. Using digital multimeter (WP 0296), test for continuity between pin 10 on engine harness connector V-C1 (WP 0018, Figure 12) and pin 65 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is not found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 100-3 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove engine enclosure left door guard (WP 0202). 4. Disconnect ECM harness connector N-C3 (WP 0018, Figure 19) from oil pressure sensor. 5. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0019-38

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 100-3 Engine Oil Pressure open/short to +Batt Continued

TEST OR INSPECTION 6. Using a digital multimeter (WP 0296), measure for voltage between pin A and pin B on ECM harness connector N-C3 (WP 0018, Figure 19).

CORRECTIVE ACTION 1. If 4.5-5.5 Volts is found, proceed to step 7. 2. If 4.5-5.5 Volts is not found, proceed to step 9.

7. Install jumper wire between pin B and pin C on ECM harness connector N-C3 (WP 0018, Figure 19). 8. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 100-4 code is present, replace oil pressure sensor. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If active 100-3 code is present, proceed to step 9.

9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 10. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2). 11. Remove jumper wire from ECM harness connector N-C3 (WP 0018, Figure 19) between pin B and pin C. 12. Using a digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 13. between pin A on ECM harness 2. If continuity is not found, replace connector N-C3 (WP 0018, ECM harness (WP 0105). Ensure Figure 19) and pin 2 on ECM harall harness connectors are reconness connector N-C1 (WP 0018, nected. Verify correct operation of Figure 2). machine (TM 5-2410-241-10). 13. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 14. between pin B on ECM harness 2. If continuity is not found, replace connector N-C3 (WP 0018, ECM harness (WP 0105). Ensure Figure 19) and pin 3 on ECM harall harness connectors are reconness connector N-C1 (WP 0018, nected. Verify correct operation of Figure 2). machine (TM 5-2410-241-10). 14. Using digital multimeter (WP 0296), test for continuity between pin C on ECM harness connector N-C3 (WP 0018, Figure 19) and pin 24 on ECM harness connector N-C1 (WP 0018, Figure 2).

0019-39

1. If continuity is found, proceed to step 15. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

100-3 Engine Oil Pressure open/short to +Batt Continued

15. Using digital multimeter (WP 0296), test for continuity between pin 24 on ECM harness connector N-C1 (WP 0018, Figure 2) and all other pins on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

100-4 Engine Oil Pressure Short to Ground

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 100-4 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect ECM harness connector N-C3 (WP 0018, Figure 19) from oil pressure sensor. 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 100-4 code is present, proceed to step 6. 2. If active 100-3 code is present, replace oil pressure sensor. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2). 8. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 9. between pin A on ECM harness 2. If continuity is not found replace connector N-C3 (WP 0018, ECM harness (WP 0105). Ensure Figure 19) and pin 2 on ECM harall harness connectors are reconness connector N-C1 (WP 0018, nected. Verify correct operation of Figure 2). machine (TM 5-2410-241-10).

0019-40

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 100-4 Engine Oil Pressure Short to Ground Continued

110-3 Engine Coolant Temperature open/short to +Batt

TEST OR INSPECTION

CORRECTIVE ACTION

9. Using digital multimeter (WP 0296), test for continuity between pin B on ECM harness connector N-C3 (WP 0018, Figure 19) and pin 3 on ECM harness connector N-C1 (WP 0018,Figure 2).

1. If continuity is found, proceed to step 10. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

10. Using digital multimeter (WP 0296), test for continuity between pin C on ECM harness connector N-C3 (WP 0018, Figure 19) and pin 24 on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 11. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

11. Using digital multimeter (WP 0296), test for continuity between pin 24 on ECM harness connector N-C1 (WP 0018, Figure 2) and all other pins on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 110-3 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect ECM harness connector N-C11 (WP 0018, Figure 20) from coolant temperature sensor. 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Using digital multimeter (WP 0296), measure for voltage between pin 1 and pin 2 on ECM harness connector N-C11 (WP 0018, Figure 20). 6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0019-41

1. If 4.5-5.5 Volts is found, proceed to step 6. 2. If 4.5-5.5 Volts is not found, proceed to step 8.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 110-3 Engine Coolant Temperature open/short to +Batt - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

7. Install jumper wire between pin 1 and pin 2 on ECM harness connector N-C11 (WP 0018, Figure 20). 8. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 9. On MSD, check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 110-4 code is present, replace coolant temperature sensor (WP 0064). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 110-3 code is present, proceed to step 10.

10. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 11. Remove jumper wire from ECM harness connector N-C11 (WP 0018, Figure 20) between pin 1 and pin 2. 12. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from ECM. 13. Using a digital multimeter (WP 0296), test for continuity between pin 1 on ECM harness connector N-C11 (WP 0018, Figure 20) and pin 32 on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 14. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

14. Using digital multimeter (WP 0296), test for continuity between pin 2 on ECM harness connector N-C11 (WP 0018, Figure 20) and pin 18 on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 15. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0019-42

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

110-3 Engine Coolant Temperature open/short to +Batt - Continued

15. Using digital multimeter (WP 0296), test for continuity between pin 32 on ECM harness connector N-C1 (WP 0018, Figure 2) and all other pins on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

110-4 Engine Coolant Temperature Short to Ground

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 110-4 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect ECM harness connector N-C11 (WP 0018, Figure 20) from coolant temperature sensor. 4. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 110-3 code is present, replace coolant temperature sensor (WP 0064). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 110-4 code is present, proceed to step 5.

5. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 6. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from ECM. 7. Using digital multimeter (WP 0296), test for continuity between pin 1 on ECM harness connector N-C11 (WP 0018 Figure 20) and pin 32 on ECM harness connector N-C1 (WP 0018, Figure 2).

0019-43

1. If continuity is found, proceed to step 8. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 110-4 Engine Coolant Temperature short to ground - Continued

168-2 System Voltage Intermittent/Erratic

TEST OR INSPECTION

CORRECTIVE ACTION

8. Using digital multimeter (WP 0296), test for continuity between pin 2 on ECM harness connector N-C11 (WP 0018, Figure 20) and pin 18 on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 9. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

9. Using digital multimeter (WP 0296), test for continuity between pin 32 on ECM harness connector N-C1 (WP 0018, Figure 2) and all other pins on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 168-2 code is present proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Perform battery test (WP 0030).

1. If problem is found, verify correct operation of machine (TM 5-2410241-10). 2. If batteries are OK, proceed to step 3.

0019-44

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 168-2 System Voltage Intermittent/Erratic Continued

TEST OR INSPECTION 3. Inspect Battery and Alternator Cables (WP 0029).

CORRECTIVE ACTION 1. If problem is found, verify correct operation of machine (TM 5-2410241-10). 2. If battery and alternator cables are OK, proceed to step 4.

4. Open fuse panel door (Figure 10, Item 1)

Figure 10. Fuse Panel Door.

0019-45

019

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 168-2 System Voltage Intermittent/Erratic Continued

TEST OR INSPECTION

CORRECTIVE ACTION

5. Remove fuse #21 (Figure 11, Item 1) located in the fuse panel (Figure 11, Item 2). 6. Using digital multimeter (WP 0296), test for continuity between blades on fuse.

Figure 11. Fuse #21.

1. If Fuse #21 is OK, verify correct operation of machine (TM 5-2410241-10). 2. If problem is found, proceed to step 7.

019

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from engine ECM. 9. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 10. Using digital multimeter 1. If voltage is found, proceed to (WP 0296), measure for voltage step 11. between pin 48 on ECM harness 2. If voltage is not found, proceed to connector V-C4 (WP 0018, step 14. Figure 1) and 61 pin on ECM harness connector V-C4 (WP 0018, Figure 1).

0019-46

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 168-2 System Voltage Intermittent/Erratic Continued

TEST OR INSPECTION

CORRECTIVE ACTION

11. Using digital multimeter 1. If voltage is found, proceed to (WP 0296), measure for voltage step 12. between pin 52 on ECM harness 2. If voltage is not found, proceed to connector V-C4 (WP 0018, step 14. Figure 1) and pin 63 on ECM harness connector V-C4 (WP 0018, Figure 1). 12. Using digital multimeter 1. If voltage is found, proceed to (WP 0296), measure for voltage step 13. between pin 53 on ECM harness 2. If voltage is not found, proceed to connector V-C4 (WP 0018, step 14. Figure 1) and pin 65 on ECM harness connector V-C4 (WP 0018, Figure 1). 13. Using digital multimeter 1. If voltage is found, replace engine (WP 0296), measure for voltage ECM (WP 0101). Ensure all harbetween pin 70 ECM harness ness connectors are reconnected. connector V-C4 (WP 0018, Verify correct operation of Figure 1) and pin 63 on ECM harmachine (TM 5-2410-241-10). ness connector V-C4 (WP 0018, 2. If voltage is not found, perform Figure 1). malfunction Engine Will Not Crank in this work package. 14. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 15. Disconnect engine ECM harness connector V-C1 (WP 0018, Figure 12) from platform harness connector MA-C22 (WP 0018, Figure 11). 16. Using digital multimeter (WP 0296), test for continuity between pin 48 on ECM harness connector V-C4 (WP 0018, Figure 1) and pin 2 on ECM harness connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, proceed to step 17. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

17. Using digital multimeter (WP 0296), test for continuity between pin 48 on ECM harness connector V-C4 (WP 0018, Figure 1) and pin 11 on ECM harness connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, proceed to step 18. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0019-47

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 168-2 System Voltage Intermittent/Erratic Continued

TEST OR INSPECTION

CORRECTIVE ACTION

18. Using digital multimeter (WP 0296), test for continuity between pin 52 on ECM harness connector V-C4 (WP 0018, Figure 1) and pin 2 on ECM harness connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, proceed to step 19. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

19. Using digital multimeter (WP 0296), test for continuity between pin 52 on ECM harness connector V-C4 (WP 0018, Figure 1) and pin 11 on ECM harness connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, proceed to step 20. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

20. Using digital multimeter (WP 0296), test for continuity between pin 53 on ECM harness connector V-C4 (WP 0018, Figure 1) and pin 2 on ECM harness connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, proceed to step 21. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

21. Using digital multimeter (WP 0296), test for continuity between pin 53 on ECM harness connector V-C4 (WP 0018, Figure 1) and pin 11 on ECM harness connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, proceed to step 22. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

22. Using digital multimeter (WP 0296), test for continuity between pin 61 on ECM harness connector V-C4 (WP 0018, Figure 1) and ground.

1. If continuity is found, proceed to step 23. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

23. Using digital multimeter (WP 0296), test for continuity between pin 63 on ECM harness connector V-C4 (WP 0018, Figure 1) and ground.

1. If continuity is found, proceed to step 24. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0019-48

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 168-2 System Voltage Intermittent/Erratic Continued

TEST OR INSPECTION

CORRECTIVE ACTION

24. Using digital multimeter (WP 0296), test for continuity between pin 65 on ECM harness connector V-C4 (WP 0018, Figure 1) and ground.

1. If continuity is found, proceed to step 25. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

25. Disconnect ECM harness connector MA-C3 (WP 0018, Figure 21) from fuse panel harness connector A-C1 (WP 0018, Figure 22). 26. Using digital multimeter (WP 0296), test for continuity between pin 11 on ECM harness connector MA-C3 (WP 0018, Figure 21) and pin 2 on ECM harness connector MA-C22 (WP 0018, Figure 11).

1. If continuity is found, proceed to step 27. 2. If continuity is not found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

27. Using digital multimeter (WP 0296), test for continuity between pin 12 on ECM harness connector MA-C3 (WP 0018, Figure 21) and pin 11 on ECM harness connector MA-C22 (WP 0018, Figure 11).

1. If continuity is found, proceed to step 28. 2. If continuity is not found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

28. Open fuse panel door (Figure 12, Item 1).

Figure 12. Fuse Panel Door.

0019-49

019

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 168-2 System Voltage Intermittent/Erratic Continued

TEST OR INSPECTION

CORRECTIVE ACTION

29. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 30. between pin 11 on fuse panel wir- 2. If continuity is not found, replace ing harness connector A-C1 fuse panel wiring harness (WP 0018, Figure 22) and left (WP 0176). Ensure all harness cavity of ECM Fuse #21 connectors are reconnected. Ver(Figure 13, Item 1). ify correct operation of machine (TM 5-2410-241-10). 30. Using digital multimeter 1. If continuity is found, replace (WP 0296), test for continuity engine ECM (WP 0101). Ensure between pin 12 on fuse panel wirall harness connectors are reconing harness connector A-C1 nected. Verify correct operation of (WP 0018, Figure 22) and left machine (TM 5-2410-241-10). cavity of ECM Fuse #21 2. If continuity is not found, replace (Figure 13, Item 1). fuse panel wiring harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

Figure 13. Fuse #21.

0019-50

019

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 172-3 Intake Manifold Air Temp Open/Short to +Batt

TEST OR INSPECTION 1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

CORRECTIVE ACTION 1. If active 172-3 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect ECM harness connector NC-C2 (WP 0018, Figure 25) from Intake manifold air temperature sensor (WP 0066). 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Using a digital multimeter (WP 0296), measure for voltage between pin 1 and pin 2 on ECM harness connector NC-C2 (WP 0018, Figure 25).

1. If 4.5-5.5 Volts is found, proceed to step 6. 2. If 4.5-5.5 Volts is not found, proceed to step 9.

6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Install jumper wire between pin 1 and pin 2 on intake manifold air temperature jumper connector NC-C2 (WP 0018, Figure 25). 8. Check for Diagnostic Codes or Event Codes (WP 0013).

9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 10. Remove jumper wire from intake manifold air temperature jumper connector NC-C2 (WP 0018, Figure 25) between pin 1 and pin 2.

0019-51

1. If active 172-4 code is present, Replace intake manifold temperature sensor (WP 0066). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 172-3 code is present, proceed to step 9.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 172-3 Intake Manifold Air Temp Open/Short to +Batt - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

11. Disconnect intake manifold air temperature jumper connector NC-C1 (WP 0018, Figure 26) from ECM harness connector N-C10 (WP 0018, Figure 23). 12. Using a digital multimeter (WP 0296), test for continuity between pin 1 on intake manifold air temperature jumper connector NC-C1 (WP 0018, Figure 26) and pin 1 on intake manifold air temperature jumper connector NC-C2 (WP 0018, Figure 25).

1. If continuity is found, proceed to step 13. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

13. Using digital multimeter (WP 0296), test for continuity between pin 2 on intake manifold air temperature jumper connector NC-C1 (WP 0018, Figure 26) and pin 2 on intake manifold air temperature jumper connector NC-C2 (WP 0018, Figure 25).

1. If continuity is found, proceed to step 14. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

14. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from ECM. 15. Using digital multimeter (WP 0296), test for continuity between pin 1 on ECM harness connector N-C10 (WP 0018, Figure 23) and pin 35 on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 16. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

16. Using digital multimeter (WP 0296), test for continuity between pin 2 on ECM harness connector N-C10 (WP 0018, Figure 23) and pin 18 on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 17. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0019-52

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

172-3 Intake Manifold Air Temp Open/Short to +Batt - Continued

17. Using digital multimeter (WP 0296), test for continuity between pin 35 ECM harness connector N-C1 (WP 0018, Figure 2) and all other pins on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

172-4 Intake Manifold Air Temp Short to Ground

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 172-4 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect ECM harness connector NC-C2 (WP 0018, Figure 25) from Intake manifold air temperature sensor (WP 0054). 4. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 172-3 code is present, replace intake manifold temperature sensor (WP 0066). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 172-4 code is present, proceed to step 5.

5. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 6. Disconnect intake manifold air temperature jumper connector NC-C1 (WP 0018, Figure 26) from ECM harness connector N-C10 (WP 0018, Figure 23). 7. Using digital multimeter (WP 0296), test for continuity between pin 1 on intake manifold air temperature jumper connector NC-C1 (WP 0018, Figure 26) and pin 1 on intake manifold air temperature jumper connector NC-C2 (WP 0018, Figure 25).

0019-53

1. If continuity is found, proceed to step 8. 2. If continuity is not found, replace intake manifold air inlet temperature sensor harness (WP 0054). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

172-4 Intake Manifold Air Temp Short to Ground Continued

8. Using digital multimeter (WP 0296), test for continuity between pin 2 on intake manifold air temperature jumper connector NC-C1 (WP 0018, Figure 26) and pin 2 on intake manifold air temperature jumper connector NC-C2 (WP 0018, Figure 25).

1. If continuity is found, proceed to step 9. 2. If continuity is not found, replace intake manifold air inlet temperature sensor harness (WP 0054). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 10. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from ECM.

174-3 Fuel Temperature Open/Short to +Batt

11. Using digital multimeter (WP 0296), test for continuity between pin 1 on ECM harness connector N-C10 (WP 0018, Figure 23) and pin 35 on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 12. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

12. Using digital multimeter (WP 0296), test for continuity between pin 2 on ECM harness connector N-C10 (WP 0018, Figure 23) and pin 18 on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 13. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

13. Using digital multimeter (WP 0296), test for continuity between pin 35 on ECM harness connector N-C1 (WP 0018, Figure 2) and all other pins on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 174-3 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0019-54

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 174-3 Fuel Temperature Open/Short to +Batt Continued

TEST OR INSPECTION

CORRECTIVE ACTION

3. Disconnect ECM harness connector N-C9 (WP 0018, Figure 24) from fuel temperature sensor (WP 0065). 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Using digital multimeter (WP 0296), measure for voltage between pin 1 and pin 2 on ECM harness connector N-C9 (WP 0018, Figure 24).

1. If 4.5-5.5 Volts is found, proceed to step 6. 2. If 4.5-5.5 Volts is not found, proceed to step 10.

6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Install jumper wire between pin 1 and pin 2 on ECM harness connector N-C9 (WP 0018, Figure 24). 8. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 9. Check for Diagnostic Codes or Event Codes (WP 0013).

10. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 11. Remove jumper wire from ECM harness connector N-C9 (WP 0018, Figure 24) between pin 1 and pin 2. 12. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from ECM.

0019-55

1. If active 174-4 code is present, replace fuel temperature sensor (WP 0065). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 174-3 code is present, proceed to step 10.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 174-3 Fuel Temperature Open/Short to +Batt Continued

174-4 Fuel Temperature Short to Ground

TEST OR INSPECTION

CORRECTIVE ACTION

13. Using digital multimeter (WP 0296), test for continuity between pin 1 on ECM harness connector N-C9 (WP 0018, Figure 24) and pin 33 on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 14. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

14. Using digital multimeter (WP 0296), test for continuity between pin 2 on ECM harness connector N-C9 (WP 0018, Figure 24) and pin 18 on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 15. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

15. Using digital multimeter (WP 0296), test for continuity between pin 33 on ECM harness connector N-C1 (WP 0018, Figure 2) and all other pins on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 172-4 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect ECM harness connector N-C9 (WP 0018, Figure 24) from fuel temperature sensor (WP 0065). 4. Check for Diagnostic Codes or Event Codes (WP 0013).

5. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0019-56

1. If active 174-3 code is present, replace fuel temperature sensor (WP 0065). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 174-4 code is present, proceed to step 5.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 174-4 Fuel Temperature Short to Ground Continued

190-2 Loss of Engine Speed Signal

TEST OR INSPECTION

CORRECTIVE ACTION

6. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from ECM. 7. Using digital multimeter (WP 0296), test for continuity between pin 1 on ECM harness connector N-C9 (WP 0018, Figure 24) and pin 33 on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 8. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

8. Using digital multimeter (WP 0296), test for continuity between pin 2 on ECM harness connector N-C9 (WP 0018, Figure 24) and pin 18 on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 9. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

9. Using digital multimeter (WP 0296), test for continuity between pin 33 on ECM harness connector N-C1 (WP 0018, Figure 2) and all other pins on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 190-2 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

CAUTION Do not disconnect connector from crankshaft sensor. Failure to follow this caution could cause equipment damage. 3. Disconnect ECM harness connector N-C13 (WP 0018, Figure 27) from crankshaft position sensor pigtail connector (WP 0018, Figure 28) (WP 0094).

0019-57

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 190-2 Loss of Engine Speed Signal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

4. Using digital multimeter 1. If resistance of 75 - 230 Ohms is (WP 0296), measure resistance found, proceed to step 5. between pin 1 and pin 2 on crank- 2. If resistance of 75 - 230 Ohms is shaft position sensor connector not found, replace crankshaft (WP 0018, Figure 28). position sensor (WP 0094). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 5. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from ECM. 6. Using digital multimeter (WP 0296), test for continuity between pin 1 on ECM harness connector N-C13 (WP 0018, Figure 27) and pin 49 on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 7. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

7. Using digital multimeter (WP 0296), test for continuity between pin 2 on ECM harness connector N-C13 (WP 0018, Figure 27) and pin 48 on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 8. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

8. Using digital multimeter (WP 0296), test for continuity between pin 49 on ECM harness connector N-C1 (WP 0018, Figure 2) and all other pins on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 9.

9. Using digital multimeter (WP 0296), test for continuity between pin 48 on ECM harness connector N-C1 (WP 0018, Figure 2) and all other pins on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0019-58

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

190-11 Engine Speed Sensor Mechanical Failure

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 190-11 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

CAUTION Do not disconnect connector from crankshaft sensor. Failure to follow this caution could cause equipment damage. 3. Disconnect crankshaft position connector NC-13 (WP 0018 Figure 27) from crankshaft position sensor pigtail connector (WP 0018, Figure 28) (WP 0094). 4. Using digital multimeter 1. If resistance of 75 - 230 Ohms is (WP 0296), measure resistance found, proceed to step 5. between pin 1 and pin 2 on crank- 2. If resistance of 75 - 230 Ohms is shaft position sensor connector not found, replace crankshaft (WP 0018, Figure 28). position sensor (WP 0094). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 5. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from ECM. 6. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 7. between pin 1 on crankshaft posi- 2. If continuity is not found, replace tion connector NC-13 (WP 0018, ECM harness (WP 0105). Ensure Figure 27) and pin 49 on ECM all harness connectors are reconharness connector N-C1 nected. Verify correct operation of (WP 0018, Figure 2). machine (TM 5-2410-241-10). 7. Using a digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 8. between pin 2 on crankshaft posi- 2. If continuity is not found, replace tion connector NC-13 (WP 0018, ECM harness (WP 0105). Ensure Figure 27) and pin 48 on ECM all harness connectors are reconharness connector N-C1 nected. Verify correct operation of (WP 0018, Figure 2). machine (TM 5-2410-241-10).

0019-59

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

190-11 Engine Speed Sensor Mechanical Failure Continued

8. Using digital multimeter (WP 0296), test for continuity between pin 49 on ECM harness connector N-C1 (WP 0018, Figure 2) and all other pins on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 9.

9. Using digital multimeter (WP 0296), test for continuity between pin 48 on ECM harness connector N-C1 (WP 0018, Figure 2) and all other pins on ECM harness connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 247-9 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation

247-9 J1939 Data Link Communications

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from ECM. 4. Disconnect platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) from engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) (WP 0055). 5. Disconnect resistor Can/Data link (WP 0018, Figure 30) from engine ECM resistor Can/ Data link VC12 (WP 0018, Figure 29). 6. Using digital multimeter 1. If resistance of 108 - 132 Ohms is (WP 0296), measure resistance found, proceed to step 7. between pin A and pin B on resis- 2. If resistance of 108 - 132 Ohms is tor Can/Data link (WP 0018, not found, replace Can/Data link Figure 30). resistor. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0019-60

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

247-9 J1939 Data Link Com- 7. Using digital multimeter 1. If continuity is found, proceed to munications - Continued (WP 0296), test for continuity step 8. between pin 36 on engine har2. If continuity is not found replace ness (engine to platform) connecengine main harness (WP 0055). tor V-C1 (WP 0018, Figure 12) Ensure all harness connectors and pin 50 on engine ECM conare reconnected. Verify correct nector V-C4 (WP 0018, Figure 1). operation of machine (TM 5-2410-241-10). 8. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 9. between pin 37 on engine har2. If continuity is not found, replace ness (engine to platform) connecengine main harness (WP 0055). tor V-C1 (WP 0018, Figure 12) Ensure all harness connectors and pin 34 on engine ECM harare reconnected. Verify correct ness connector V-C4 (WP 0018, operation of machine (TM 5-2410Figure 1). 241-10). 9. Using digital multimeter (WP 0296), test for continuity between pin A on engine ECM resistor Can/Data link V-C12 (WP 0018, Figure 29) and pin 50 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 10. 2. If continuity is not found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

10. Using digital multimeter (WP 0296), test for continuity between pin B on engine ECM resistor Can/Data link V-C12 (WP 0018, Figure 29) and pin 34 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 11. 2. If continuity is not found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

11. Using digital multimeter (WP 0296), test for continuity between pin 34 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is not found, proceed to step 12.

12. Using digital multimeter (WP 0296), test for continuity between pin 50 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is not found, proceed to step 13.

0019-61

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

247-9 J1939 Data Link Com- 13. Disconnect powertrain ECM munications - Continued steering harness X-C1 (WP 0018, Figure 34) from platform harness MA-C14 (WP 0018, Figure 33). 14. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 15. between pin 36 on platform har2. If continuity is not found, replace ness (platform to engine) connecplatform harness (WP 0209). tor MA-C22 (WP 0018, Figure 11) Ensure all harness connectors and pin 20 on platform harness are reconnected. Verify correct MA-C14 (WP 0018, Figure 33). operation of machine (TM 5-2410241-10). 15. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 16. between pin 37 on platform har2. If continuity is not found, replace ness (platform to engine) connecplatform harness (WP 0209). tor MA-C22 (WP 0018, Figure 11) Ensure all harness connectors and pin 21 on platform harness are reconnected. Verify correct MA-C14 (WP 0018, Figure 33). operation of machine (TM 5-2410241-10). 16. Using digital multimeter (WP 0296), test for continuity between pin 21 on platform harness MA-C14 (WP 0018, Figure 33) and all other pins on platform harness MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found proceed to step 17.

17. Using digital multimeter (WP 0296), test for continuity between pin 20 on platform harness MA-C14 (WP 0018, Figure 33) and all other pins on platform harness MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found proceed to step 18.

18. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 4) from powertrain ECM. 19. Disconnect resistor Can/Data link (W P0009.1, Figure 32) from powertrain ECM resistor Can/Data link X-C10 (WP 0018, Figure 31).

0019-62

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

247-9 J1939 Data Link Com- 20. Using digital multimeter 1. If resistance of 108 - 132 Ohms is munications - Continued (WP 0296), measure resistance found, proceed to step 21. between pin A and pin B on resis- 2. If resistance of 108 - 132 Ohms is tor Can/Data link (WP 0018, not found, replace Can/Data link Figure 32). resistor. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 21. Using digital multimeter (WP 0296), test for continuity between pin 20 on powertrain ECM steering harness X-C1 (WP 0018, Figure 34) and pin 67 on powertrain ECM connector X-C3 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 22. 2. If continuity is not found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

22. Using digital multimeter (WP 0296), test for continuity between pin 21 on powertrain ECM steering harness X-C1 (WP 0018, Figure 34) and pin 68 on powertrain ECM connector X-C3 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 23. 2. If continuity is not found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

23. Using digital multimeter (WP 0296), test for continuity between pin A on powertrain ECM resistor Can/Data link X-C10 (WP 0018, Figure 31) and pin 67 on powertrain ECM connector X-C3 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 24. 2. If continuity is not found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

24. Using digital multimeter (WP 0296), test for continuity between pin B on powertrain ECM resistor Can/Data link X-C10 (WP 0018, Figure 31) and pin 68 on powertrain ECM connector X-C3 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 25. 2. If continuity is not found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

25. Using digital multimeter (WP 0296), test for continuity between pin 68 on powertrain ECM connector X-C3 (WP 0018, Figure 4) and all other pins on powertrain ECM connector X-C3 (WP 0018, Figure 4).

1. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 26.

0019-63

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

247-9 J1939 Data Link Com- 26. Using digital multimeter munications - Continued (WP 0296), test for continuity between pin 67 on powertrain ECM connector X-C3 (WP 0018, Figure 4) and all other pins on powertrain ECM connector X-C3 (WP 0018, Figure 4).

1. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

253-2 Personality Module Mismatch

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 253-2 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Verify correct flash files are programmed in engine ECM. Refer to Flash Programming (WP 0017).

1. If flash files are incorrect, install correct flash file (WP 0017). 2. If flash files are correct, replace engine ECM (WP 0101). Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 261-13 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Perform engine timing calibration (WP 0025).

Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 262-3 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

261-13 Engine Timing Calibration Required

262-3 5 Volt DC Power Supply Short to +Batt

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect ECM harness connector at oil pressure sensor N-C3 (WP 0018, Figure 19) from oil pressure sensor (WP 0091). 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0019-64

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

262-3 5 Volt DC Power Supply Short to +Batt Continued

NOTE Ignore all codes other then 262-3, which will be generated due to harness disconnection. 5. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active code 262-3 code is present, proceed to step 6. 2. If 262-3 code is not active, replace oil pressure sensor (WP 0091). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Disconnect atmospheric pressure sensor connector N-C4 (WP 0018, Figure 35) from atmospheric pressure sensor (WP 0090). 8. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 9. Check for Diagnostic Codes or Event Codes (WP 0013).

10. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 11. Disconnect air inlet manifold pressure sensor connector/turbocharger outlet pressure sensor connector N-C5 (WP 0018, Figure 36) from inlet manifold pressure sensor (WP 0092). 12. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0019-65

1. If active code 262-3 code is present, proceed to step 10. 2. If 262-3 code is not active, replace atmospheric pressure sensor (WP 0090). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 262-3 5 Volt DC Power Supply Short to +Batt Continued

TEST OR INSPECTION 13. Check for Diagnostic Codes or Event Codes (WP 0013).

CORRECTIVE ACTION 1. If active code 262-3 code is present, proceed to step 14. 2. If 262-3 code is not active, replace inlet manifold pressure sensor (WP 0092). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

14. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 15. Disconnect turbocharger inlet pressure sensor connector V-C20 (WP 0018, Figure 37) from turbo inlet pressure sensor (WP 0066). 16. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 17. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active code 262-3 code is present, proceed to step 18. 2. If 262-3 code is not active, replace turbo inlet pressure sensor (WP 0066). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

18. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 19. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from ECM. 20. Using digital multimeter (WP 0296), test for continuity between pin 2 on engine ECM connector N-C1 (WP 0018, Figure 2) and all other pins on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found proceed to step 21.

21. Using digital multimeter (WP 0296), test for continuity between pin 3 on engine ECM connector N-C1 (WP 0018, Figure 2) and all other pins on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 22.

0019-66

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 262-3 5 Volt DC Power Supply Short to +Batt Continued

262-4 5 Volt DC Power Supply Short to Ground

TEST OR INSPECTION

CORRECTIVE ACTION

22. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from ECM. 23. Using digital multimeter (WP 0296), test for continuity between pin 2 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 24.

24. Using digital multimeter (WP 0296), test for continuity between pin 3 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 262-4 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect ECM harness connector at oil pressure sensor N-C3 (WP 0018, Figure 19) from oil pressure sensor (WP 0091). 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Check for Diagnostic Codes or Event Codes (WP 0013).

6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0019-67

1. If active code 262-4 code is present, proceed to step 6. 2. If 262-4 code is not active, replace oil pressure sensor (WP 0091). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 262-4 5 Volt DC Power Supply Short to Ground Continued

TEST OR INSPECTION

CORRECTIVE ACTION

7. Disconnect atmospheric pressure sensor connector N-C4 (WP 0018, Figure 35) from atmospheric pressure sensor (WP 0090). 8. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 9. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active code 262-4 code is present, proceed to step 10. 2. If 262-4 code is not active, replace atmospheric pressure sensor (WP 0090). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

10. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 11. Disconnect air inlet manifold pressure sensor connector/turbocharger outlet pressure sensor connector N-C5 (WP 0018, Figure 36) from inlet manifold pressure sensor (WP 0092). 12. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 13. Check for Diagnostic Codes or Event Codes (WP 0013).

14. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 15. Disconnect turbocharger inlet pressure sensor connector V-C20 (WP 0018, Figure 37) from turbo inlet pressure sensor (WP 0066). 16. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0019-68

1. If active code 262-4 code is present, proceed to step 14. 2. If 262-4 code is not active, replace inlet manifold pressure sensor (WP 0092). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 262-4 5 Volt DC Power Supply Short to Ground Continued

TEST OR INSPECTION 17. Check for Diagnostic Codes or Event Codes (WP 0013).

CORRECTIVE ACTION 1. If active code 262-4 code is present, proceed to step 18. 2. If 262-4 code is not active, replace turbo inlet pressure sensor (WP 0066). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

18. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 19. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from ECM. 20. Using digital multimeter (WP 0296), test for continuity between pin 2 on engine ECM connector N-C1 (WP 0018, Figure 2) and all other pins on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 21.

21. Using digital multimeter (WP 0296), test for continuity between pin 3 on engine ECM connector N-C1 (WP 0018, Figure 2) and all other pins on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 22.

22. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from ECM. 23. Using digital multimeter (WP 0296), test for continuity between pin 2 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

0019-69

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 24.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

262-4 5 Volt DC Power Supply Short to Ground Continued

24. Using digital multimeter (WP 0296), test for continuity between pin 3 on engine ECM connector V-C4 (WP 0018 Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

264-8 Decel Throttle Position Signal Abnormal

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 264-8 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect decelerator position sensor connector - dash harness side E-C28 (WP 0018, Figure 9) from decelerator position sensor (WP 0258). 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Using digital multimeter 1. If voltage of 11.5-12.5 Volts is (WP 0296), measure for voltage found, replace decelerator pedal between pins B and C on decelersensor (WP 0258). Ensure all ator position sensor connector harness connectors are recondash harness side E-C28 nected. Verify correct operation of (WP 0018, Figure 9). machine (TM 5-2410-241-10). 2. If 11.5-12.5 Volts is not found, proceed to step 6. 6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Disconnect platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) from engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) (WP 0055).

0019-70

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 264-8 Decel Throttle Position Signal Abnormal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

8. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 9. between pin 17 on platform har2. If continuity is not found, replace ness (platform to engine) connecplatform harness (WP 0209) and tor MA-C22 (WP 0018, Figure 11) instrument panel harness and pin C on decelerator position (WP 0260). Ensure all harness sensor connector - dash harness connectors are reconnected. Verside E-C28 (WP 0018, Figure 9). ify correct operation of machine (TM 5-2410-241-10). 9. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 10. between pin 18 on platform har2. If continuity is not found, replace ness (platform to engine) connecplatform harness (WP 0209) and tor MA-C22 (WP 0018, Figure 11) instrument panel harness and pin B on decelerator position (WP 0260). Ensure all harness sensor connector - dash harness connectors are reconnected. Verside E-C28 (WP 0018, Figure 9). ify correct operation of machine (TM 5-2410-241-10). 10. Using digital multimeter 1. If continuity is found, replace plat(WP 0296), test for continuity form harness (WP 0209) and between pin 17 on platform harinstrument panel harness ness (platform to engine) connec(WP 0260). Ensure all harness tor MA-C22 (WP 0018, Figure 11) connectors are reconnected. Verand all other pins on platform harify correct operation of machine ness (platform to engine) connec(TM 5-2410-241-10). tor MA-C22 (WP 0018, Figure 11). 2. If continuity is not found, proceed to step 11. 11. Using digital multimeter 1. If continuity is found, replace plat(WP 0296), test for continuity form harness (WP 0209) and between pin 18 on platform harinstrument panel harness ness (platform to engine) connec(WP 0260). Ensure all harness tor MA-C22 (WP 0018, Figure 11) connectors are reconnected. Verand all other pins on platform harify correct operation of machine ness (platform to engine) connec(TM 5-2410-241-10). tor MA-C22 (WP 0018, Figure 11). 2. If continuity is not found, proceed to step 12. 12. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from engine ECM. (WP 0101). 13. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 14. between pin 18 on engine har2. If continuity is not found, replace ness (engine to platform) connecengine harness (WP 0055). tor V-C1 (WP 0018, Figure 12) Ensure all harness connectors and pin 5 on engine ECM connecare reconnected. Verify correct tor V-C4 (WP 0018, Figure 1). operation of machine (TM 5-2410241-10).

0019-71

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 264-8 Decel Throttle Position Signal Abnormal Continued

266-2 Incorrect Crank without Inject Inputs

TEST OR INSPECTION

CORRECTIVE ACTION

14. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 15. between pin 17 on engine har2. If continuity is not found, replace ness (engine to platform) connecengine harness (WP 0055). tor V-C1 (WP 0018, Figure 12) Ensure all harness connectors and pin 66 on engine ECM conare reconnected. Verify correct nector V-C4 (WP 0018, Figure 1). operation of machine (TM 5-2410241-10). 15. Using digital multimeter (WP 0296), test for continuity between pin 5 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is not found, proceed to step 16. 2. If continuity is found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

16. Using digital multimeter (WP 0296), test for continuity between pin 66 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 266-2 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect harness connector to crank without injector connector V-C3 (WP 0018, Figure 40) from crank normal mode (harness 121-2844) CV-C1 (WP 0018, Figure 38).

0019-72

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 266-2 Incorrect Crank without Inject Inputs Continued

TEST OR INSPECTION

CORRECTIVE ACTION

4. Using digital multimeter (WP 0296), test for continuity between pin A and pin B on crank normal mode (harness 121-2844) CV-C1 (WP 0018, Figure 38)

1. If continuity is not found, replace crank without injection harness (WP 0056). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 5.

5. Using digital multimeter (WP 0296), test for continuity between pin A and pin C on crank without injection (harness 121-2844) CV-C2 (WP 0018, Figure 39).

1. If continuity is not found, replace crank without injection harness (WP 0056). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 6.

6. Disconnect engine ECM connector V-C4 (WP 0018 Figure 1) from engine ECM (WP 0101). 7. Using digital multimeter (WP 0296), test for continuity between pin A on harness connector to crank without injector connector V-C3 (WP 0018, Figure 40) and pin 5 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 8. 2. If continuity is not found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

8. Using digital multimeter (WP 0296), test for continuity between pin B on harness connector to crank without injection connector V-C3 (WP 0018, Figure 40) and pin 35 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 9. 2. If continuity is not found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

9. Using digital multimeter (WP 0296), test for continuity between pin C on harness connector to crank without injector connector V-C3 (WP 0018, Figure 40) and pin 44 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 10. 2. If continuity is not found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0019-73

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 266-2 Incorrect Crank without Inject Inputs Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Using digital multimeter (WP 0296), test for continuity between pin 35 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is not found, proceed to step 11. 2. If continuity is found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

11. Using digital multimeter (WP 0296), test for continuity between pin 44 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is not found, proceed to step 12. 2. If continuity is found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

12. Using digital multimeter (WP 0296), test for continuity between pin 35 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

268-2 Check Programmable Parameters

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 268-2 code is present, program injector trim files. Refer to Injector replacement (WP 0069). 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

273-3 Turbo Outlet Pressure Open/Short to +Batt

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 273-3 code is present proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0019-74

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

273-3 Turbo Outlet Pressure Open/Short to +Batt Continued

3. Disconnect air inlet manifold pressure sensor connector/turbocharger outlet pressure sensor connector N-C5 (WP 0018, Figure 36) from air inlet manifold pressure sensor.

CORRECTIVE ACTION

4. Install jumper wire between pin B and pin C on air inlet manifold pressure sensor connector/turbocharger outlet pressure sensor connector N-C5 (WP 0018, Figure 36). 5. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 6. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 273-4 code is present, replace air inlet manifold pressure sensor (WP 0092). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 273-3 code is present, proceed to step 7.

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Remove jumper wire from Air inlet manifold pressure sensor connector/turbocharger outlet pressure sensor connector N-C5 (WP 0018, Figure 36) between pin B and pin C. 9. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2). 10. Using digital multimeter (WP 0296), test for continuity between pin B on air inlet manifold pressure sensor connector/ turbocharger outlet pressure sensor connector N-C5 (WP 0018, Figure 36) and pin 3 on engine ECM connector N-C1 (WP 0018, Figure 2).

0019-75

1. If continuity is found, proceed to step 11. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

273-3 Turbo Outlet Pressure Open/Short to +Batt Continued

11. Using digital multimeter (WP 0296), test for continuity between pin C on air inlet manifold pressure sensor connector/ turbocharger outlet pressure sensor connector N-C5 (WP 0018, Figure 36) and pin 40 on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 12. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

12. Using digital multimeter (WP 0296), test for continuity between pin 40 on engine ECM connector N-C1 (WP 0018, Figure 2) and all other pins on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 273-4 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

273-4 Turbo Outlet Pressure Short to Ground

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect air inlet manifold pressure sensor connector/turbocharger outlet pressure sensor connector N-C5 (WP 0018, Figure 36) from air inlet manifold pressure sensor. 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Check for Diagnostic Codes or Event Codes (WP 0013).

6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0019-76

1. If active 273-3 code is present, replace air inlet manifold pressure sensor (WP 0092). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 273-4 code is present, proceed to step 6.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

273-4 Turbo Outlet Pressure Short to Ground Continued

7. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2).

CORRECTIVE ACTION

8. Using digital multimeter (WP 0296), test for continuity between pin B on air inlet manifold pressure sensor connector/ turbocharger outlet pressure sensor connector N-C5 (WP 0018, Figure 36) and pin 3 on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 9. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

9. Using digital multimeter (WP 0296), test for continuity between pin C on Air inlet manifold pressure sensor connector/ turbocharger outlet pressure sensor connector N-C5 (WP 0018, Figure 36) and pin 40 on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 10. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

10. Using digital multimeter (WP 0296), test for continuity between pin 40 on engine ECM connector N-C1 (WP 0018, Figure 2) and all other pins on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

274-3 Atmospheric Pres1. Connect MSD (WP 0016). Select sure Open/Short to +Batt 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013). 2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect atmospheric pressure sensor connector N-C4 (WP 0018, Figure 35) from atmospheric pressure sensor. 4. Install jumper wire between pin B and pin C on atmospheric pressure sensor connector N-C4 (WP 0018, Figure 35).

0019-77

1. If active 274-3 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 274-3 Atmospheric Pressure Open/Short to +Batt - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

5. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 6. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 274-4 code is present, replace atmospheric pressure sensor (WP 0090). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 274-3 code is present, proceed to step 7.

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Remove jumper wire from atmospheric pressure sensor connector N-C4 (WP 0018, Figure 35) between pin B and pin C. 9. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2). 10. Using digital multimeter (WP 0296), test for continuity between pin B on atmospheric pressure sensor connector N-C4 (WP 0018, Figure 35) and pin 3 on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 11. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

11. Using digital multimeter (WP 0296), test for continuity between pin C on atmospheric pressure sensor connector N-C4 (WP 0018, Figure 35) and pin 14 on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 12. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

12. Using digital multimeter (WP 0296), test for continuity between pin 14 engine ECM connector N-C1 (WP 0018, Figure 2) and all other pins on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0019-78

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 274-4 Atmospheric Pressure Short to Ground

TEST OR INSPECTION 1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

CORRECTIVE ACTION 1. If active 274-4 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect atmospheric pressure sensor connector N-C4 (WP 0018, Figure 35) from Atmospheric pressure sensor. 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 274-3 code is present, replace atmospheric pressure sensor (WP 0090). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 274-4 code is present, proceed to step 6.

6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from ECM. 8. Using digital multimeter (WP 0296), test for continuity between pin B on atmospheric pressure sensor connector N-C4 (WP 0018, Figure 35) and pin 3 on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 9. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

9. Using digital multimeter (WP 0296), test for continuity between pin C on atmospheric pressure sensor connector N-C4 (WP 0018, Figure 35) and pin 14 on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 10. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0019-79

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

274-4 Atmospheric Pressure Short to Ground Continued

10. Using digital multimeter (WP 0296), test for continuity between pin 14 on engine ECM connector N-C1 (WP 0018, Figure 2) and all other pins on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

275-3 Turbo Inlet Pressure Open/Short to +Batt

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and test for Diagnostic Codes or Event Codes (WP 0013).

1. If active 275-3 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect turbocharger inlet pressure sensor connector V-C20 (WP 0018, Figure 37) from turbo charger inlet pressure sensor. 4. Install jumper wire between pin B and pin C on turbocharger inlet pressure sensor connector V-C20 (WP 0018, Figure 37). 5. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 6. Check for Diagnostic Codes or Event Codes (WP 0013).

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Remove jumper wire from turbocharger inlet pressure sensor connector V-C20 (WP 0018, Figure 37) between pin B and pin C.

0019-80

1. If active 275-4 code is present, replace turbocharger inlet pressure sensor (WP 0066). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 275-3 code is present, proceed to step 7.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 275-3 Turbo Inlet Pressure Open/Short to +Batt Continued

275-4 Turbo Inlet Pressure Short to Ground

TEST OR INSPECTION

CORRECTIVE ACTION

9. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1). 10. Using digital multimeter (WP 0296), test for continuity between pin B on turbocharger inlet pressure sensor connector V-C20 (WP 0018, Figure 37) and pin 3 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 11. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

11. Using digital multimeter (WP 0296), test for continuity between pin C on A turbocharger inlet pressure sensor connector V-C20 (WP 0018, Figure 37) and pin 15 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 12. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

12. Using digital multimeter (WP 0296), test for continuity between pin 15 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 275-4 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect turbo charger inlet pressure sensor connector V-C20 (WP 0018, Figure 37) from turbo charger inlet pressure sensor. 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0019-81

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 275-4 Turbo Inlet Pressure Short to ground Continued

TEST OR INSPECTION 5. Check for Diagnostic Codes or Event Codes (WP 0013).

CORRECTIVE ACTION 1. If active 275-3 code is present, replace turbo charger inlet pressure sensor (WP 0066). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 275-4 code is present, proceed to step 6.

6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1).

296-9 Unable to Communicate with Transmission ECM

8. Using digital multimeter (WP 0296), test for continuity between pin B on turbocharger inlet pressure sensor connector V-C20 (WP 0018, Figure 37) and pin 3 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found proceed to step 9. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

9. Using digital multimeter (WP 0296), test for continuity between pin C on turbocharger inlet pressure sensor connector V-C20 (WP 0018, Figure 37) and pin 15 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 10. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

10. Using digital multimeter (WP 0296), test for continuity between pin 15 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 296-9 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0019-82

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 296-9 Unable to Communicate with Transmission ECM - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

3. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from ECM. 4. Disconnect platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) from engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) (WP 0055). 5. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 6. between pin 40 on engine har2. If continuity is not found, replace ness (engine to platform) connecengine main harness (WP 0055). tor V-C1 (WP 0018, Figure 12) Ensure all harness connectors and pin 8 on engine ECM connecare reconnected. Verify correct tor V-C4 (WP 0018, Figure 1). operation of machine (TM 5-2410241-10). 6. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 7. between pin 39 on engine har2. If continuity is not found, replace ness (engine to platform) connecengine main harness (WP 0055). tor V-C1 (WP 0018, Figure 12) Ensure all harness connectors and pin 9 on engine ECM connecare reconnected. Verify correct tor V-C4 (WP 0018, Figure 1). operation of machine (TM 5-2410241-10). 7. Using digital multimeter (WP 0296), test for continuity between pin 8 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is not found, proceed to step 8.

8. Using digital multimeter (WP 0296), test for continuity between pin 9 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is not found, proceed to step 9.

9. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262).

0019-83

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 296-9 Unable to Communicate with Transmission ECM - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Disconnect powertrain ECM steering harness X-C1 (WP 0018, Figure 34) from platform harness MA-C14 (WP 0018, Figure 33). 11. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 12. between pin 40 on platform har2. If continuity is not found, replace ness (platform to engine) connecplatform harness (WP 0209). tor MA-C22 (WP 0018, Figure 11) Ensure all harness connectors and pin 23 on platform harness are reconnected. Verify correct MA-C14 (WP 0018, Figure 33). operation of machine (TM 5-2410241-10). 12. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 13. between pin 39 on platform har2. If continuity is not found, replace ness (platform to engine) connecplatform harness (WP 0209). tor MA-C22 (WP 0018, Figure 11) Ensure all harness connectors and pin 22 on platform harness are reconnected. Verify correct MA-C14 (WP 0018, Figure 33). operation of machine (TM 5-2410241-10). 13. Using digital multimeter (WP 0296), test for continuity between pin 22 on platform harness MA-C14 (WP 0018, Figure 33) and all other pins on platform harness MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 14.

14. Using digital multimeter (WP 0296), test for continuity between pin 23 on platform harness MA-C14 (WP 0018, Figure 33) and all other pins on platform harness MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 15.

15. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 16. Using digital multimeter (WP 0296), test for continuity between pin 23 on powertrain ECM steering harness X-C1 (WP 0018, Figure 34) and pin 10 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

0019-84

1. If continuity is found, proceed to step 17. 2. If continuity is not found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 296-9 Unable to Communicate with Transmission ECM - Continued

342-2 Loss of Secondary Engine Speed Signal

TEST OR INSPECTION

CORRECTIVE ACTION

17. Using digital multimeter (WP 0296), test for continuity between pin 22 on powertrain ECM steering harness X-C1 (WP 0018, Figure 34) and pin 20 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 18. 2. If continuity is not found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

18. Using digital multimeter (WP 0296), test for continuity between pin 10 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and all other pins on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 19.

19. Using digital multimeter (WP 0296), test for continuity between pin 20 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and all other pins on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 342-2 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect camshaft position connector N-C14 (WP 0018, Figure 41) from camshaft position sensor (WP 0018, Figure 42) (WP 0093).

0019-85

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 342-2 Loss of Secondary Engine Speed Signal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

4. Using digital multimeter (WP 0296), measure resistance between pin 1 and pin 2 on camshaft position sensor (WP 0018, Figure 42).

1. If resistance of 600 - 1800 Ohms is found proceed to step 5. 2. If resistance of 600 - 1800 Ohms is not found, replace camshaft position speed sensor (WP 0093). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

5. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from ECM. 6. Using digital multimeter (WP 0296), test for continuity between pin 1 on camshaft position connector N-C14 (WP 0018, Figure 41) and pin 59 on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 7. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

7. Using digital multimeter (WP 0296), test for continuity between pin 2 on camshaft position connector N-C14 (WP 0018, Figure 41) and pin 58 on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 8. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

8. Using digital multimeter (WP 0296), test for continuity between pin 59 on engine ECM connector N-C1 (WP 0018, Figure 2) and all other pins on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 9.

9. Using digital multimeter (WP 0296), test for continuity between pin 58 on engine ECM connector N-C1 (WP 0018, Figure 2) and all other pins on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0019-86

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

342-11 Secondary Engine Speed Sensor Mechanical Failure

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

CORRECTIVE ACTION 1. If active 342-11 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect camshaft position connector N-C14 (WP 0018, Figure 41) from camshaft position sensor (WP 0018, Figure 42) (WP 0093). 4. Using digital multimeter (WP 0296), measure resistance between pin 1 and pin 2 on camshaft position sensor (WP 0018, Figure 42).

1. If resistance of 600 - 1800 Ohms is found, proceed to step 5. 2. If resistance of 600 - 1800 Ohms is not found, replace camshaft position speed sensor (WP 0093). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

5. Disconnect engine ECM connector N-C1 (WP 0018, Figure 2) from ECM. 6. Using digital multimeter (WP 0296), test for continuity between pin 1 on camshaft position connector N-C14 (WP 0018, Figure 41) and pin 59 on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 7. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

7. Using digital multimeter (WP 0296), test for continuity between pin 2 on camshaft position connector N-C14 (WP 0018, Figure 41) and pin 58 on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, proceed to step 8. 2. If continuity is not found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0019-87

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 342-11 Secondary Engine Speed Sensor Mechanical Failure - Continued

545-5 Ether Start Relay Open/Short to +Batt

TEST OR INSPECTION

CORRECTIVE ACTION

8. Using digital multimeter (WP 0296), test for continuity between pin 59 on engine ECM connector N-C1 (WP 0018, Figure 2) and all other pins on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, proceed to step 9.

9. Using digital multimeter (WP 0296), test for continuity between pin 58 on engine ECM connector N-C1 (WP 0018, Figure 2) and all other pins on engine ECM connector N-C1 (WP 0018, Figure 2).

1. If continuity is found, replace ECM harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 545-5 code is present, proceed to step 2. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect engine harness ether relay connector V-C18 (WP 0018, Figure 43) from ether relay. 4. Install jumper wire in pins 2 and 5 on engine harness ether relay connector V-C18 (WP 0018, Figure 43). 5. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 6. Check for Diagnostic Codes or Event Codes (WP 0013).

0019-88

1. If active 545-5 code is present, proceed to step 7. 2. If active code 545-6 is present, replace ether aid relay (WP 0060). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 545-5 Ether Start Relay Open/Short to +Batt Continued

TEST OR INSPECTION

CORRECTIVE ACTION

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Remove jumper wire in pins 2 and 5 on engine harness ether relay connector V-C18 (WP 0018, Figure 43). 9. Disconnect engine ECM connector V-C4 (WP 0018 Figure 1) from engine ECM (WP 0101).

545-6 Ether Start Relay Short to Ground

10. Using digital multimeter (WP 0296), test for continuity between pin 2 on engine harness ether relay connector V-C18 (WP 0018, Figure 43) and pin 21 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 11. 2. If continuity is not found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

11. Using digital multimeter (WP 0296), test for continuity between pin 5 on engine harness ether relay connector V-C18 (WP 0018, Figure 43) and pin 3 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 12. 2. If continuity is not found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

12. Using digital multimeter (WP 0296), test for continuity between pin 21 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

1. Remove ether cylinder (TM 5-2410-241-10). 2. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

0019-89

1. If active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, proceed to step 3.

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 545-6 Ether Start Relay Short to Ground Continued

TEST OR INSPECTION

CORRECTIVE ACTION

3. Select Diagnostics (Figure 14, Item 1), Diagnostics Test (Figure 14, Item 2), Override Parameter (Figure 14, Item 3).

Figure 14. Ether Override Parameters.

019

4. Highlight Ether Injection (Figure 15, Item 2) and select CHANGE button (Figure 15, Item 1).

Figure 15. Select Ether Injection.

0019-90

019

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 545-6 Ether Start Relay Short to Ground Continued

TEST OR INSPECTION

CORRECTIVE ACTION

5. Select drop down arrow, highlight ON (Figure 16, Item 1), select OK button (Figure 16, Item 2). Select Yes button (Figure 16, Item 3) to change parameter.

Figure 16. Selection Box and Yes Box.

0019-91

019

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 545-6 Ether Start Relay Short to Ground Continued

TEST OR INSPECTION 6. Select Active Codes button (Figure 17, Item 1).

CORRECTIVE ACTION 1. If active 545-5 code is present, proceed to step 7. 2. If no active codes are present, problem does not exist at this time. Resume normal operation.

Figure 17. Override in Progress and Active Code Box. 7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Disconnect engine harness ether relay connector V-C18 (WP 0018, Figure 43) from ether relay. 9. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 10. Check for Diagnostic Codes or Event Codes (WP 0013).

11. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 12. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from engine ECM. (WP 0101).

0019-92

1. If active 545-5 code is present, replace ether aid relay (WP 0060). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If no active codes are present, proceed to step 11.

019

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION 545-6 Ether Start Relay Short to Ground Continued

E017 High Engine Coolant Temperature Warning

TEST OR INSPECTION

CORRECTIVE ACTION

13. Using digital multimeter (WP 0296), test for continuity between pin 2 on engine harness ether relay connector V-C18 (WP 0018, Figure 43) and pin 21 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 14. 2. If continuity is not found replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

14. Using digital multimeter (WP 0296), test for continuity between pin 5 on engine harness ether relay connector V-C18 (WP 0018, Figure 43) and pin 3 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 15. 2. If continuity is not found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

15. Using digital multimeter (WP 0296), test for continuity between pin 21 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is not found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, proceed to step 2.

2. Inspect cooling system for damage. Refer to cooling system inspections (WP 0026).

1. If problem is found, verify correct operation of machine (TM 5-2410241-10). 2. If cooling system is OK, proceed to step 3.

3. Inspect air inlet and exhaust system for damage. Refer to Air Inlet and Exhaust Inspection (WP 0027).

1. If problem is found, verify correct operation of machine (TM 5-2410241-10). 2. If air inlet and exhaust system is OK, proceed to Troubleshooting Index (WP 0013).

0019-93

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

E027 High Inlet Air Tempera- 1. Connect MSD (WP 0016). Select ture Warning 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

E031 Air Inlet Restriction Derate

E039 Low Engine Oil Pressure Derate

E100 Low Engine Oil Pressure Warning

CORRECTIVE ACTION 1. If active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, proceed to step 2.

2. Inspect cooling system for damage. Refer to Cooling System inspections (WP 0026).

1. If problem is found, verify correct operation of machine (TM 5-2410241-10). 2. If cooling system is OK, proceed to step 3.

3. Inspect air inlet and exhaust system for damage. Refer to Air Inlet and Exhaust Inspection (WP 0027).

1. If problem is found, verify correct operation of machine (TM 5-2410241-10). 2. If air inlet and exhaust system is OK, proceed to Troubleshooting Index (WP 0013).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, the problem does not exist at this time. Resume normal operation.

2. Inspect air inlet and exhaust system for damage. Refer to Air Inlet and Exhaust Inspection (WP 0027).

1. If problem is found, verify correct operation of machine (TM 5-2410241-10). 2. If air inlet and exhaust system is OK, proceed to Troubleshooting Index (WP 0013).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, proceed to step 2.

2. Perform oil pressure inspection. Refer to Engine lubrication tests inspections. (WP 0024).

Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, proceed to step 2.

2. Perform oil pressure inspection. Refer to Engine Lubrication Tests Inspections (WP 0024).

Verify correct operation of machine (TM 5-2410-241-10).

0019-94

TM 5-2410-241-23-1

0019

Table 2. Engine Troubleshooting Procedures - Continued. MALFUNCTION E190 Engine Overspeed Warning

TEST OR INSPECTION 1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

CORRECTIVE ACTION 1. If active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, proceed to step 2.

2. Conditions Which Generate This Code: This event code indicates operator error. No troubleshooting is required. This is an informational event code only. The Engine Electronic Control Module (ECM) monitors the following:

E272 Inlet Air Restriction Warning

•

Engine speed is above 2,700 RPM for more than 0.6 seconds.

•

Event indicates excessive engine speed. Event does not represent a fault with engine speed/timing sensors or engine ECM.

•

Engine ECM logs event and a warning will display on the control panel.

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, proceed to step 2.

2. Inspect air inlet and exhaust system for damage. Refer to Air Inlet and Exhaust Inspection (WP 0027).

1. If problem is found, verify correct operation of machine (TM 5-2410241-10). 2. If air inlet and exhaust system is OK, proceed to Troubleshooting Index (WP 0013).

END OF TASK END OF WORK PACKAGE

0019-95/(96 blank)

236 TM 5-2410-241-23-1

0020

FIELD MAINTENANCE 0 0

2 0

-

POWERTRAIN TROUBLESHOOTING PROCEDURES

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Adapter Kit, Test (WP 0302, Item 5) Test Set, Electronic (MSD) (WP 0302, Item 62) Materials/Parts Rag, Wiping (WP 0303, Item 24) References WP 0013 WP 0016 WP 0017 WP 0018 WP 0028 WP 0029 WP 0030 WP 0037 WP 0055 WP 0101 WP 0122 WP 0142 WP 0143 WP 0144 WP 0145

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

References - Continued WP 0146 WP 0147 WP 0155 WP 0169 WP 0173 WP 0174 WP 0175 WP 0176 WP 0178 WP 0179 WP 0199 WP 0207 WP 0209 WP 0231 WP 0241 WP 0237 WP 0258 WP 0260 WP 0262 WP 0294 WP 0296

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Equipment Condition

0

Machine parked (TM 5-2410-241-10) Engine left door guard removed (when required) (WP 0202) 0

0

0

GENERAL

0

0020

This work package contains troubleshooting information for the D7R Dozer. Each malfunction or symptom listed is followed by the possible cause(s) and suggested remedy or remedies. This work package should be used as an aid in the isolation and correction of system problems.

0020-1

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures. MALFUNCTION 70-2 Parking Brake Switch Data Erratic, Intermittent, or Incorrect

0020

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 70-2 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove left platform access panel (WP 0207). 4. Disconnect parking brake switch connector X-C6 (WP 0018 Figure 44) from parking brake switch (WP 0018, Figure 45). 5. Push parking brake switch downward to the OFF position (TM 52410-241-10). 6. Using a digital multimeter (WP 0296), test for continuity between pin 3 and 11 on parking brake switch (WP 0018 Figure 45).

1. If continuity is NOT found, proceed to step 7. 2. If continuity is found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

7. Pull parking brake switch upward to the ON position (TM 5-2410241-10). 8. Using a digital multimeter (WP 0296), test for continuity between pin 3 and 11 on parking brake switch (WP 0018 Figure 45).

9. Pull parking brake switch upward to the ON position (TM 5-2410241-10).

0020-2

1. If continuity is found, proceed to step 9. 2. If continuity is NOT found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 70-2 Parking Brake Switch Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Using a digital multimeter (WP 0296), test for continuity between pin 4 and 11 on parking brake switch (WP 0018, Figure 45).

1. If continuity is NOT found, proceed to step 11. 2. If continuity is found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

11. Push parking brake switch downward to the OFF position (TM 52410-241-10). 12. Using a digital multimeter (WP 0296), test for continuity between pin 4 and 11 on parking brake switch (WP 0018, Figure 45).

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

13. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from the powertrain ECM. 14. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 15. pin 35 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 3 on parking brake switch con0178). Ensure all harness connecnector X-C6 (WP 0018, Figure 44). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 40 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 4 on parking brake switch con0178). Ensure all harness connecnector X-C6 (WP 0018, Figure 44). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 16. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 17. pin 35 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, Figure tors are reconnected. Verify cor4). rect operation of machine (TM 52410-241-10).

0020-3

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 70-3 Parking Brake Switch Voltage Above Normal

TEST OR INSPECTION

CORRECTIVE ACTION

17. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0175). pin 40 on powertrain ECM connecEnsure all harness connectors are tor X-C2 (WP 0018, Figure 4) and reconnected. Verify correct operaall other pins in powertrain ECM tion of machine (TM 5-2410-241connector X-C2 (WP 0018, 10). Figure 4). 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 70-3 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove left platform access panel (WP 0207). 4. Disconnect parking brake switch connector X-C6 (WP 0018, Figure 44) from parking brake switch (WP 0018, Figure 45). 5. Using a digital multimeter (WP 0296), test for continuity between pin 11 on parking brake switch connector X-C6 (WP 0018, Figure 44) and machine ground.

1. If continuity is found, proceed to step 6. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

6. Push parking brake switch downward to the OFF position (TM 52410-241-10). 7. Using a digital multimeter (WP 0296), test for continuity between pin 3 and 11 on parking brake switch (WP 0018, Figure 45).

0020-4

1. If continuity is NOT found, proceed to step 8. 2. If continuity is found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 70-3 Parking Brake Switch Voltage Above Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

8. Pull parking brake switch upward to the ON position (TM 5-2410241-10). 9. Using a digital multimeter (WP 0296), test for continuity between pin 3 and 11 on parking brake switch (WP 0018, Figure 45).

1. If continuity is found, proceed to step 10. 2. If continuity is NOT found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

10. Pull parking brake switch upward to the ON position (TM 5-2410241-10). 11. Using a digital multimeter (WP 0296), test for continuity between pin 4 and 11 on parking brake switch (WP 0018, Figure 45).

1. If continuity is NOT found, proceed to step 12. 2. If continuity is found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

12. Push parking brake switch downward to the OFF position (TM 52410-241-10). 13. Using a digital multimeter (WP 0296), test for continuity between pin 4 and 11 on parking brake switch (WP 0018, Figure 45).

1. If continuity is found, proceed to step 14. 2. If continuity is not found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

14. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from the powertrain ECM. 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 35 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 3 on parking brake switch con0178). Ensure all harness connecnector X-C6 (WP 0018, Figure 44). tors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-5

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 70-3 Parking Brake Switch Voltage Above Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

16. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 17. pin 40 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 4 on parking brake switch con0178). Ensure all harness connecnector X-C6 (WP 0018, Figure 44). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 17. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 18. pin 35 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10). 18. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0175). pin 40 on powertrain ECM connecEnsure all harness connectors are tor X-C2 (WP 0018, Figure 4) and reconnected. Verify correct operaall other pins in powertrain ECM tion of machine (TM 5-2410-241connector X-C2 (WP 0018, 10). Figure 4). 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

70-4 Parking Brake Switch Voltage Below Normal

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013). 2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove left platform access panel (WP 0207). 4. Disconnect parking brake switch connector X-C6 (WP 0018, Figure 44) from parking brake switch (WP 0018, Figure 45). 5. Push parking brake switch downward to the OFF position (TM 52410-241-10).

0020-6

1. If active 70-4 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 70-4 Parking Brake Switch Voltage Below Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

6. Using a digital multimeter (WP 0296), test for continuity between pin 3 and 11 on parking brake switch (WP 0018, Figure 45).

1. If continuity is NOT found, proceed to step 7. 2. If continuity is found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

7. Pull parking brake switch upward to the ON position (TM 5-2410241-10). 8. Using a digital multimeter (WP 0296), test for continuity between pin 3 and 11 on parking brake switch (WP 0018, Figure 45).

1. If continuity is found, proceed to step 9. 2. If continuity is NOT found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

9. Pull parking brake switch upward to the ON position (TM 5-2410241-10). 10. Using a digital multimeter (WP 0296), test for continuity between pin 4 and 11 on parking brake switch (WP 0018, Figure 45).

1. If continuity is NOT found, proceed to step 11. 2. If continuity is found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

11. Push parking brake switch downward to the OFF position (TM 52410-241-10). 12. Using a digital multimeter (WP 0296), test for continuity between pin 4 and 11 on parking brake switch (WP 0018, Figure 45).

13. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from the powertrain ECM.

0020-7

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 70-4 Parking Brake Switch Voltage Below Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

14. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 15. pin 35 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 3 on parking brake switch con0178). Ensure all harness connecnector X-C6 (WP 0018, Figure 44). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 40 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 4 on parking brake switch con0178). Ensure all harness connecnector X-C6 (WP 0018, Figure 44). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 16. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 17. pin 35 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10). 17. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0175). pin 40 on powertrain ECM connecEnsure all harness connectors are tor X-C2 (WP 0018, Figure 4) and reconnected. Verify correct operaall other pins in powertrain ECM tion of machine (TM 5-2410-241connector X-C2 (WP 0018, 10). Figure 4). 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

168-3 Electrical System Voltage Above Normal

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 168-3 code is present, proceed to step 2. 2. If active 168-3 code is NOT present, proceed to step 3.

2. Inspect batteries for proper installation (WP 0155).

1. If problem is found, verify correct operation of machine (TM 5-2410241-10). 2. If problem is NOT found, proceed to step 3.

3. Start engine (TM 5-2410-241-10).

0020-8

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

168-3 Electrical System Volt- 4. Check for Diagnostic Codes or age Above Normal - ConEvent Codes (WP 0013). tinued

168-4 Electrical System Voltage Below Normal

CORRECTIVE ACTION 1. If active 168-3 code is present, proceed to step 5. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

5. Test alternator charging system (WP 0028).

1. If problem is found, verify correct operation of machine (TM 5-2410241-10). 2. If alternator charging system is OK, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 168-4 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Perform Battery Test (WP 0030).

1. If problem is found, verify correct operation of machine (TM 5-2410241-10). 2. If batteries are OK, proceed to step 3.

3. Inspect battery and alternator cables (WP 0029).

1. If problem is found, verify correct operation of machine (TM 5-2410241-10). 2. If batteries and alternator cables are OK, proceed to step 4.

0020-9

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

0020

CORRECTIVE ACTION

168-4 Electrical System Volt- 4. Turn ignition switch and battery age Below Normal - Condisconnect switch to OFF position tinued (TM 5-2410-241-10). 5. Open fuse panel door (Figure 1, Item 1) (TM 5-2410-241-10).

Figure 1. Fuse Panel Door.

0020-10

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

0020

CORRECTIVE ACTION

168-4 Electrical System Volt- 6. Remove ECM Fuse #19 (Figure 2, age Below Normal - ConItem 1) from fuse panel (Figure 2, tinued Item 2 (TM 5-2410-241-10).

Figure 2. ECM Fuse #19.

0020

7. Using a digital multimeter (WP 0296), test for continuity between blades of ECM Fuse #19.

1. If continuity is NOT found, replace ECM Fuse #19, and proceed to step 8. 2. If continuity is found, install ECM Fuse #19 on fuse panel, and proceed to step 10.

8. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10).

1. If ECM Fuse #19 is blown, proceed to step 31. 2. If code 168-4 returns, proceed to step 9. 3. If ECM Fuse #19 is OK and code 168-4 does not return, verify correct operation of machine (TM 52410-241-10).

9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 10. Remove left platform access panel (WP 0207). 11. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM.

0020-11

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

168-4 Electrical System Volt- 12. Turn ignition switch and battery age Below Normal - Condisconnect switch to ON position tinued (TM 5-2410-241-10). 13. Using a digital multimeter (WP 0296), measure for voltage between pin 31 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and pin 32 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If 24 volts or higher is found, proceed to step 14. 2. If voltage less than 24 volts is found, proceed to step 17.

14. Using a digital multimeter (WP 0296), measure for voltage between pin 38 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and pin 32 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If 24 volts or higher is found, proceed to step 15. 2. If voltage less than 24 volts is found, proceed to step 17.

15. Using a digital multimeter (WP 0296), measure for voltage between pin 39 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and pin 32 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If 24 volts or higher is found, proceed to step 16. 2. If voltage less than 24 volts is found, proceed to step 17.

16. Using a digital multimeter (WP 0296), measure for voltage between pin 47 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and pin 32 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If 24 volts or higher is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 2. If voltage less than 24 volts is found, proceed to step 17.

17. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 18. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33).

0020-12

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

168-4 Electrical System Volt- 19. Using a digital multimeter (WP 1. If continuity is found, proceed to age Below Normal - Con0296), test for continuity between step 20. tinued pin 31 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 1 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, Figure tors are reconnected. Verify cor34). rect operation of machine (TM 52410-241-10). 20. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 21. pin 38 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 1 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, Figure tors are reconnected. Verify cor34). rect operation of machine (TM 52410-241-10). 21. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 22. pin 39 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018 Figure 4) and steering control harness (WP pin 2 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, Figure tors are reconnected. Verify cor34). rect operation of machine (TM 52410-241-10). 22. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 23. pin 47 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018 Figure 4) and steering control harness (WP pin 2 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, Figure tors are reconnected. Verify cor34). rect operation of machine (TM 52410-241-10).

NOTE Pins 1 and 2 will have continuity to each other. 23. Using a digital multimeter (WP 0296), test for continuity between pin 2 on steering control harness connector X-C1 (WP 0018 Figure 34) and pins 3 through 70 on steering control harness connector X-C1 (WP 0018 Figure 34). 24. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22).

0020-13

3. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 4. If continuity is NOT found, proceed to step 24.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

168-4 Electrical System Volt- 25. Using a digital multimeter (WP age Below Normal - Con0296), test for continuity between tinued pin 21 on platform harness connector MA-C3 (WP 0018, Figure 21) and pin 1 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 26. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

26. Using a digital multimeter (WP 0296), test for continuity between pin 22 on platform harness connector MA-C3 (WP 0018, Figure 21) and pin 2 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 27. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

NOTE Pins 1 and 2 will have continuity to each other. 27. Using a digital multimeter (WP 0296), test for continuity between pin 2 on platform harness connector MA-C14 (WP 0018, Figure 33) and pins 3-70 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 28.

28. Remove ECM Fuse #19 (Figure 3, Item 1) from fuse panel (Figure 3, Item 2). (TM 5-2410-241-10). 29. Using a digital multimeter (WP 0296), test for continuity between pin 21 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and left cavity of ECM Fuse #19.

0020-14

1. If continuity is found, proceed to step 30. 2. If continuity is NOT found, replace fuse panel wiring harness (WP 0176). Install ECM Fuse #19 on fuse panel. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

168-4 Electrical System Volt- 30. Using a digital multimeter (WP age Below Normal - Con0296), test for continuity between tinued pin 22 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and left cavity of ECM Fuse #19.

Figure 3. ECM Fuse #19. 31. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 32. Remove ECM Fuse #19 (Figure 3, Item 1) from fuse panel (Figure 3, Item 2). (TM 5-2410-241-10). 33. Remove left platform access panel (WP 0207). 34. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22).

0020-15

0020

CORRECTIVE ACTION 1. If continuity is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace fuse panel wiring harness (WP 0176). Install ECM Fuse #19 on fuse panel. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

168-4 Electrical System Volt- 35. Using a digital multimeter (WP age Below Normal - Con0296), test for continuity between tinued pin 21 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and machine ground.

1. If continuity is NOT found, proceed to step 36. 2. If continuity is found, replace fuse panel wiring harness (WP 0181). Replace ECM Fuse #19 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

36. Using a digital multimeter (WP 0296), test for continuity between pin 22 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and machine ground.

1. If continuity is NOT found, proceed to step 37. 2. If continuity is found, replace fuse panel wiring harness (WP 0181). Replace ECM Fuse #19 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

37. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 38. Using a digital multimeter (WP 0296), test for continuity between pin 21 on platform harness connector MA-C3 (WP 0018, Figure 21) and all other pins in platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is NOT found, proceed to step 39. 2. If continuity is found, replace platform harness (WP 0209). Replace ECM Fuse #19 (TM 5-2410-24110). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

39. Using a digital multimeter (WP 0296), test for continuity between pin 21 on platform harness connector MA-C3 (WP 0018, Figure 21) and machine ground.

1. If continuity is NOT found, proceed to step 40. 2. If continuity is found, replace platform harness (WP 0209). Replace ECM Fuse #19 (TM 5-2410-24110). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-16

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

168-4 Electrical System Voltage Below Normal - Continued

40. Using a digital multimeter (WP 0296), test for continuity between pin 22 on platform harness connector MA-C3 (WP 0018, Figure 21) and all other pins in platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is NOT found, proceed to step 41. 2. If continuity is found, replace platform harness (WP 0209). Replace ECM Fuse #19 (TM 5-2410-24110). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

41. Using a digital multimeter (WP 0296), test for continuity between pin 22 on platform harness connector MA-C3 (WP 0018, Figure 21) and machine ground.

1. If continuity is NOT found, proceed to step 42. 2. If continuity is found, replace platform harness (WP 0209). Replace ECM Fuse #19 (TM 5-2410-24110). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

42. Using a digital multimeter (WP 0296), test for continuity between pin 1 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 43. 2. If continuity is found, replace platform harness (WP 0209). Replace ECM Fuse #19 (TM 5-2410-24110). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

43. Using a digital multimeter (WP 0296), test for continuity between pin 2 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 44. 2. If continuity is found, replace platform harness (WP 0209). Replace ECM Fuse #19 (TM 5-2410-24110). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

44. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 45. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from ECM.

0020-17

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 168-4 Electrical System Voltage Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

46. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 47. pin 31 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Replace ECM Fuse #19 connector X-C2 (WP 0018, Figure (TM 5-2410-241-10). Ensure all 4). harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 47. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 48. pin 31 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP machine ground. 0178). Replace ECM Fuse #19 (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 48. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 49. pin 31 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all pins in powertrain ECM connec0178). Replace ECM Fuse #19 tor X-C 3 (WP 0018, Figure 3). (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 49. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 50. pin 38 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Replace ECM Fuse #19 connector X-C2 (WP 0018, (TM 5-2410-241-10). Ensure all Figure 4). harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 50. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 51. pin 38 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP machine ground. 0178). Replace ECM Fuse #19 (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-18

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 168-4 Electrical System Voltage Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

51. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 52. pin 38 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all pins in powertrain ECM connec0178). Replace ECM Fuse #19 tor X-C 3 (WP 0018, Figure 3). (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 52. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 53. pin 39 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Replace ECM Fuse #19 connector X-C2 (WP 0018, (TM 5-2410-241-10). Ensure all Figure 4). harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 53. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 54. pin 39 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP machine ground. 0178). Replace ECM Fuse #19 (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 54. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 55. pin 39 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all pins in powertrain ECM connec0178). Replace ECM Fuse #19 tor X-C 3 (WP 0018, Figure 3). (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 55. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 56. pin 47 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Replace ECM Fuse #19 connector X-C2 (WP 0018, (TM 5-2410-241-10). Ensure all Figure 4). harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-19

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

168-4 Electrical System Volt- 56. Using a digital multimeter (WP 1. If continuity is NOT found, proceed age Below Normal - Con0296), test for continuity between to step 57. tinued pin 47 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP machine ground. 0178). Replace ECM Fuse #19 (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 57. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0180). pin 47 on powertrain ECM connecReplace ECM Fuse #19 (TM 5tor X-C2 (WP 0018, Figure 4) and 2410-241-10). Ensure all harness all pins in powertrain ECM connecconnectors are reconnected. Vertor X-C 3 (WP 0018, Figure 3). ify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, replace steering control harness (WP 0178). Replace ECM Fuse #19 (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 177-3 Transmission Oil Temperature Sensor (Sump) Voltage Above Normal

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 177-3 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove lower rear bottom guard (WP 0199). 4. Disconnect transmission oil temperature sensor connector V-C8 (WP 0018, Figure 46) from transmission temperature sensor. 5. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 6. Using a digital multimeter (WP 0296), measure for voltage between pin 1 and pin 2 on transmission oil temperature sensor connector V-C8 (WP 0018, Figure 46).

0020-20

1. If 4.5-5.5 volts is found, proceed to step 7. 2. If 4.5-5.5 volts is NOT found, proceed to step 13.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

177-3 Transmission Oil Tem- 7. Turn ignition switch and battery perature Sensor (Sump) Voltdisconnect switch to OFF position age Above Normal (TM 5-2410-241-10). Continued 8. Install jumper wire between pin 1 and pin 2 on transmission oil temperature sensor connector V-C8 (WP 0018, Figure 46). 9. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 10. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 177-4 code is present, proceed to step 11. 2. If active 177-3 code is present, proceed to step 13.

11. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 12. Remove jumper wire between pin 1 and pin 2 on transmission oil temperature sensor connector VC8 (WP 0018, Figure 46).

Replace transmission temperature sensor (WP 0146). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

13. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). Remove jumper wire between pin 1 and pin 2 on transmission oil temperature sensor connector V-C8 (WP 0018, Figure 46). 14. Disconnect engine harness (engine to platform) connector VC1 (WP 0018, Figure 12) from platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11). 15. Using a digital multimeter (WP 0296), test for continuity between pin 1 on transmission oil temperature sensor connector V-C8 (WP 0018, Figure 46) and pin 38 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12).

0020-21

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

177-3 Transmission Oil Temperature Sensor (Sump) Voltage Above Normal Continued

16. Using a digital multimeter (WP 0296), test for continuity between pin 2 on transmission oil temperature sensor connector V-C8 (WP 0018, Figure 46) and pin 35 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, proceed to step 17. 2. If continuity is NOT found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

17. Using a digital multimeter (WP 0296), test for continuity between pin 38 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and all other pins in engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is NOT found, proceed to step 18.

18. Using a digital multimeter (WP 0296), test for continuity between pin 35 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and all other pins in engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is NOT found, proceed to step 19.

19. Remove left platform access panel (WP 0207). 20. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 21. Using a digital multimeter (WP 0296), test for continuity between pin 45 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin 38 on platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11).

0020-22

1. If continuity is found, proceed to step 22. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 177-3 Transmission Oil Temperature Sensor (Sump) Voltage Above Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

22. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 23. pin 18 on platform harness con2. If continuity is NOT found, replace nector MA-C14 (WP 0018, Figure platform harness (WP 0209). 33) and pin 35 on platform harEnsure all harness connectors are ness (platform to engine) connecreconnected. Verify correct operator MA-C22 (WP 0018, Figure 11). tion of machine (TM 5-2410-24110). 23. Using a digital multimeter (WP 0296), test for continuity between pin 45 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 24. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

24. Using a digital multimeter (WP 0296), test for continuity between pin 18 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 25. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

25. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from ECM. 26. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from ECM. 27. Using a digital multimeter (WP 0296), test for continuity between pin 45 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 29 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 28. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

28. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 29. pin 29 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10).

0020-23

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

177-3 Transmission Oil Tem- 29. Using a digital multimeter (WP perature Sensor (Sump) Volt0296), test for continuity between age Above Normal pin 18 on steering control harness Continued connector X-C1 (WP 0018, Figure 34) and pin 22 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

CORRECTIVE ACTION 1. If continuity is found, proceed to step 30. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

30. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0180). pin 22 on powertrain ECM connecEnsure all harness connectors are tor X-C3 (WP 0018, Figure 3) and reconnected. Verify correct operaall other pins in powertrain ECM tion of machine (TM 5-2410-241connector X-C3 (WP 0018, 10). Figure 3). 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 177-4 Transmission Oil Temperature Sensor (Sump) Voltage Below Normal

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 177-3 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove lower rear bottom guard (WP 0199). 4. Disconnect transmission oil temperature sensor connector V-C8 (WP 0018, Figure 46) from transmission temperature sensor. 5. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 6. Check for Diagnostic Codes or Event Codes (WP 0013).

0020-24

1. If active 177-3 code is present, replace transmission temperature sensor (WP 0146). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 177-4 code is present, proceed to step 7.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

177-4 Transmission Oil Temperature Sensor (Sump) Voltage Below Normal Continued

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

CORRECTIVE ACTION

8. Disconnect engine harness (engine to platform) connector VC1 (WP 0018, Figure 12) from platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11). 9. Using a digital multimeter (WP 0296), test for continuity between pin 1 on transmission oil temperature sensor connector V-C8 (WP 0018, Figure 46) and pin 38 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, proceed to step 10. 2. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

10. Using a digital multimeter (WP 0296), test for continuity between pin 2 on transmission oil temperature sensor connector V-C8 (WP 0018, Figure 46) and pin 35 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, proceed to step 11. 2. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

11. Using a digital multimeter (WP 0296), test for continuity between pin 38 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and all other pins in engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is NOT found, proceed to step 12.

12. Using a digital multimeter (WP 0296), test for continuity between pin 35 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and all other pins in engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is NOT found, proceed to step 13.

13. Remove left platform access panel (WP 0207).

0020-25

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 177-4 Transmission Oil Temperature Sensor (Sump) Voltage Below Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

14. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 45 on platform harness con2. If continuity is NOT found, replace nector MA-C14 (WP 0018, Figure platform harness (WP 0209). 33) and pin 38 on platform harEnsure all harness connectors are ness (platform to engine) connecreconnected. Verify correct operator MA-C22 (WP 0018, Figure 11). tion of machine (TM 5-2410-24110). 16. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 17. pin 18 on platform harness con2. If continuity is NOT found, replace nector MA-C14 (WP 0018, Figure platform harness (WP 0209). 33) and pin 35 on platform harEnsure all harness connectors are ness (platform to engine) connecreconnected. Verify correct operator MA-C22 (WP 0018, Figure 11). tion of machine (TM 5-2410-24110). 17. Using a digital multimeter (WP 0296), test for continuity between pin 45 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 18. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

18. Using a digital multimeter (WP 0296), test for continuity between pin 18 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 19. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

19. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from ECM. 20. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from ECM.

0020-26

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

177-4 Transmission Oil Temperature Sensor (Sump) Voltage Below Normal Continued

21. Using a digital multimeter (WP 0296), test for continuity between pin 45 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 29 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 22. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

22. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 23. pin 29 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10). 23. Using a digital multimeter (WP 0296), test for continuity between pin 18 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 22 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 24. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

24. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0175). pin 22 on powertrain ECM connecEnsure all harness connectors are tor X-C3 (WP 0018, Figure 3) and reconnected. Verify correct operaall other pins in powertrain ECM tion of machine (TM 5-2410-241connector X-C3 (WP 0018, 10). Figure 3). 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 247-9 Data Link Abnormal Update Rate

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013). 2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from ECM.

0020-27

1. If active 247-9 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 247-9 Data Link Abnormal Update Rate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

4. Disconnect platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) from engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12). 5. Disconnect Resistor CAN/Data Link (WP 0018, Figure 30) from Engine ECM Resistor - CAN/Data Link V-C12 (WP 0018, Figure 29). 6. Using a digital multimeter (WP 1. If resistance of 108 to 132 ohms is 0296), measure resistance found, proceed to step 7. between pin A and pin B on Resis- 2. If resistance of 108 to 132 ohms is tor CAN/Data Link (WP 0018, NOT found, replace CAN/Data Figure 30). Link Resistor. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 7. Using a digital multimeter (WP 0296), test for continuity between pin 36 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and pin 50 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 8. 2. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

8. Using a digital multimeter (WP 0296), test for continuity between pin 37 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and pin 34 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 9. 2. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

9. Using a digital multimeter (WP 0296), test for continuity between pin A on Engine ECM Resistor CAN/Data Link V-C12 (WP 0018, Figure 29) and pin 50 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 10. 2. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020-28

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 247-9 Data Link Abnormal Update Rate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Using a digital multimeter (WP 0296), test for continuity between pin B on Engine ECM Resistor CAN/Data Link V-C12 (WP 0018, Figure 29) and pin 34 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 11. 2. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

11. Using a digital multimeter (WP 0296), test for continuity between pin 34 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins in engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is NOT found, proceed to step 12.

12. Using a digital multimeter (WP 0296), test for continuity between pin 50 on engine ECM connector V-C4 (WP 0018, Figure 1) and all other pins in engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is NOT found, proceed to step 13.

13. Remove left platform access panel (WP 0207). 14. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 15. Using a digital multimeter (WP 0296), test for continuity between pin 36 on platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) and pin 20 on platform harness connector MA-C14 (WP 0018, Figure 33).

0020-29

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

247-9 Data Link Abnormal Update Rate - Continued

16. Using a digital multimeter (WP 0296), test for continuity between pin 37 on platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) and pin 21 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 17. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

17. Using a digital multimeter (WP 0296), test for continuity between pin 21 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 18.

18. Using a digital multimeter (WWP 0296), test for continuity between pin 20 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 19.

19. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 20. Disconnect Resistor Can/Data Link (WP 0018, Figure 32) from Powertrain ECM Resistor - CAN/ Data Link X-C10 (WP 0018, Figure 31). 21. Using a digital multimeter (WP 1. If resistance of 108 to 132 ohms is 0296), measure resistance found, proceed to step 22. between pin A and pin B on Resis- 2. If resistance of 108 to 132 ohms is tor CAN/Data Link (WP 0018, FigNOT found, replace CAN/Data ure 32). Link Resistor. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-30

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

247-9 Data Link Abnormal Update Rate - Continued

22. Using a digital multimeter (WP 0296), test for continuity between pin 20 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 67 powertrain ECM harness connector X-C3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 23. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

23. Using a digital multimeter (WP 0296), test for continuity between pin 21 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 68 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 24. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

24. Using a digital multimeter (WP 0296), test for continuity between pin A on Powertrain ECM Resistor - CAN/Data Link X-C10 (WP 0018, Figure 31) and pin 67 on powertrain ECM connector XC3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 25. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

25. Using a digital multimeter (WP 0296), test for continuity between pin B on Powertrain ECM Resistor - CAN/Data Link X-C10 (WP 0018, Figure 31) and pin 68 on powertrain ECM connector XC3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 26. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

26. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between steering control harness (WP pin 68 on powertrain ECM connec0178). Ensure all harness connector X-C3 (WP 0018, Figure 3) and tors are reconnected. Verify corall other pins in powertrain ECM rect operation of machine (TM 5connector X-C3 (WP 0018, 2410-241-10). Figure 3). 2. If continuity is NOT found, proceed to step 27.

0020-31

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

247-9 Data Link Abnormal Update Rate - Continued

27. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between steering control harness (WP pin 67 on powertrain ECM connec0178). Ensure all harness connector X-C3 (WP 0018, Figure 3) and tors are reconnected. Verify corall other pins in powertrain ECM rect operation of machine (TM 5connector X-C3 (WP 0018, 2410-241-10). Figure 3). 2. If continuity is NOT found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

298-2 Service Brake Pedal Switch Data Erratic, Intermittent, or Incorrect

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 298-2 code is present, proceed to step 4. 2. If active 298-2 code is NOT present, proceed to step 2.

2. Fully depress and hold brake pedal down. 3. Check for Diagnostic Codes or Event Codes (WP 0013).

4. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0020-32

1. If active 298-2 code is present, proceed to step 4. 2. If no active code is present, the problem does NOT exist at this time. Resume normal operation.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 298-2 Service Brake Pedal Switch Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

5. Open fuse panel door (Figure 4, Item 1) (TM 5-2410-241-10).

Figure 4. Fuse Panel Door.

0020-33

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

298-2 Service Brake Pedal Switch Data Erratic, Intermittent, or Incorrect - Continued

6. Remove Fuse #15 (Figure 5, Item 1) from fuse panel (Figure 5, Item 2).

Figure 5. Fuse #15.

0020

CORRECTIVE ACTION

0020

7. Using a digital multimeter (WP 0296), test for continuity between blades of Fuse #15.

1. If continuity is NOT found, replace Fuse #15, and proceed to step 8. 2. If continuity is found, install Fuse #15 on fuse panel, and proceed to step 9.

8. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10).

1. If Fuse #15 is blown, proceed to step 25. 2. If active 298-2 code is present, proceed to step 9. 3. If Fuse #15 is OK, and code 298-2 is NOT present, verify correct operation of machine (TM 5-2410241-10).

0020-34

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 298-2 Service Brake Pedal Switch Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

NOTE Do not remove MSD or turn ignition switch and battery disconnect switch to OFF position after adjustment. 9. Adjust service brake pedal limit switch (WP 0037). 10. Fully depress and release service brake pedal. 11. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 298-2 code is present, proceed to step 12. 2. If code 298-2 is NOT present, verify correct operation of machine (TM 5-2410-241-10).

12. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 13. Disconnect dash harness brake switch connector E-C23 (WP 0018, Figure 47) from service brake switch harness connector KK-C1 (WP 0018, Figure 48) (WP 0174). 14. Fully depress and hold service brake pedal down. 15. Using a digital multimeter (WP 0296), test for continuity between pin 1 and 2 on service brake switch harness connector KK-C1 (WP 0018, Figure 48). 16. Remove service brake switch (WP 0174).

0020-35

1. If continuity is found, proceed to step 18. 2. If continuity is NOT found, proceed to step 16.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued.

0020

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

298-2 Service Brake Pedal Switch Data Erratic, Intermittent, or Incorrect - Continued

17. Using a digital multimeter (WP 0296), test for continuity between gray wire (Figure 6, Item 2) and red wire (Figure 6, Item 1) while depressing the service brake limit switch.

1. If continuity is found, replace service brake harness (WP 0174). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is NOT found, replace service brake limit switch (WP 0174). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

Figure 6. Brake Switch Wires. 18. Install a jumper between pin 1 and pin 2 on dash harness brake switch connector E-C23 (WP 0018, Figure 47). 19. Remove left platform access panel (WP 0207). 20. Disconnect ECM harness connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 21. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22).

0020-36

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

298-2 Service Brake Pedal Switch Data Erratic, Intermittent, or Incorrect - Continued

22. Using a digital multimeter (WP 0296), test for continuity between pin 5 on ECM harness connector X-C3 (WP 0018, Figure 3) and pin 13 on platform harness connector MA-C3 (WP 0018, Figure 22).

1. If continuity is found, replace fuse panel wiring harness (WP 0181). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is NOT found, proceed to step 23.

23. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 24. Using a digital multimeter (WP 0296), test for continuity between pin 17 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin 13 on platform harness connector MA-C3 (WP 0018, Figure 22).

1. If continuity is found, replace steering control wiring harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

25. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 26. Disconnect service brake dump solenoid connector MA-C6 (WP 0018, Figure 69) from secondary brake dump solenoid (WP 0018, Figure 70). 27. Remove left platform access panel (WP 0207). 28. Disconnect ECM harness connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 29. Using a digital multimeter (WP 0296), test for continuity between pin 5 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and machine ground.

0020-37

1. If continuity is found, proceed to step 30. 2. If continuity is NOT found, proceed to step 32.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

298-2 Service Brake Pedal Switch Data Erratic, Intermittent, or Incorrect - Continued

30. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 31. Using a digital multimeter (WP 0296), test for continuity between pin 17 on platform harness connector MA-C14 (WP 0018, Figure 33) and machine ground.

CORRECTIVE ACTION

1. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

32. Fully depress and hold service 1. If continuity is found, proceed to brake pedal down. Using a digital step 33. multimeter (WP 0296), test for 2. If continuity is NOT found, replace continuity between pin 5 on powerservice brake dump solenoid (WP train ECM connector X-C3 (WP 0147). Ensure all harness connec0018, Figure 3) and machine tors are reconnected. Verify corground. rect operation of machine (TM 52410-241-10). 33. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22). 34. Using a digital multimeter (WP 0296), test for continuity between pin 13 on platform harness connector MA-C3 (WP 0018, Figure 21) and machine ground.

0020-38

1. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 2. If continuity is NOT found, replace fuse panel wiring harness (WP 0181). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10)

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-8 Transmission Lever Position Sensor Out of Range

TEST OR INSPECTION

CORRECTIVE ACTION

1. Ensure parking brake switch isin the OFF position (TM 5-2410-24110). 2. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 299-8 code is present, proceed to step 3. 2. If no active code is present, the problem does NOT exist at this time. Resume normal operation.

3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Remove left platform access panel (WP 0207). 5. Disconnect Forward/Neutral/ Reverse (FNR) sensor connector X-C8 (WP 0018, Figure 49) from the FNR sensor (WP 0237). 6. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 7. Using a digital multimeter 1. If voltage of 22 to 25 volts is found, (WP 0296), measure for voltage proceed to step 8. between pins 1 and 2 on FNR sen- 2. If less than 22 volts is found, prosor connector X-C8 (WP 0018, ceed to step 9. Figure 49). 8. Using a digital multimeter 1. If voltage of 4.5 to 5.5 volts is (WP 0296), measure for voltage found, replace FNR sensor between pins 3 and 2 on FNR sen(WP 0237). Ensure all harness sor connector X-C8 (WP 0018, connectors are reconnected. VerFigure 49). ify correct operation of machine (TM 5-2410-241-10). 2. If less than 4.5 volts is found, proceed to step 9. 9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0020-39

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-8 Transmission Lever Position Sensor Out of Range - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

10. Open fuse panel door (Figure 7, Item 1) (TM 5-2410-241-10).

Figure 7. Fuse Panel Door.

0020-40

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-8 Transmission Lever Position Sensor Out of Range - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

11. Remove Fuse # 5 (Figure 8, Item 1) from fuse panel (Figure 8, Item 2) (TM 5-2410-241-10).

Figure 8. Fuse #5. 12. Using a digital multimeter (WP 0296), test for continuity between blades of Fuse #5.

0020

1. If continuity is found, install Fuse #5 on fuse panel, and proceed to step 13. 2. If continuity is NOT found, replace Fuse #5, and proceed to step 24.

13. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 14. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 15. pin 6 on steering control harness 2. If continuity is NOT found, replace connector X-C1 (WP 0018, Figure steering control harness (WP 34) and pin 1 on FNR sensor con0178). Ensure all harness connecnector X-C8 (WP 0018, Figure 49). tors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-41

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-8 Transmission Lever Position Sensor Out of Range - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

15. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22). 16. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 17. pin 3 on platform harness connec- 2. If continuity is NOT found, replace tor MA-C3 (WP 0018, Figure 21) platform harness (WP 0209). and pin 6 on platform harness conEnsure all harness connectors are nector MA-C14 (WP 0018, Figure reconnected. Verify correct opera33). tion of machine (TM 5-2410-24110). 17. Remove ECM Fuse #5 (Figure 9, Item 1) from fuse panel (Figure 9, Item 2). 18. Using a digital multimeter (WP 0296), test for continuity between pin 3 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and left cavity of ECM Fuse #5 (Figure 9, Item 1) located in fuse panel (Figure 9, Item 2).

Figure 9. Fuse #5.

0020-42

1. If continuity is found, proceed to step 19. 2. If continuity is NOT found, replace fuse panel wiring harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-8 Transmission Lever Position Sensor Out of Range - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

19. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from ECM. 20. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from ECM. 21. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 22. pin 13 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 2 on FNR sensor connector X0178). Ensure all harness connecC8 (WP 0018, Figure 49). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 22. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 23. pin 33 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP pin 3 on FNR sensor connector X0178). Ensure all harness connecC8 (WP 0018, Figure 49). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 23. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0175). pin 33 on powertrain ECM connecEnsure all harness connectors are tor X-C3 (WP 0018, Figure 3) and reconnected. Verify correct operaall other pins in powertrain ECM tion of machine (TM 5-2410-241connector X-C3 (WP 0018, 10). Figure 3). 2. If continuity is found, replace steering control harness (WP 0178) Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 24. Disconnect parking brake switch connector X-C6 (WP 0018, Figure 44) from parking brake switch (WP 0018, Figure 45). 25. Disconnect dash harness brake position sensor connector E-C27 (WP 0018, Figure 52) from brake pedal position sensor (WP 0258). 26. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10)

0020-43

1. If Fuse #5 is OK, proceed to step 27. 2. If Fuse #5 is blown, proceed to step 33.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-8 Transmission Lever Position Sensor Out of Range - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

27. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 28. Reconnect dash harness brake position sensor connector E-C27 (WP 0018, Figure 52) on brake pedal position sensor (WP 0258). 29. Turn ignition switch and battery disconnect switch to ON position and operate brake pedal several times (TM 5-2410-241-10).

1. If Fuse #5 is OK, proceed to step 30. 2. If Fuse #5 is blown, replace brake pedal position sensor (WP 0258). Replace Fuse #5 (TM 5-2410-24110). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

30. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 31. Reconnect parking brake switch connector X-C6 (WP 0018, Figure 44) on parking brake switch (WP 0018, Figure 45). 1. If Fuse #5 is OK, replace forward 32. Turn ignition switch and battery neutral reverse sensor (WP 0237). disconnect switch to ON position Ensure all harness connectors are and operate parking brake switch reconnected. Verify correct operaseveral times (TM 5-2410-241-10). tion of machine (TM 5-2410-24110). 2. If Fuse #5 is blown, replace parking brake switch (WP 0237). Replace Fuse #5 (TM 5-2410-24110). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 33. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0020-44

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-8 Transmission Lever Position Sensor Out of Range - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

34. Remove Fuse # 5 (Figure 10, Item 1) from fuse panel (Figure 10, Item 2) (TM 5-2410-241-10).

Figure 10. Fuse #5.

0020

35. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22). 36. Using a digital multimeter (WP 0296), test for continuity between pin 3 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and machine ground.

37. Disconnect platform harness connector MA-C14 (WP 0018, Figure 33) from steering control harness connector X-C1 (WP 0018, Figure 34). 38. Disconnect platform harness connector MA-C13 from RH console harness (WP 0018, Figure 158).

0020-45

1. If continuity is NOT found, proceed to step 37. 2. If continuity is found, replace fuse panel wiring harness (WP 0181). Replace Fuse #5 (TM 5-2410-24110). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-8 Transmission Lever Position Sensor Out of Range - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

39. Using a digital multimeter (WP 0296), test for continuity between pin 3 on platform harness connector MA-C3 (WP 0018, Figure 21) and all other pins in platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is NOT found, proceed to step 40. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

40. Using a digital multimeter (WP 0296), test for continuity between pin 3 on platform harness connector MA-C3 (WP 0018, Figure 21) and machine ground.

1. If continuity is NOT found, proceed to step 41. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

41. Using a digital multimeter (WP 0296), test for continuity between pin 6 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 42. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

42. Using a digital multimeter (WP 0296), test for continuity between pin 6 on platform harness connector MA-C14 (WP 0018, Figure 33) and machine ground.

1. If continuity is NOT found, proceed to step 43. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-46

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-8 Transmission Lever Position Sensor Out of Range - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

43. Using a digital multimeter (WP 0296), test for continuity between pin 6 on steering control harness connector X-C1 (WP 0018, Figure 34) and all other pins in steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is NOT found, proceed to step 44. 2. If continuity is found, replace steering control harness (WP 0178). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

44. Using a digital multimeter (WP 0296), test for continuity between pin 6 on steering control harness connector X-C1 (WP 0018, Figure 34) and machine ground.

1. If continuity is NOT found, proceed to step 45. 2. If continuity is found, replace steering control harness (WP 0178). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

45. Using a digital multimeter (WP 0296), test for continuity between pin 2 on platform harness connector MA-C13 (WP 0018, Figure 158) and all other pins in platform harness connector MA-C13 (WP 0018, Figure 158).

1. If continuity is NOT found, proceed to step 46. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

46. Using a digital multimeter (WP 0296), test for continuity between pin 2 on platform harness connector MA-C13 (WP 0018, Figure 158) and machine ground.

1. If continuity is NOT found, replace right cab switch panel harness (WP 0179). Replace Fuse #5 (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-47

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-13 Transmission Lever Position Sensor Out of Calibration

TEST OR INSPECTION 1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

0020

CORRECTIVE ACTION 1. If active 299-13 code is present, proceed to step 2. 2. If no active code is present, the problem does NOT exist at this time. Resume normal operation.

2. Select Powertrain D7 ECM on the left side of screen. 3. Select Service (Figure 11, Item 1), Calibrations (Figure 11, Item 2), FNR Shifter Sensor Calibrations (Figure 11, Item 3).

Figure 11. Calibration Selection.

0020-48

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-13 Transmission Lever Position Sensor Out of Calibration - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

4. Set up Calibration conditions: a. Apply the parking brake (Figure 12, Item 1) (TM 52410-241-10). b. Engine speed should be 0 rpm (Figure 12, Item 1) (TM 52410-241-10). 5. When setup conditions are met, select NEXT (Figure 12, Item 2) button.

Figure 12. Calibration Setup.

0020-49

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-13 Transmission Lever Position Sensor Out of Calibration - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

6. Place shift lever in F position (Figure 13, Item 1) (TM 5-2410-24110).

Figure 13. Calibrating Forward Position.

0020-50

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-13 Transmission Lever Position Sensor Out of Calibration - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

7. Move shift lever to the N position (Figure 14, Item 1) (TM 5-2410241-10).

Figure 14. Calibrating Neutral Position.

0020-51

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-13 Transmission Lever Position Sensor Out of Calibration - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

8. Move shift lever to R position (Figure 15, Item 1) (TM 5-2410-24110).

Figure 15. Calibrating Reverse Position.

0020-52

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-13 Transmission Lever Position Sensor Out of Calibration - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

9. Move the shift lever to the N position (Figure 16, Item 1) (TM 52410-241-10).

Figure 16. Calibrating Neutral Position.

0020-53

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 299-13 Transmission Lever Position Sensor Out of Calibration - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

10. Repeat steps 6 through 9.

11. Select FINISH (Figure 17, Item 1) button.

Figure 17. Calibration Finish. 12. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 13. Remove MSD (WP 0016).

0020-54

Verify correct operation of machine (TM 5-2410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 368-2 Autoshift Switch Data Erratic, Intermittent, or Incorrect

TEST OR INSPECTION 1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

0020

CORRECTIVE ACTION 1. If active 368-2 code is present, proceed to step 4. 2. If active 368-2 code is NOT present, proceed to step 2.

2. Activate Auto Shift Switch (TM 52410-241-10). 3. Check for Diagnostic Codes or Event Codes (WP 0013) (Figure 18, Item 1).

1. If active 368-2 code is present, proceed to step 4. 2. If no active code is present, the problem does NOT exist at this time. Resume normal operation.

Figure 18. Diagnostic Codes.

0020

4. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 5. Remove left platform access panel (WP 0207). 6. Disconnect bi-directional mode switch connector E-C11 (WP 0018, Figure 50) from auto shift switch. 7. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 8. Using a digital multimeter (WP 0296), measure for voltage between pins A and C on bi-directional mode switch connector EC11 (WP 0018, Figure 50).

0020-55

1. If voltage of 12.5 to 13.5 volts is found, proceed to step 9. 2. If voltage of 12.5 to 13.5 volts is NOT found, proceed to step 10.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 368-2 Autoshift Switch Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

9. Using a digital multimeter (WP 0296), measure for voltage between pins B and C on bi-directional mode switch connector EC11 (WP 0018, Figure 50).

1. If voltage of 12.5 to 13.5 volts is found, replace auto shift switch (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If voltage of 12.5 to 13.5 volts is NOT found, proceed to step 10.

10. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 11. Remove left platform access panel (WP 0207). 12. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 13. Using a digital multimeter (WP 0296), test for continuity between pin A on dash harness autoshift switch connector E-C11 (WP 0018, Figure 50) and pin 14 on platform harness connector MAC14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 14. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

14. Using a digital multimeter (WP 0296), test for continuity between pin B on dash harness autoshift switch connector E-C11 (WP 0018, Figure 50) and pin 15 on platform harness connector MAC14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

15. Using a digital multimeter (WP 0296), test for continuity between pin 14 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 16. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-56

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 368-2 Autoshift Switch Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

16. Using a digital multimeter (WP 0296), test for continuity between pin 15 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 17. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

17. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 18. pin C on dash harness autoshift 2. If continuity is NOT found, replace switch connector E-C11 (WP platform harness (WP 0209). 0018, Figure 50) and pin 4 on platEnsure all harness connectors are form harness connector MA-C14 reconnected. Verify correct opera(WP 0018, Figure 33). tion of machine (TM 5-2410-24110). 18. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 19. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 20. pin 42 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 14 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 20. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 21. pin 41 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 15 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, Figure tors are reconnected. Verify cor34). rect operation of machine (TM 52410-241-10). 21. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 22. pin 41 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10).

0020-57

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 368-2 Autoshift Switch Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

22. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 23. pin 42 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10). 23. Using a digital multimeter (WP 1. If continuity is found, replace pow0296), test for continuity between ertrain ECM (WP 0175). Ensure all pin 32 on powertrain ECM connecharness connectors are recontor X-C2 (WP 0018, Figure 4) and nected. Verify correct operation of pin 4 on steering control harness machine (TM 5-2410-241-10). connector X-C1 (WP 0018, 2. If continuity is NOT found, replace Figure 34). steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

444-3 Starter Motor Relay Voltage Above Normal

1. Connect MSD and select Power1. If active 444-3 code is present, train D7 ECM and Check for Diagproceed to step 2. nostic Codes or event codes (WP 2. If no active codes are present, the 0013). problem does NOT exist at this time. Resume normal operation. 2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove left platform access panel (WP 0207). 4. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 5. Using a digital multimeter (WP 0296), measure resistance between pin 7 and 8 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If resistance is 24 to 30 ohms, proceed to step 6. 2. If resistance is NOT 24 to 30 ohms, proceed to step 7.

6. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0175). pin 7 on powertrain ECM connecEnsure all harness connectors are tor X-C3 (WP 0018, Figure 3) and reconnected. Verify correct operaall other pins (except pin 8) in powtion of machine (TM 5-2410-241ertrain ECM connector X-C3 (WP 10). 0018, Figure 3). 2. If continuity is found, proceed to step 7.

0020-58

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 444-3 Starter Motor Relay Voltage Above Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

7. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 8. Using a digital multimeter (WP 0296), test for continuity between pin 66 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 7 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 9. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

9. Using a digital multimeter (WP 0296), test for continuity between pin 67 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 8 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 10. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

10. Using a digital multimeter (WP 0296), test for continuity between pin 8 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 11. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-59

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 444-3 Starter Motor Relay Voltage Above Normal Continued

0020

TEST OR INSPECTION

CORRECTIVE ACTION

11. Using a digital multimeter (WP 0296), test for continuity between pin 7 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 12. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

12. Open fuse panel door (Figure 19, Item 1) (TM 5-2410-241-10).

Figure 19. Fuse Panel Door.

0020

13. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22). 14. Using a digital multimeter (WP 0296), test for continuity between pin 4 on platform harness connector MA-C3 (WP 0018, Figure 21) and pin 66 on platform harness connector MA-C14 (WP 0018, Figure 33).

0020-60

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 444-3 Starter Motor Relay Voltage Above Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 5 on platform harness connec- 2. If continuity is NOT found, replace tor MA-C3 (WP 0018, Figure 21) platform harness (WP 0209). and pin 67 on platform harness Ensure all harness connectors are connector MA-C14 (WP 0018, Figreconnected. Verify correct operaure 33). tion of machine (TM 5-2410-24110). 16. Using a digital multimeter (WP 0296), test for continuity between pin 4 on platform harness connector MA-C3 (WP 0018, Figure 21) and all other pins in platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is NOT found, proceed to step 17. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

17. Using a digital multimeter (WP 0296), test for continuity between pin 5 on platform harness connector MA-C3 (WP 0018, Figure 21) and all other pins in platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is NOT found, proceed to step 18. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

18. Remove fuse panel (WP 0176). 19. Disconnect fuse panel harness start relay connector A-C3 (WP 0018, Figure 51) from starter relay (WP 0176). 20. Using a digital multimeter (WP 0296), test for continuity between pin 4 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and pin 1 on fuse panel harness start relay connector A-C3 (WP 0018, Figure 51).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace fuse panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

21. Using a digital multimeter (WP 0296), test for continuity between pin 5 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and pin 2 on fuse panel harness start relay connector A-C3 (WP 0018, Figure 51).

1. If continuity is found, proceed to step 22. 2. If continuity is NOT found, replace fuse panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020-61

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 444-3 Starter Motor Relay Voltage Above Normal Continued

444-5 Starter Motor Relay Voltage Below Normal

TEST OR INSPECTION

CORRECTIVE ACTION

22. Using a digital multimeter (WP 0296), test for continuity between pin 4 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and all other pins in fuse panel wiring harness connector A-C1 (WP 0018, Figure 22).

1. If continuity is NOT found, proceed to step 23. 2. If continuity is found, replace fuse panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

23. Using a digital multimeter (WP 0296), test for continuity between pin 5 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and all other pins in fuse panel wiring harness connector A-C1 (WP 0018, Figure 22).

1. If continuity is NOT found, replace starter relay (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, replace fuse panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 444-5 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

0020

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove left platform access panel (WP 0207). 4. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 5. Using a digital multimeter (WP 0296), measure resistance between pin 7 and 8 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If resistance is 24 to 30 ohms, proceed to step 6. 2. If resistance is NOT 24 to 30 ohms, proceed to step 7.

6. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0175). pin 7 on powertrain ECM connecEnsure all harness connectors are tor X-C3 (WP 0018, Figure 3) and reconnected. Verify correct operaall other pins (except pin 8) in powtion of machine (TM 5-2410-241ertrain ECM connector X-C3 (WP 10). 0018, Figure 3). 2. If continuity is found, proceed to step 7.

0020-62

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 444-5 Starter Motor Relay Voltage Below Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

7. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 8. Using a digital multimeter (WP 0296), test for continuity between pin 66 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 7 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 9. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

9. Using a digital multimeter (WP 0296), test for continuity between pin 67 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 8 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 10. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

10. Using a digital multimeter (WP 0296), test for continuity between pin 8 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 11. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

11. Using a digital multimeter (WP 0296), test for continuity between pin 7 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 12. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-63

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 444-5 Starter Motor Relay Voltage Below Normal Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

12. Open fuse panel door (Figure 20, Item 1) (TM 5-2410-241-10).

Figure 20. Fuse Panel Door.

0020

13. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22). 14. Using a digital multimeter (WP 0296), test for continuity between pin 4 on platform harness connector MA-C3 (WP 0018, Figure 21) and pin 66 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

15. Using a digital multimeter (WP 0296), test for continuity between pin 5 on platform harness connector MA-C3 (WP 0018, Figure 21) and pin 67 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020-64

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 444-5 Starter Motor Relay Voltage Below Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

16. Using a digital multimeter (WP 0296), test for continuity between pin 4 on platform harness connector MA-C3 (WP 0018, Figure 21) and all other pins in platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is NOT found, proceed to step 17. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

17. Using a digital multimeter (WP 0296), test for continuity between pin 5 on platform harness connector MA-C3 (WP 0018, Figure 21) and all other pins in platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is NOT found, proceed to step 18. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

18. Remove fuse panel (WP 0176). 19. Disconnect fuse panel harness start relay connector A-C3 (WP 0018, Figure 51) from start relay (WP 0176). 20. Using a digital multimeter (WP 0296), test for continuity between pin 4 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and pin 1 on fuse panel harness start relay connector A-C3 (WP 0018, Figure 51).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace fuse panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

21. Using a digital multimeter (WP 0296), test for continuity between pin 5 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and pin 2 on fuse panel harness start relay connector A-C3 (WP 0018, Figure 51).

1. If continuity is found, proceed to step 22. 2. If continuity is NOT found, replace fuse panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

22. Using a digital multimeter (WP 0296), test for continuity between pin 4 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and all other pins in fuse panel wiring harness connector A-C1 (WP 0018, Figure 22).

1. If continuity is NOT found, proceed to step 23. 2. If continuity is found, replace fuse panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-65

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

444-5 Starter Motor Relay Voltage Below Normal Continued

23. Using a digital multimeter (WP 0296), test for continuity between pin 5 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and all other pins in fuse panel wiring harness connector A-C1 (WP 0018, Figure 22).

1. If continuity is NOT found, replace starter relay (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, replace fuse panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

444-6 Starter Motor Relay Current Above Normal

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 444-6 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

0020

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove left platform access panel (WP 0207). 4. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 5. Using a digital multimeter (WP 0296), measure resistance between pin 7 and 8 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If resistance is 24 to 30 ohms, proceed to step 6. 2. If resistance is NOT 24 to 30 ohms, proceed to step 8.

6. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 7. pin 7 on powertrain ECM connec- 2. If continuity is found, proceed to tor X-C3 (WP 0018, Figure 3) and step 8. all other pins (except pin 8) in powertrain ECM connector X-C3 (WP 0018, Figure 3). 7. Using a digital multimeter (WP 0296), test for continuity between pin 7 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and machine ground.

0020-66

1. If continuity is NOT found, replace powertrain ECM (WP 0180). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is found, proceed to step 8.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 444-6 Starter Motor Relay Current Above Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

8. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 9. Using a digital multimeter (WP 0296), test for continuity between pin 66 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 7 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 10. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

10. Using a digital multimeter (WP 0296), test for continuity between pin 67 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 8 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 11. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

11. Using a digital multimeter (WP 0296), test for continuity between pin 8 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 12. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

12. Using a digital multimeter (WP 0296), test for continuity between pin 7 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 13. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

13. Using a digital multimeter (WP 0296), test for continuity between pin 7 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and machine ground.

1. If continuity is NOT found, proceed to step 14. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-67

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 444-6 Starter Motor Relay Current Above Normal Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

14. Open fuse panel door (Figure 21, Item 1) (TM 5-2410-241-10).

Figure 21. Fuse Panel Door.

0020

15. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22). 16. Using a digital multimeter (WP 0296), test for continuity between pin 4 on platform harness connector MA-C3 (WP 0018, Figure 21) and pin 66 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 17. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

17. Using a digital multimeter (WP 0296), test for continuity between pin 5 on platform harness connector MA-C3 (WP 0018, Figure 21) and pin 67 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 18. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020-68

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 444-6 Starter Motor Relay Current Above Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

18. Using a digital multimeter (WP 0296), test for continuity between pin 4 on platform harness connector MA-C3 (WP 0018, Figure 21) and all other pins in platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is NOT found, proceed to step 19. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

19. Using a digital multimeter (WP 0296), test for continuity between pin 4 on platform harness connector MA-C3 (WP 0018, Figure 21) and machine ground.

1. If continuity is NOT found, proceed to step 20. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

20. Using a digital multimeter (WP 0296), test for continuity between pin 5 on platform harness connector MA-C3 (WP 0018, Figure 21) and all other pins in platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is NOT found, proceed to step 21. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

21. Remove fuse panel (WP 0176). 22. Disconnect fuse panel harness start relay connector A-C3 (WP 0018, Figure 51) from start relay (WP 0176). 23. Using a digital multimeter (WP 0296), test for continuity between pin 4 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and pin 1 on fuse panel harness start relay connector AC3 (WP 0018, Figure 51).

1. If continuity is found, proceed to step 24. 2. If continuity is NOT found, replace fuse panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

24. Using a digital multimeter (WP 0296), test for continuity between pin 5 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and pin 2 on fuse panel harness start relay connector AC3 (WP 0018, Figure 51).

1. If continuity is found, proceed to step 25. 2. If continuity is NOT found, replace fuse panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020-69

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 444-6 Starter Motor Relay Current Above Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

25. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 26. pin 4 on fuse panel wiring harness 2. If continuity is found, replace fuse connector A-C1 (WP 0018, panel harness (WP 0176). Ensure Figure 22) and all other pins in all harness connectors are reconfuse panel wiring harness connecnected. Verify correct operation of tor A-C1 (WP 0018, Figure 22). machine (TM 5-2410-241-10). 26. Using a digital multimeter (WP 0296), test for continuity between pin 4 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and machine ground.

1. If continuity is NOT found, proceed to step 27. 2. If continuity is found, replace fuse panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

27. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between starter relay (WP 0176). Ensure all pin 5 on fuse panel wiring harness harness connectors are reconconnector A-C1 (WP 0018, nected. Verify correct operation of Figure 22) and all other pins in machine (TM 5-2410-241-10). fuse panel wiring harness connec- 2. If continuity is found, replace fuse tor A-C1 (WP 0018, Figure 22). panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 468-3 Service Brake Pedal Position Sensor Voltage Above Normal

1. Ensure parking brake switch in the OFF position (TM 5-2410-241-10). 2. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013). 3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Disconnect dash harness brake position sensor connector E-C27 (WP 0018, Figure 52) from brake pedal position sensor (WP 0258). 5. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10).

0020-70

1. If active 468-3 code is present, proceed to step 3. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-3 Service Brake Pedal Position Sensor Voltage Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

6. Using a digital multimeter (WP 0296), measure for voltage between pins A and B on dash harness brake position sensor connector E-C27 (WP 0018, Figure 52).

1. If voltage of 23 to 25 volts is found, proceed to step 7. 2. If 23 to 25 volts is NOT found, proceed to step 8.

7. Using a digital multimeter (WP 0296), measure for voltage between pins B and C on dash harness brake position sensor connector E-C27 (WP 0018, Figure 52).

1. If voltage of 4.5 to 5.5 volts is found, replace brake pedal position sensor (WP 0258). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 4.5 to 5.5 volts is NOT found, proceed to step 8.

8. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0020-71

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-3 Service Brake Pedal Position Sensor Voltage Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

9. Open fuse panel door (Figure 22, Item 1) (TM 5-2410-241-10).

Figure 22. Fuse Panel Door.

0020-72

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-3 Service Brake Pedal Position Sensor Voltage Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

10. Remove Fuse # 5 (Figure 23, Item 1) from fuse panel (Figure 23, Item 2) (TM 5-2410-241-10).

Figure 23. Fuse #5. 11. Using a digital multimeter (WP 0296), test for continuity between blades of Fuse #5.

0020

1. If continuity is found, install Fuse #5 on fuse panel, and proceed to step 12. 2. If continuity is NOT found, replace Fuse #5, and proceed to step 26.

12. Remove left platform access panel (WP 0207). 13. Disconnect platform harness connector MA-C14 (WP 0018, Figure 33) from steering control harness connector X-C1 (WP 0018, Figure 34). 14. Using a digital multimeter (WP 0296), test for continuity between pin 65 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin C on dash harness brake position sensor connector E-C27 (WP 0018, Figure 52).

0020-73

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-3 Service Brake Pedal Position Sensor Voltage Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

15. Using a digital multimeter (WP 0296), test for continuity between pin 4 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin B on dash harness brake position sensor connector E-C27 (WP 0018, Figure 52).

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

16. Using a digital multimeter (WP 0296), test for continuity between pin 65 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 17. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

17. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 18. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 19. Using a digital multimeter (WP 0296), test for continuity between pin 65 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 32 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 20. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

20. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 21. pin 32 on powertrain ECM connec- 2. If continuity is found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, Figure tors are reconnected. Verify cor3). rect operation of machine (TM 52410-241-10).

0020-74

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-3 Service Brake Pedal Position Sensor Voltage Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

21. Using a digital multimeter (WP 0296), test for continuity between pin 4 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 13 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 22. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

22. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22). 23. Using a digital multimeter (WP 0296), test for continuity between pin 3 on platform harness connector MA-C3 (WP 0018, Figure 21) and pin A on dash harness brake position sensor connector E-C27 (WP 0018, Figure 52).

24. Remove Fuse # 5 (Figure 24, Item 1) from fuse panel (Figure 24, Item 2) (TM 5-2410-241-10).

0020-75

1. If continuity is found, proceed to step 24. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-3 Service Brake Pedal Position Sensor Voltage Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

25. Using a digital multimeter (WP 1. If continuity is found, replace pow0296), test for continuity between ertrain ECM (WP 0175). Install pin 3 on fuse panel wiring harness Fuse#5 on fuse panel. Ensure all connector A-C1 (WP 0018, Figure harness connectors are recon22) and left cavity of Fuse #5 (Fignected. Verify correct operation of ure 24, Item 1) on fuse panel (Figmachine (TM 5-2410-241-10). ure 24, Item 2). 2. If continuity is NOT found, replace fuse panel harness (WP 0176). Install Fuse #5 on fuse panel. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

Figure 24. Fuse #5.

0020

26. Remove left platform access panel (WP 0207). 27. Disconnect parking brake switch connector X-C6 (WP 0018, Figure 44) from parking brake switch (WP 0018, Figure 45). 28. Disconnect forward/neutral/ reverse sensor connector X-C8 (WP 0018, Figure 49) from forward neutral reverse sensor (WP 0237). 29. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10).

0020-76

1. If Fuse #5 is OK, proceed to step 30. 2. If Fuse #5 is blown, proceed to step 36.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-3 Service Brake Pedal Position Sensor Voltage Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

30. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 31. Reconnect dash harness brake position sensor connector E-C27 (WP 0018, Figure 52) on brake pedal position sensor (WP 0258). 32. Turn ignition switch and battery disconnect switch to ON position and operate brake pedal several times (TM 5-2410-241-10).

1. If Fuse #5 is OK, proceed to step 33. 2. If Fuse #5 is blown, replace brake pedal position sensor (WP 0258). Replace Fuse #5 (TM 5-2410-24110). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

33. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 34. Reconnect parking brake switch connector X-C6 (WP 0018, Figure 44) on parking brake switch (WP 0018, Figure 45). 1. If Fuse #5 is OK, replace forward 35. Turn ignition switch and battery neutral reverse sensor (WP 0237). disconnect switch to ON position Ensure all harness connectors are and operate parking brake switch reconnected. Verify correct operaseveral times (TM 5-2410-241-10). tion of machine (TM 5-2410-24110). 2. If Fuse #5 is blown, replace parking brake switch (WP 0237). Replace Fuse #5 (TM 5-2410-24110). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 36. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0020-77

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-3 Service Brake Pedal Position Sensor Voltage Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

37. Remove Fuse # 5 (Figure 25, Item 1) from fuse panel (Figure 25, Item 2) (TM 5-2410-241-10).

Figure 25. Fuse #5.

0020

38. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22). 39. Using a digital multimeter (WP 0296), test for continuity between pin 3 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and machine ground.

40. Disconnect platform harness connector MA-C14 (WP 0018, Figure 33) from steering control harness connector X-C1 (WP 0018, Figure 34). 41. Disconnect platform harness connector MA-C13 from RH console harness (WP 0018, Figure 158).

0020-78

1. If continuity is NOT found, proceed to step 40. 2. If continuity is found, replace fuse panel wiring harness (WP 0181). Replace Fuse #5 (TM 5-2410-24110). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-3 Service Brake Pedal Position Sensor Voltage Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

42. Using a digital multimeter (WP 0296), test for continuity between pin 3 on platform harness connector MA-C3 (WP 0018, Figure 21) and all other pins in platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is NOT found, proceed to step 43. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

43. Using a digital multimeter (WP 0296), test for continuity between pin 3 on platform harness connector MA-C3 (WP 0018, Figure 21) and machine ground.

1. If continuity is NOT found, proceed to step 44. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

44. Using a digital multimeter (WP 0296), test for continuity between pin 6 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 45. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

45. Using a digital multimeter (WP 0296), test for continuity between pin 6 on platform harness connector MA-C14 (WP 0018, Figure 33) and machine ground.

1. If continuity is NOT found, proceed to step 46. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-79

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-3 Service Brake Pedal Position Sensor Voltage Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

46. Using a digital multimeter (WP 0296), test for continuity between pin 6 on steering control harness connector X-C1 (WP 0018, Figure 34) and all other pins in steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is NOT found, proceed to step 47. 2. If continuity is found, replace steering control harness (WP 0178). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

47. Using a digital multimeter (WP 0296), test for continuity between pin 6 on steering control harness connector X-C1 (WP 0018, Figure 34) and machine ground.

1. If continuity is NOT found, proceed to step 48. 2. If continuity is found, replace steering control harness (WP 0178). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

48. Using a digital multimeter (WP 0296), test for continuity between pin 2 on platform harness connector MA-C13 (WP 0018, Figure 158) and all other pins in platform harness connector MA-C13 (WP 0018, Figure 158).

1. If continuity is NOT found, proceed to step 49. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

49. Using a digital multimeter (WP 0296), test for continuity between pin 2 on platform harness connector MA-C13 (WP 0018, Figure 158) and machine ground.

1. If continuity is NOT found, replace right cab switch panel harness (WP 0179). Replace Fuse #5 (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #5 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-80

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-4 Service Brake Pedal Position Sensor Voltage Below Normal

TEST OR INSPECTION

CORRECTIVE ACTION

1. Ensure parking brake switch is in the OFF position (TM 5-2410-24110). 2. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 468-4 code is present, proceed to step 3. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Disconnect dash harness brake position sensor connector E-C27 (WP 0018, Figure 52) from brake pedal position sensor (WP 0258). 5. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 6. Check for Diagnostic Codes (WP 0013).

1. If active 468-4 code is still present, proceed to step 7. 2. If active 468-3 code is now present, replace brake pedal position sensor (WP 0258). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Remove left platform access panel (WP 0207). 9. Disconnect platform harness connector MA-C14 (WP 0018, Figure 33) from steering control harness connector X-C1 (WP 0018, Figure 34). 10. Using a digital multimeter (WP 0296), test for continuity between pin 65 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

0020-81

1. If continuity is NOT found, proceed to step 11. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-4 Service Brake Pedal Position Sensor Voltage Below Normal - Continued

TEST OR INSPECTION 11. Using a digital multimeter (WP 0296), test for continuity between pin 65 on platform harness connector MA-C14 (WP 0018, Figure 33) and machine ground.

CORRECTIVE ACTION 1. If continuity is NOT found, proceed to step 12. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

12. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 13. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 14. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 15. pin 32 on powertrain ECM connec- 2. If continuity is found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, Figure tors are reconnected. Verify cor3). rect operation of machine (TM 52410-241-10). 15. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 16. pin 32 on powertrain ECM connec- 2. If continuity is found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP machine ground. 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 16. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0180). pin 32 on powertrain ECM connecEnsure all harness connectors are tor X-C3 (WP 0018, Figure 3) and reconnected. Verify correct operaall pins in powertrain ECM connection of machine (TM 5-2410-241tor X-C2 (WP 0018, Figure 4). 10). 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-82

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-8 Service Brake Pedal Position Sensor Signal Abnormal

TEST OR INSPECTION

CORRECTIVE ACTION

1. Ensure parking brake switch is in the OFF position (TM 5-2410-24110). 2. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 468-8 code is present, proceed to step 3. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Disconnect dash harness brake position sensor connector E-C27 (WP 0018, Figure 52) from brake pedal position sensor (WP 0258). 5. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 6. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 468-3 code is present, proceed to step 7. 2. If active 468-3 code is NOT present, proceed to step 8.

7. Connect a jumper wire between pins B and C on dash harness brake position sensor connector E-C27 (WP 0018, Figure 52).

1. If active 468-4 code is present, replace brake pedal position sensor (WP 0258). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 468-4 code is NOT present, remove jumper wire, and proceed to step 8.

8. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0020-83

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-8 Service Brake Pedal Position Signal Abnormal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

9. Open fuse panel door (Figure 26, Item 1) (TM 5-2410-241-10).

Figure 26. Fuse Panel Door.

0020-84

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-8 Service Brake Pedal Position Sensor Signal Abnormal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

10. Remove Fuse #5 (Figure 27, Item 1) from fuse panel (Figure 27, Item 2) (TM 5-2410-241-10).

Figure 27. Fuse #5. 11. Inspect Fuse #5 and fuse panel for damage IAW Electrical General Maintenance Procedures (WP 0296).

12. Remove left platform access panel (WP 0207). 13. Disconnect platform harness connector MA-C14 (WP 0018, Figure 33) from steering control harness connector X-C1 (WP 0018, Figure 34).

0020-85

0020

1. If Fuse #5 is damaged, replace Fuse #5. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If fuse panel is damaged, replace fuse panel (WP 0181). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 3. If no damage is present, install Fuse #5 (Figure 27, Item 1) on fuse panel (Figure 27, Item 2). Proceed to step 12.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-8 Service Brake Pedal Position Sensor Signal Abnormal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

14. Using a digital multimeter (WP 0296), test for continuity between pin 65 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin C on dash harness brake position sensor connector E-C27 (WP 0018, Figure 52).

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

15. Using a digital multimeter (WP 0296), test for continuity between pin 4 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin B on dash harness brake position sensor connector E-C27 (WP 0018, Figure 52).

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

16. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 17. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 18. Using a digital multimeter (WP 0296), test for continuity between pin 65 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 32 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 19. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

19. Using a digital multimeter (WP 0296), test for continuity between pin 4 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 13 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 20. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

20. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22).

0020-86

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 468-8 Service Brake Pedal Position Sensor Signal Abnormal - Continued

0020

TEST OR INSPECTION

CORRECTIVE ACTION

21. Using a digital multimeter (WP 0296), test for continuity between pin 3 on platform harness connector MA-C3 (WP 0018, Figure 21) and pin A on dash harness brake position sensor connector E-C27 (WP 0018, Figure 52).

1. If continuity is found, proceed to step 22. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

22. Remove Fuse #5 (Figure 28, Item 1) from fuse panel (Figure 28, Item 2) (TM 5-2410-241-10). 23. Using a digital multimeter (WP 1. If continuity is found, replace pow0296), test for continuity between ertrain ECM (WP 0175). Install pin 3 on fuse panel wiring harness Fuse #5 on fuse panel. Ensure all connector A-C1 (WP 0018, Figure harness connectors are recon22) and left cavity of Fuse #5 (Fignected. Verify correct operation of ure 28, Item 1) on fuse panel (Figmachine (TM 5-2410-241-10). ure 28, Item 2). 2. If continuity is NOT found, replace fuse panel harness (WP 0176). Install Fuse #5 on fuse panel. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

Figure 28. Fuse #5.

0020-87

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 585-2 Transmission Output Speed Sensor #1 Data Erratic, Intermittent, or Incorrect

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 585-2 code is present, proceed to step 4. 2. If active 585-2 code is NOT present, proceed to step 2.

2. Operate machine forward and backward. 3. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 585-2 code is present, proceed to step 4. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

4. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 5. Remove left platform access panel (WP 0207). 6. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM.

NOTE Set multimeter to k ohm range. 7. Using a digital multimeter (WP 0296), measure resistance between pin 2 and 3 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If resistance is 600 to 1,800 ohms, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 2. If resistance is NOT 600 to 1800 ohms, proceed to step 8.

8. Disconnect platform harness connector MA-C14 (WP 0018, Figure 33) from steering control harness connector X-C1 (WP 0018, Figure 34). 9. Using a digital multimeter (WP 0296), test for continuity between pin 2 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and pin 8 on steering control harness connector X-C1 (WP 0018, Figure 34).

0020-88

1. If continuity is found, proceed to step 10. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 585-2 Transmission Output Speed Sensor #1 Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Using a digital multimeter (WP 0296), test for continuity between pin 3 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and pin 9 on steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 11. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

11. Using a digital multimeter (WP 0296), test for continuity between pin 9 on steering control harness connector X-C1 (WP 0018, Figure 34) and all other pins in steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is NOT found, proceed to step 12. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

12. Using a digital multimeter (WP 0296), test for continuity between pin 8 on steering control harness connector X-C1 (WP 0018, Figure 34) and all other pins in steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is NOT found, proceed to step 13. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

13. Remove rear floor plate (WP 0231). 14. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54). 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 9 on platform harness connec- 2. If continuity is NOT found, replace tor to transmission jumper harness platform harness (WP 0209). MA-C7 (WP 0018, Figure 53) and Ensure all harness connectors are pin 8 on platform harness connecreconnected. Verify correct operator MA-C14 (WP 0018, Figure 33). tion of machine (TM 5-2410-24110). 16. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 17. pin 10 on platform harness con2. If continuity is NOT found, replace nector to transmission jumper harplatform harness (WP 0209). ness MA-C7 (WP 0018, Figure 53) Ensure all harness connectors are and pin 9 on platform harness conreconnected. Verify correct operanector MA-C14 (WP 0018, tion of machine (TM 5-2410-241Figure 33). 10).

0020-89

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 585-2 Transmission Output Speed Sensor #1 Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

17. Using a digital multimeter (WP 0296), test for continuity between pin 9 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 18. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

18. Using a digital multimeter (WP 0296), test for continuity between pin 8 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 19. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

19. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 20. Using a digital multimeter (WP 0296), test for continuity between pin 9 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin H on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

21. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 22. pin 10 on transmission jumper har- 2. If continuity is NOT found, replace ness connector MP-C2 (WP 0018, transmission jumper harness (WP Figure 54) and pin A on transmis0169). Ensure all harness connecsion jumper harness connector tors are reconnected. Verify corMP-C1 (WP 0018, Figure 55). rect operation of machine (TM 52410-241-10). 22. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 23. pin 10 on transmission jumper har- 2. If continuity is found, replace ness connector MP-C2 (WP 0018, transmission jumper harness (WP Figure 54) and all other pins in 0169). Ensure all harness connectransmission jumper harness contors are reconnected. Verify cornector MP-C2 (WP 0018, Figure rect operation of machine (TM 554). 2410-241-10).

0020-90

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 585-2 Transmission Output Speed Sensor #1 Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

23. Using a digital multimeter (WP 0296), test for continuity between pin 9 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and all other pins in transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

1. If continuity is NOT found, proceed to step 24. 2. If continuity is found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

24. Remove transmission (WP 0142). 25. Remove transmission speed sensor #1 (WP 0143). 26. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 27. pin A on transmission harness 2. If continuity is NOT found, replace connector P-C1 (WP 0018, Figure transmission sensor harness (WP 56) and pin 1 on transmission har0173). Ensure all harness connecness speed sensor #1 connector tors are reconnected. Verify corP-C2 (WP 0018, Figure 57). rect operation of machine (TM 52410-241-10). 27. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 28. pin H on transmission harness 2. If continuity is NOT found, replace connector P-C1 (WP 0018, Figure transmission sensor harness (WP 56) and pin 2 on transmission har0173). Ensure all harness connecness speed sensor #1 connector tors are reconnected. Verify corP-C2 (WP 0018, Figure 57). rect operation of machine (TM 52410-241-10). 28. Using a digital multimeter (WP 0296), test for continuity between pin A on transmission harness connector P-C1 (WP 0018, Figure 56) and all other pins in transmission harness connector P-C1 (WP 0018, Figure 56).

1. If continuity is NOT found, proceed to step 29. 2. If continuity is found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

29. Using a digital multimeter (WP 0296), test for continuity between pin H on transmission harness connector P-C1 (WP 0018, Figure 56) and all other pins in transmission harness connector P-C1 (WP 0018, Figure 56).

1. If continuity is NOT found, replace transmission speed sensor #1 (WP 0143). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-91

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

588-2 Monitoring System Display Data Erratic, Intermittent, or Incorrect

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 588-2 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262). 4. Remove left platform access panel (WP 0207). 5. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 6. Using a digital multimeter (WP 0296), test for continuity between pin 5 on dash monitor connector E-C7 (WP 0018, Figure 5) and pin 23 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 7. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

7. Using a digital multimeter (WP 0296), test for continuity between pin 14 on dash monitor connector E-C7 (WP 0018, Figure 5) and pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 8. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

8. Using a digital multimeter (WP 0296), test for continuity between pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 2. If continuity is NOT found, proceed to step 9.

0020-92

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 588-2 Monitoring System Display Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

9. Using a digital multimeter (WP 0296), test for continuity between pin 23 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 2. If continuity is NOT found, proceed to step 10.

10. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 11. Using a digital multimeter (WP 0296), test for continuity between pin 23 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 10 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 12. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

12. Using a digital multimeter (WP 0296), test for continuity between pin 22 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 20 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

13. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between steering control harness (WP pin 10 on powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) and tors are reconnected. Verify corall other pins in powertrain ECM rect operation of machine (TM 5connector X-C2 (WP 0018, 2410-241-10). Figure 4). 2. If continuity is NOT found, proceed to step 14. 14. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between steering control harness (WP pin 20 on powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) and tors are reconnected. Verify corall other pins in powertrain ECM rect operation of machine (TM 5connector X-C2 (WP 0018, 2410-241-10). Figure 4). 2. If continuity is NOT found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020-93

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 588-9 Monitoring System Display Abnormal

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 588-9 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262). 4. Remove left platform access panel (WP 0207). 5. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 6. Using a digital multimeter (WP 0296), test for continuity between pin 5 on dash monitor connector E-C7 (WP 0018, Figure 5) and pin 23 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 7. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

7. Using a digital multimeter (WP 0296), test for continuity between pin 14 on dash monitor connector E-C7 (WP 0018, Figure 5) and pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 8. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

8. Using a digital multimeter (WP 0296), test for continuity between pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 2. If continuity is NOT found, proceed to step 9.

0020-94

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

588-9 Monitoring System Display Abnormal - Continued

9. Using a digital multimeter (WP 0296), test for continuity between pin 23 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 2. If continuity is NOT found, proceed to step 10.

10. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 11. Using a digital multimeter (WP 0296), test for continuity between pin 23 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 10 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 12. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

12. Using a digital multimeter (WP 0296), test for continuity between pin 22 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 20 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

13. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between steering control harness (WP pin 10 on powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) and tors are reconnected. Verify corall other pins in powertrain ECM rect operation of machine (TM 5connector X-C2 (WP 0018, 2410-241-10). Figure 4). 2. If continuity is NOT found, proceed to step 14. 14. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between steering control harness (WP pin 20 on powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) and tors are reconnected. Verify corall other pins in powertrain ECM rect operation of machine (TM 5connector X-C2 (WP 0018, 2410-241-10). Figure 4). 2. If continuity is NOT found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020-95

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 588-12 Monitoring System Display Bad Device or Component

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 588-12 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262). 4. Remove left platform access panel (WP 0207). 5. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 6. Using a digital multimeter (WP 0296), test for continuity between pin 5 on dash monitor connector E-C7 (WP 0018, Figure 5) and pin 23 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 7. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

7. Using a digital multimeter (WP 0296), test for continuity between pin 14 on dash monitor connector E-C7 (WP 0018, Figure 5) and pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 8. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

8. Using a digital multimeter (WP 0296), test for continuity between pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 2. If continuity is NOT found, proceed to step 9.

0020-96

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 588-12 Monitoring System Display Bad Device or Component - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

9. Using a digital multimeter (WP 0296), test for continuity between pin 23 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 2. If continuity is NOT found, proceed to step 10.

10. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 11. Using a digital multimeter (WP 0296), test for continuity between pin 23 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 10 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 12. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

12. Using a digital multimeter (WP 0296), test for continuity between pin 22 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 20 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

13. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between steering control harness (WP pin 10 on powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) and tors are reconnected. Verify corall other pins in powertrain ECM rect operation of machine (TM 5connector X-C2 (WP 0018, 2410-241-10). Figure 4). 2. If continuity is NOT found, proceed to step 14. 14. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between steering control harness (WP pin 20 on powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) and tors are reconnected. Verify corall other pins in powertrain ECM rect operation of machine (TM 5connector X-C2 (WP 0018, 2410-241-10). Figure 4). 2. If continuity is NOT found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020-97

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

590-2 Engine Control Module Data Erratic, Intermittent, or Incorrect

1. Connect MSD (WP 0016,) select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 590-2 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from ECM. 4. Disconnect platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) from engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12). 5. Using a digital multimeter (WP 0296), test for continuity between pin 40 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and pin 8 on engine ECM connector 6. V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 6. 2. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

7. Using a digital multimeter (WP 0296), test for continuity between pin 39 on engine harness (engine to platform) connector VC1 (WP 0018, Figure 12) and pin 9 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 7. 2. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

8. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between engine main harness (WP 0055). pin 8 on engine ECM connector VEnsure all harness connectors are C4 (WP 0018, Figure 1) and all reconnected. Verify correct operaother pins in engine ECM connection of machine (TM 5-2410-241tor V-C4 (WP 0018, Figure 1). 10). 2. If continuity is NOT found, proceed to step 8.

0020-98

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 590-2 Engine Control Module Data Erratic, Intermittent, or Incorrect Continued

TEST OR INSPECTION

CORRECTIVE ACTION

9. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between engine main harness (WP 0055). pin 9 on engine ECM connector VEnsure all harness connectors are C4 (WP 0018, Figure 1) and all reconnected. Verify correct operaother pins in engine ECM connection of machine (TM 5-2410-241tor V-C4 (WP 0018, Figure 1). 10). 2. If continuity is NOT found, proceed to step 9. 10. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262). 11. Remove left platform access panel (WP 0207). 12. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 13. Using a digital multimeter (WP 0296), test for continuity between pin 40 on platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) and pin 23 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

14. Using a digital multimeter (WP 0296), test for continuity between pin 39 on platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) and pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 14. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

15. Using a digital multimeter (WP 0296), test for continuity between pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 15.

0020-99

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

590-2 Engine Control Module Data Erratic, Intermittent, or Incorrect Continued

16. Using a digital multimeter (WP 0296), test for continuity between pin 23 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 16.

17. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 18. Using a digital multimeter (WP 0296), test for continuity between pin 23 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 10 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 18. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

19. Using a digital multimeter (WP 0296), test for continuity between pin 22 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 20 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 19. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

20. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between steering control harness (WP pin 10 on powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) and tors are reconnected. Verify corall other pins in powertrain ECM rect operation of machine (TM 5connector X-C2 (WP 0018, 2410-241-10). Figure 4). 2. If continuity is NOT found, proceed to step 20. 21. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between steering control harness (WP pin 20 on powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) and tors are reconnected. Verify corall other pins in powertrain ECM rect operation of machine (TM 5connector X-C2 (WP 0018, 2410-241-10). Figure 4). 2. If continuity is NOT found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-100

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

590-9 Engine Control Module Abnormal Update

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 590-9 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from engine ECM. 4. Disconnect platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) from engine harness connector (WP 0018, Figure 12). 5. Using a digital multimeter (WP 0296), test for continuity between pin 40 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and pin 8 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 6. 2. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

6. Using a digital multimeter (WP 0296), test for continuity between pin 39 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and pin 9 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 7. 2. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

7. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between engine main harness (WP 0055). pin 8 on engine ECM connector VEnsure all harness connectors are C4 (WP 0018, Figure 1) and all reconnected. Verify correct operaother pins in engine ECM connection of machine (TM 5-2410-241tor V-C4 (WP 0018, Figure 1). 10). 2. If continuity is NOT found, proceed to step 8.

0020-101

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 590-9 Engine Control Module Abnormal Update - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

8. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between engine main harness (WP 0055). pin 9 on engine ECM connector VEnsure all harness connectors are C4 (WP 0018, Figure 1) and all reconnected. Verify correct operaother pins in engine ECM connection of machine (TM 5-2410-241tor V-C4 (WP 0018, Figure 1). 10). 2. If continuity is NOT found, proceed to step 9. 9. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262). 10. Remove left platform access panel (WP 0207). 11. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 12. Using a digital multimeter (WP 0296), test for continuity between pin 40 on platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) and pin 23 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

13. Using a digital multimeter (WP 0296), test for continuity between pin 39 on platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) and pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 14. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

14. Using a digital multimeter (WP 0296), test for continuity between pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 15.

0020-102

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

590-9 Engine Control Module Abnormal Update - Continued

15. Using a digital multimeter (WP 0296), test for continuity between pin 23 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 16.

16. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 17. Using a digital multimeter (WP 0296), test for continuity between pin 23 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 10 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 18. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

18. Using a digital multimeter (WP 0296), test for continuity between pin 22 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 20 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 19. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

19. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between steering control harness (WP pin 10 on powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) and tors are reconnected. Verify corall other pins in powertrain ECM rect operation of machine (TM 5connector X-C2 (WP 0018, 2410-241-10). Figure 4). 2. If continuity is NOT found, proceed to step 20. 20. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between steering control harness (WP pin 20 on powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) and tors are reconnected. Verify corall other pins in powertrain ECM rect operation of machine (TM 5connector X-C2 (WP 0018, 2410-241-10). Figure 4). 2. If continuity is NOT found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-103

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

590-12 Engine Control Mod- 1. Connect MSD (WP 0016), select ule Data Erratic, IntermitPowertrain D7 ECM, and check for tent, or Incorrect Diagnostic Codes or Event Codes (WP 0013).

CORRECTIVE ACTION 1. If active 590-12 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from engine ECM. 4. Disconnect platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) from engine harness connector (WP 0018, Figure 12). 5. Using a digital multimeter (WP 0296), test for continuity between pin 40 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and pin 8 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 6. 2. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

6. Using a digital multimeter (WP 0296), test for continuity between pin 39 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and pin 9 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 7. 2. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

7. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between engine main harness (WP 0055). pin 8 on engine ECM connector VEnsure all harness connectors are C4 (WP 0018, Figure 1) and all reconnected. Verify correct operaother pins in engine ECM connection of machine (TM 5-2410-241tor V-C4 (WP 0018, Figure 1). 10). 2. If continuity is NOT found, proceed to step 8.

0020-104

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

590-12 Engine Control Mod- 8. Using a digital multimeter (WP 1. If continuity is found, replace ule Data Erratic, Intermit0296), test for continuity between engine main harness (WP 0055). tent, or Incorrect pin 9 on engine ECM connector VEnsure all harness connectors are Continued C4 (WP 0018, Figure 1) and all reconnected. Verify correct operaother pins in engine ECM connection of machine (TM 5-2410-241tor V-C4 (WP 0018, Figure 1). 10). 2. If continuity is NOT found, proceed to step 9. 9. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262). 10. Remove left platform access panel (WP 0207). 11. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 12. Using a digital multimeter (WP 0296), test for continuity between pin 40 on platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) and pin 23 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

13. Using a digital multimeter (WP 0296), test for continuity between pin 39 on platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) and pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 14. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

14. Using a digital multimeter (WP 0296), test for continuity between pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 15.

0020-105

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

590-12 Engine Control Mod- 15. Using a digital multimeter (WP ule Data Erratic, Intermit0296), test for continuity between tent, or Incorrect pin 23 on platform harness conContinued nector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

CORRECTIVE ACTION 1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 16.

16. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 17. Using a digital multimeter (WP 0296), test for continuity between pin 23 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 10 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 18. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

18. Using a digital multimeter (WP 0296), test for continuity between pin 22 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 20 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 19. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

19. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between steering control harness (WP pin 10 on powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) and tors are reconnected. Verify corall other pins in powertrain ECM rect operation of machine (TM 5connector X-C2 (WP 0018, 2410-241-10). Figure 4). 2. If continuity is NOT found, proceed to step 20. 20. Using a digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between steering control harness (WP pin 20 on powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) and tors are reconnected. Verify corall other pins in powertrain ECM rect operation of machine (TM 5connector X-C2 (WP 0018, 2410-241-10). Figure 4). 2. If continuity is NOT found, replace engine ECM (WP 0101). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-106

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

618-2 Left Service Brake Switch Data Erratic, Intermittent, or Incorrect

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

CORRECTIVE ACTION 1. If active 618-2 code is present, proceed to step 4. 2. If active 618-2 code is NOT present, proceed to step 2.

2. Ensure parking brake is Engaged (TM 5-2410-241-10). 3. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 618-2 code is present, proceed to step 4. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

4. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 5. Remove left platform access panel (WP 0207). 6. Disconnect parking brake switch connector X-C6 (WP 0018, Figure 44) from parking brake switch (WP 0018, Figure 45). 7. Push parking brake switch downward to the OFF position (TM 52410-241-10)). 8. Using a digital multimeter (WP 0296), test for continuity between pin 7 and 9 on parking brake switch (WP 0018, Figure 45).

1. If continuity is NOT found, proceed to step 9. 2. If continuity is found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

9. Pull parking brake switch upward to the ON position (TM 5-2410241-10). 10. Using a digital multimeter (WP 0296), test for continuity between pin 7 and 9 on parking brake switch (WP 0018, Figure 45).

11. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from the powertrain ECM.

0020-107

1. If continuity is found, proceed to step 11. 2. If continuity is NOT found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 618-2 Left Service Brake Switch Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

12. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from the powertrain ECM. 13. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 14. pin 40 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 4 on parking brake switch con0178). Ensure all harness connecnector X-C6 (WP 0018, Figure 44). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 14. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 15. pin 3 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP pin 7 on parking brake switch con0178). Ensure all harness connecnector X-C6 (WP 0018, Figure 44). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 15. Using a digital multimeter (WP 0296), test for continuity between pin 3 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 16. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

16. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0175). pin 40 on powertrain ECM connecEnsure all harness connectors are tor X-C2 (WP 0018, Figure 4) and reconnected. Verify correct operaall other pins in powertrain ECM tion of machine (TM 5-2410-241connector X-C2 (WP 0018, 10). Figure 4). 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-108

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

621-2 Downshift Switch Data Erratic, Intermittent, or Incorrect

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

0020

CORRECTIVE ACTION 1. If active 621-2 code is present, proceed to step 4. 2. If active 621-2 code is NOT present, proceed to step 2.

2. Push downshift button (Figure 29, Item 1) for 15 seconds. 3. Check for Diagnostic Codes or Event Codes (WP 0013).

Figure 29. Downshift Button.

0020-109

1. If active 621-2 code is present, proceed to step 4. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

621-2 Downshift Switch Data Erratic, Intermittent, or Incorrect - Continued

4. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

CORRECTIVE ACTION

5. Remove left platform access panel (WP 0207). 6. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from the powertrain ECM. 7. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from the powertrain ECM. 8. Disconnect steering harness downshift / upshift switch connector X-C4 (WP 0018, Figure 58) from the downshift / upshift switch connector (WP 0018, Figure 59). 9. Using a digital multimeter (WP 0296), test for continuity between pin 3 and pin 5 on downshift / upshift switch connector (WP 0018, Figure 59).

1. If continuity is found, proceed to step 10. 2. If continuity is NOT found, replace steering and transmission control handle (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

10. Push and HOLD downshift button (Figure 29, Item 1). Using a digital multimeter (WP 0296), test for continuity between pin 3 and pin 5 on downshift / upshift switch connector (WP 0018, Figure 59).

1. If continuity is NOT found, proceed to step 11. 2. If continuity is found, replace steering and transmission control handle (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

11. Push and HOLD downshift button (Figure 29, Item 1). Using a digital multimeter (WP 0296), test for continuity between pin 4 and pin 5 on downshiftt/upshift switch connector (WP 0018, Figure 59).

1. If continuity is found, proceed to step 12. 2. If continuity is NOT found, replace steering and transmission control handle (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-110

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

621-2 Downshift Switch Data Erratic, Intermittent, or Incorrect - Continued

12. Release downshift button. Using a digital multimeter (WP 0296), test for continuity between pin 4 and pin 5 on downshift / upshift switch connector (WP 0018, Figure 59).

1. If continuity is NOT found, proceed to step 13. 2. If continuity is found, replace steering and transmission control handle (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

13. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 14. pin 23 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 5 on steering harness down0178). Ensure all harness connecshift / upshift switch connector Xtors are reconnected. Verify corC4 (WP 0018, Figure 58). rect operation of machine (TM 52410-241-10). 14. Using a digital multimeter (WP 0296), test for continuity between pin 4 on steering harness downshift / upshift switch connector XC4 (WP 0018, Figure 58) and pin 30 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

15. Using a digital multimeter (WP 0296), test for continuity between pin 3 on steering harness downshift / upshift switch connector XC4 (WP 0018, Figure 58) and pin 31 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

16. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 17. pin 31 on powertrain ECM connec- 2. If continuity is found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10).

0020-111

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

0020

CORRECTIVE ACTION

621-2 Downshift Switch Data Erratic, Intermittent, or Incorrect - Continued

17. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0175). pin 30 on powertrain ECM connecEnsure all harness connectors are tor X-C3 (WP 0018, Figure 3) and reconnected. Verify correct operaall other pins in powertrain ECM tion of machine (TM 5-2410-241connector X-C3 (WP 0018, 10). Figure 3). 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

622-2 Upshift Switch Data Erratic, Intermittent, or Incorrect

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 622-2 code is present, proceed to step 4. 2. If active 622-2 code is NOT present, proceed to step 2.

2. Push Upshift button for 15 seconds (Figure 30, Item 1).

Figure 30. Upshift button. 3. Check for Diagnostic Codes or Event Codes (WP 0013).

4. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0020-112

0020

1. If active 622-2 code is present, proceed to step 4. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 622-2 Upshift Switch Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

5. Remove left platform access panel (WP 0207). 6. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from the powertrain ECM. 7. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from the powertrain ECM. 8. Disconnect steering harness downshift / upshift switch connector X-C4 (WP 0018, Figure 58) from the downshift / upshift switch connector (WP 0018, Figure 59). 9. Using a digital multimeter (WP 0296), test for continuity between pin 1 and pin 2 on downshift / upshift switch connector (WP 0018, Figure 59).

1. If continuity is found, proceed to step 10. 2. If continuity is NOT found, replace steering and transmission control handle (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

10. Push and HOLD Upshift button (Figure 30, Item 1). Using a digital multimeter (WP 0296), test for continuity between pin 1 and pin 2 on downshift / upshift switch connector (WP 0018, Figure 59).

1. If continuity is NOT found, proceed to step 11. 2. If continuity is found, replace steering and transmission control handle (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

11. Push and HOLD Upshift button (Figure 30, Item 1). Using a digital multimeter (WP 0296), test for continuity between pin 2 and pin 6 on downshift / upshift switch connector (WP 0018, Figure 59).

1. If continuity is found, proceed to step 12. 2. If continuity is NOT found, replace steering and transmission control handle (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-113

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 622-2 Upshift Switch Data Erratic, Intermittent, or Incorrect - Continued

0020

TEST OR INSPECTION

CORRECTIVE ACTION

12. Release Upshift button (Figure 31, Item 1). Using a digital multimeter (WP 0296), test for continuity between pin 2 and pin 6 on downshift / upshift switch connector (WP 0018, Figure 59).

1. If continuity is NOT found, proceed to step 13. 2. If continuity is found, replace steering and transmission control handle (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

Figure 31. Upshift Button.

0020

13. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 14. pin 23 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 2 on steering harness down0178). Ensure all harness connecshift / upshift switch connector Xtors are reconnected. Verify corC4 (WP 0018, Figure 58). rect operation of machine (TM 52410-241-10). 14. Using a digital multimeter (WP 0296), test for continuity between pin 1 on steering harness downshift / upshift switch connector XC4 (WP 0018, Figure 58) and pin 29 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

0020-114

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 622-2 Upshift Switch Data Erratic, Intermitten, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

15. Using a digital multimeter (WP 0296), test for continuity between pin 6 on steering harness downshift / upshift switch connector XC4 (WP 0018, Figure 58) and pin 28 on powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

16. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 17. pin 28 on powertrain ECM connec- 2. If continuity is found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, Figure tors are reconnected. Verify cor3). rect operation of machine (TM 52410-241-10). 17. Using a digital multimeter (WP 3. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0175). pin 29 on powertrain ECM connecEnsure all harness connectors are tor X-C3 (WP 0018, Figure 3) and reconnected. Verify correct operaall other pins in powertrain ECM tion of machine (TM 5-2410-241connector X-C3 (WP 0018, Figure 10). 3). 4. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 650-2 Harness Code Data Erratic, Intermittent, or Incorrect

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 650-2 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Check for proper software in powertrain ECM. Refer to ECM programming (WP 0017).

1. If software in powertrain ECM is wrong, install proper software (WP 0017). Verify correct operation of machine (TM 5-2410-241-10). 2. If software in powertrain ECM is OK, proceed to step 3.

3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Remove left platform access panel (WP 0207).

0020-115

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 650-2 Harness Code Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

5. Disconnect harness code plug connector to steering harness XC9 (WP 0018, Figure 60) from the steering harness code plug (WP 0018, Figure 61). 6. Using a digital multimeter (WP 0296), test for continuity between pin 6 and pins 4, 3, 2, and 1 on steering harness code plug (WP 0018, Figure 61).

1. If continuity is NOT found, replace steering harness code plug. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is found, proceed to step 7.

7. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from the powertrain ECM. 8. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from the powertrain ECM. 9. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 10. pin 13 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 6 on harness code plug con0178). Ensure all harness connecnector to steering harness X-C9 tors are reconnected. Verify cor(WP 0018, Figure 60). rect operation of machine (TM 52410-241-10). 10. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 11. pin 55 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP pin 1 on harness code plug con0178). Ensure all harness connecnector to steering harness X-C9 tors are reconnected. Verify cor(WP 0018, Figure 60). rect operation of machine (TM 52410-241-10). 11. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 12. pin 58 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP pin 2 on harness code plug con0178). Ensure all harness connecnector to steering harness X-C9 tors are reconnected. Verify cor(WP 0018, Figure 60). rect operation of machine (TM 52410-241-10).

0020-116

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 650-2 Harness Code Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

12. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 13. pin 59 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP pin 3 on harness code plug con0178). Ensure all harness connecnector to steering harness X-C9 tors are reconnected. Verify cor(WP 0018, Figure 60). rect operation of machine (TM 52410-241-10). 13. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 14. pin 60 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP pin 4 on harness code plug con0178). Ensure all harness connecnector to steering harness X-C9 tors are reconnected. Verify cor(WP 0018, Figure 60). rect operation of machine (TM 52410-241-10). 14. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 15. pin 55 on powertrain ECM connec- 2. If continuity is found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10). 15. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 16. pin 58 on powertrain ECM connec- 2. If continuity is found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10). 16. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 17. pin 59 on powertrain ECM connec- 2. If continuity is found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10).

0020-117

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

650-2 Harness Code Data Erratic, Intermittent, or Incorrect - Continued

17. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0175). pin 60 on powertrain ECM connecEnsure all harness connectors are tor X-C3 (WP 0018, Figure 3) and reconnected. Verify correct operaall other pins in powertrain ECM tion of machine (TM 5-2410-241connector X-C3 (WP 0018, 10). Figure 3). 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

668-12 Shift Lever Bad Device or Component

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 668-12 code is present, proceed to step 2.

2. This diagnostic code is produced when Forward, Neutral, Reverse shift mechanism is NOT fully seated into the shift selection detente position.

1. 668-12 indicates operator error. No troubleshooting is required. This is an informational code only.

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 672-2 code is present, proceed to step 4. 2. If active 672-2 code is NOT present, proceed to step 2.

672-2 Torque Converter Output Speed Sensor Data Erratic, Intermittent, or Incorrect

2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Code may only set with machine in motion. Operate machine forward and backward. 3. Check for Diagnostic Codes or Event Codes (WP 0013).

4. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 5. Adjust torque converter output speed sensor (WP 0122). 6. Code may only set with machine in motion. Operate machine forward and backward.

0020-118

1. If active 672-2 code is present, proceed to step 4. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 672-2 Torque Converter Output Speed Sensor Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION 7. Check for Diagnostic Codes or Event Codes (WP 0013).

CORRECTIVE ACTION 1. If active 672-2 code is present, proceed to step 8. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

8. Disconnect engine harness torque converter output speed sensor connector V-C10 (WP 0018, Figure 62) from the torque converter output speed sensor (WP 0018, Figure 63) (WP 0122). 9. Using a digital multimeter (WP 0296), test for continuity between pin 1 on torque converter output speed sensor connector (WP 0018, Figure 63) and outside housing of torque converter output speed sensor (WP 0018, Figure 63).

1. If continuity is NOT found, proceed to step 10. 2. If continuity is found, replace torque converter output speed sensor (WP 0122). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

10. Using a digital multimeter (WP 0296), test for continuity between pin 2 on torque converter output speed sensor connector (WP 0018, Figure 63) and outside housing of torque converter output speed sensor (WP 0018, Figure 63).

1. If continuity is NOT found, proceed to step 11. 2. If continuity is found, replace torque converter output speed sensor (WP 0122). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

11. Using a digital multimeter (WP 0296), measure resistance between pin 1 and pin 2 on torque converter output speed sensor connector (WP 0018, Figure 63). Resistance should be 75 to 230 ohms.

1. If resistance is greater than 230 ohms, replace torque converter output speed sensor (WP 0122). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If resistance is less than 75 ohms, proceed to step 12.

12. Disconnect engine harness (engine to platform) connector VC1 (WP 0018, Figure 12) from platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11).

0020-119

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 672-2 Torque Converter Output Speed Sensor Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

13. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 14. pin 2 on engine harness torque 2. If continuity is NOT found, replace converter output speed sensor engine harness (WP 0055). connector V-C10 (WP 0018, Ensure all harness connectors are Figure 62) and pin 29 on engine reconnected. Verify correct operaharness (engine to platform) contion of machine (TM 5-2410-241nector V-C1 (WP 0018, Figure 12). 10). 14. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 15. pin 1 on engine harness torque 2. If continuity is NOT found, replace converter output speed sensor engine harness (WP 0055). connector V-C10 (WP 0018, Ensure all harness connectors are Figure 62) and pin 30 on engine reconnected. Verify correct operaharness (engine to platform) contion of machine (TM 5-2410-241nector V-C1 (WP 0018, Figure 12). 10). 15. Using a digital multimeter (WP 0296), test for continuity between pin 30 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and all other pins in engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is NOT found, proceed to step 16.

16. Using a digital multimeter (WP 0296), test for continuity between pin 29 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and all other pins in engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is NOT found, proceed to step 17.

17. Remove left platform access panel (WP 0207). 18. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 19. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 20. pin 12 on platform harness con2. If continuity is NOT found, replace nector MA-C14 (WP 0018, Figure platform harness (WP 0209). 33) and pin 29 on platform harEnsure all harness connectors are ness (platform to engine) connecreconnected. Verify correct operator MA-C22 (WP 0018, Figure 11). tion of machine (TM 5-2410-24110).

0020-120

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 672-2 Torque Converter Output Speed Sensor Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

20. Using a digital multimeter (WP 0296), test for continuity between pin 13 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin 30 on platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

21. Using a digital multimeter (WP 0296), test for continuity between pin 12 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 22. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

22. Using a digital multimeter (WP 0296), test for continuity between pin 13 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MAC14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 23. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

23. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 24. Using a digital multimeter (WP 0296), test for continuity between pin 12 on steering control harness connector X-C1 (WP 0018, Figure 34) and pin 15 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 25. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

25. Using a digital multimeter (WP 0296), test for continuity between pin 13 on steering control harness connector X-C1(WP 0018, Figure 34) and pin 16 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 26. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-121

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 672-2 Torque Converter Output Speed Sensor Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

26. Using a digital multimeter 1. If continuity is NOT found, proceed (WP 0296), test for continuity to step 27. between pin 16 on powertrain 2. If continuity is found, replace ECM connector X-C2 (WP 0018, steering control harness (WP Figure 4) and all other pins in pow0178). Ensure all harness connecertrain ECM connector X-C2 (WP tors are reconnected. Verify cor0018, Figure 4). rect operation of machine (TM 52410-241-10). 27. Using a digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between powertrain ECM (WP 0180). pin 15 on powertrain ECM connecEnsure all harness connectors are tor X-C2 (WP 0018, Figure 4) and reconnected. Verify correct operaall other pins in powertrain ECM tion of machine (TM 5-2410-241connector X-C2 (WP 0018, 10). Figure 4). 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

673-2 Transmission Output Speed Sensor #2 Data Erratic, Intermittent, or Incorrect

1. Connect MSD (WP 0016), select powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 673-2 code is present, proceed to step 4. 2. If active 673-2 code is NOT present, proceed to step 2.

2. Operate machine forwards and backwards. 3. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 673-2 code is present, proceed to step 4. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

4. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 5. Remove left platform access panel (WP 0207). 6. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 7. Using a digital multimeter (WP 1. If resistance is 600 to 1,800 ohms, 0296), measure resistance replace powertrain ECM (WP between pin 4 and pin 5 on power0175). Ensure all harness connectrain ECM connector X-C2 (WP tors are reconnected. Verify cor0018, Figure 4). rect operation of machine (TM 52410-241-10). 2. If resistance is NOT 600 to 1,800 ohms, proceed to step 8.

0020-122

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 673-2 Transmission Output Speed Sensor #2 Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

8. Disconnect platform harness connector MA-C14 (WP 0018, Figure 33) from steering control harness connector X-C1 (WP 0018, Figure 34). 9. Using a digital multimeter (WP 0296), test for continuity between pin 4 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and pin 10 on steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 10. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

10. Using a digital multimeter (WP 0296), test for continuity between pin 5 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and pin 11 on steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 11. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

11. Using a digital multimeter (WP 0296), test for continuity between pin 4 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, proceed to step 12. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

12. Using a digital multimeter (WP 0296), test for continuity between pin 5 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, proceed to step 13. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

13. Remove rear floor plate (WP 0231). 14. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

0020-123

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 673-2 Transmission Output Speed Sensor #2 Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

15. Using a digital multimeter (WP 0296), test for continuity between pin 11 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 10 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

16. Using a digital multimeter (WP 0296), test for continuity between pin 12 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 11 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 17. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

17. Using a digital multimeter 1. If continuity is NOT found, proceed (WP 0296), test for continuity to step 18. between pin 11 on platform har2. If continuity is found, replace platness connector MA-C14 (WP form harness (WP 0209). Ensure 0018, Figure 33) and all other pins all harness connectors are reconin platform harness connector MAnected. Verify correct operation of C14 (WP 0018, Figure 33). machine (TM 5-2410-241-10). 18. Using a digital multimeter (WP 0296), test for continuity between pin 10 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 19. 2. If continuity is found, replace platform harness (WP 0209) Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

19. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 20. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 21. pin 11 on transmission jumper har- 2. If continuity is NOT found, replace ness connector MP-C2 (WP 0018, transmission jumper harness (WP Figure 54) and pin B on transmis0174). Ensure all harness connecsion jumper harness connector tors are reconnected. Verify corMP-C1 (WP 0018, Figure 55). rect operation of machine (TM 52410-241-10).

0020-124

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 673-2 Transmission Output Speed Sensor #2 Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

21. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 22. pin 12 on transmission jumper har- 2. If continuity is NOT found, replace ness connector MP-C2 (WP 0018, transmission jumper harness (WP Figure 54) and pin C on transmis0174). Ensure all harness connecsion jumper harness connector tors are reconnected. Verify corMP-C1 (WP 0018, Figure 55). rect operation of machine (TM 52410-241-10). 22. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 23. pin 11 on transmission jumper har- 2. If continuity is found, replace ness connector MP-C2 (WP 0018, transmission jumper harness (WP Figure 54) and all other pins in 0174). Ensure all harness connectransmission jumper harness contors are reconnected. Verify cornector MP-C2 (WP 0018, rect operation of machine (TM 5Figure 54). 2410-241-10). 23. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 24. pin 12 on transmission jumper har- 2. If continuity is found, replace ness connector MP-C2 (WP 0018, transmission jumper harness (WP Figure 54) and all other pins in 0169). Ensure all harness connectransmission jumper harness contors are reconnected. Verify cornector MP-C2 (WP 0018, rect operation of machine (TM 5Figure 54). 2410-241-10). 24. Remove transmission (WP 0144). 25. Remove transmission speed sensor #2 (WP 0144). 26. Using a digital multimeter (WP 0296), test for continuity between pin B on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 2 on transmission harness speed sensor #2 connector P-C8 (WP 0018, Figure 64).

1. If continuity is found, proceed to step 27. 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

27. Using a digital multimeter (WP 0296), test for continuity between pin C on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 1 on transmission harness speed sensor #2 connector P-C8 (WP 0018, Figure 64).

1. If continuity is found, proceed to step 28. 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-125

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 673-2 Transmission Output Speed Sensor #2 Data Erratic, Intermittent, or Incorrect - Continued

681-3 Parking Brake Solenoid Voltage Above Normal

TEST OR INSPECTION

CORRECTIVE ACTION

28. Using a digital multimeter 1. If continuity is NOT found, proceed (WP 0296), test for continuity to step 29. between pin B on transmission 2. If continuity is found, replace harness connector P-C1 transmission sensor harness (WP 0018, Figure 56) and all other (WP 0173). Ensure all harness pins in transmission harness conconnectors are reconnected. Vernector P-C1 (WP 0018, Figure 56). ify correct operation of machine (TM 5-2410-241-10). 29. Using a digital multimeter (WP 0296), test for continuity between pin C on transmission harness connector P-C1 (WP 0018, Figure 56) and all other pins in transmission harness connector P-C1 (WP 0018, Figure 56).

1. If continuity is NOT found, replace transmission speed sensor #2 (WP 0146). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 681-3 code is present, proceed to step 4. 2. If active 681-3 code is NOT present, proceed to step 2.

2. Ensure parking brake switch is in OFF position (TM 5-2410-241-10). 3. Check for Diagnostic Codes or Event Codes (WP 0013).

4. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 5. Remove left platform access panel (WP 0207). 6. Disconnect parking brake switch connector X-C6 (WP 0018, Figure 44) from parking brake switch (WP 0018, Figure 45). 7. Ensure parking brake switch is in the OFF position (TM 5-2410-24110).

0020-126

1. If active 681-3 code is present, proceed to step 4. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

681-3 Parking Brake Solenoid Voltage Above Normal - Continued

8. Using a digital multimeter (WP 0296), test for continuity between pin 7 and 9 on parking brake switch (WP 0018, Figure 45).

1. If continuity is NOT found, proceed to step 9. 2. If continuity is found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

9. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from the powertrain ECM. 10. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from the powertrain ECM. 11. Disconnect platform harness connector MA-C14 (WP 0018, Figure 33) from steering control harness connector X-C1 (WP 0018, Figure 34. 12. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 13. pin 3 on powertrain ECM connec- 2. If continuity is found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP all pins in powertrain ECM connec0178). Ensure all harness connector X-C3 (WP 0018, Figure 3). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 13. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 14. pin 3 on powertrain ECM connec- 2. If continuity is found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP all pins in powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) from tors are reconnected. Verify corthe powertrain ECM. rect operation of machine (TM 52410-241-10). 14. Using a digital multimeter (WP 0296), test for continuity between pin 3 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 33 on steering control harness connector X-C1 (WP 0018, Figure 34).

0020-127

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

681-3 Parking Brake Solenoid Voltage Above Normal - Continued

15. Using a digital multimeter (WP 0296), test for continuity between pin 4 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 7 on steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

16. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 17. pin 3 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP pin 7 on parking brake switch con0178). Ensure all harness connecnector X-C6 (WP 0018, Figure 44). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 17. Remove rear floor plate (WP 0231). 18. Disconnect platform harness park brake dump solenoid connector MA-C4 (WP 0018, Figure 65) from park brake dump solenoid (WP 0018, Figure 66). 19. Using a digital multimeter (WP 0296), test for continuity between pin 1 on platform harness park brake dump solenoid connector MA-C4 (WP 0018, Figure 65) and pin 33 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 20. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

20. Using a digital multimeter (WP 0296), test for continuity between pin 33 on platform harness connector MA-C14 (WP 0018, Figure 33) and all pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 21. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-128

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

681-3 Parking Brake Solenoid Voltage Above Normal - Continued

21. Using a digital multimeter (WP 0296), measure resistance between pin 1 and pin 2 on park brake dump solenoid (WP 0018, Figure 66).

1. If resistance of 39 to 44 ohms is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If resistance of 39 to 44 ohms is NOT found, replace park brake dump solenoid (WP 0147). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

681-5 Parking Brake Solenoid Voltage Below Normal

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 681-5 code is present, proceed to step 4. 2. If active 681-5 code is NOT present, proceed to step 2.

2. Ensure parking brake switch is in the OFF position (TM 5-2410-24110). 3. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 681-5 code is present, proceed to step 4. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

4. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 5. Remove left platform access panel (WP 0207). 6. Disconnect parking brake switch harness connector X-C6 (WP 0018, Figure 44) from parking brake switch (WP 0018, Figure 45). 7. Ensure parking brake switch is in the OFF position (TM 5-2410-24110). 8. Using a digital multimeter (WP 0296), test for continuity between pin 7 and 9 on parking brake switch (WP 0018, Figure 45).

0020-129

1. If continuity is NOT found, proceed to step 9. 2. If continuity is found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 681-5 Parking Brake Solenoid Voltage Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

9. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from the powertrain ECM. 10. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from the powertrain ECM. 11. Disconnect platform harness connector MA-C14 (WP 0018, Figure 33) from steering control harness connector X-C1 (WP 0018, Figure 34). 12. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 13. pin 3 on powertrain ECM connec- 2. If continuity is found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP all pins in powertrain ECM connec0178). Ensure all harness connector X-C3 (WP 0018, Figure 3). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 13. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 14. pin 3 on powertrain ECM connec- 2. If continuity is found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP all pins in powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) from tors are reconnected. Verify corthe powertrain ECM. rect operation of machine (TM 52410-241-10). 14. Using a digital multimeter (WP 0296), test for continuity between pin 3 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 33 on steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

15. Using a digital multimeter (WP 0296), test for continuity between pin 4 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 7 on steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-130

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 681-5 Parking Brake Solenoid Voltage Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

16. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 17. pin 3 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP pin 7 on parking brake switch con0178). Ensure all harness connecnector X-C6 (WP 0018, Figure 44). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 17. Remove rear floor plate (WP 0231). 18. Disconnect platform harness park brake dump solenoid connector MA-C4 (WP 0018, Figure 65) from park brake dump solenoid (WP 0018, Figure 66). 19. Using a digital multimeter (WP 0296), test for continuity between pin 1 on platform harness park brake dump solenoid connector MA-C4 (WP 0018, Figure 65) and pin 33 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 20. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

20. Using a digital multimeter (WP 0296), test for continuity between pin 33 on platform harness connector MA-C14 (WP 0018, Figure 33) and all pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 21. 2. If continuity is found, replace platform harness (WP 0209).Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

21. Using a digital multimeter (WP 0296), measure resistance between pin 1 and pin 2 on park brake dump solenoid (WP 0018, Figure 66).

1. If resistance of 39 to 44 ohms is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If resistance of 39 to 44 ohms is NOT found, replace park brake dump solenoid (WP 0147). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-131

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

681-6 Parking Brake Solenoid Current Above Normal

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

CORRECTIVE ACTION 1. If active 681-6 code is present, proceed to step 4. 2. If active 681-6 code is NOT present, proceed to step 2.

2. Ensure parking brake switch is in the OFF position (TM 5-2410-24110). 3. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 681-6 code is present, proceed to step 4. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

4. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 5. Remove left platform access panel (WP 0207). 6. Disconnect parking brake switch connector X-C6 (WP 0018, Figure 44) from parking brake switch (WP 0018, Figure 45). 7. Ensure parking brake switch is in the OFF position (TM 5-2410-24110). 8. Using a digital multimeter (WP 0296), test for continuity between pin 7 and 9 on parking brake switch (WP 0018, Figure 45).

9. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from the powertrain ECM. 10. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from the powertrain ECM. 11. Disconnect platform harness connector MA-C14 (WP 0018, Figure 33) from steering control harness connector X-C1 (WP 0018, Figure 34.

0020-132

1. If continuity is NOT found, proceed to step 9. 2. If continuity is found, replace parking brake switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 681-6 Parking Brake Solenoid Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

12. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 13. pin 3 on powertrain ECM connec- 2. If continuity is found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP all pins in powertrain ECM connec0178). Ensure all harness connector X-C3 (WP 0018, Figure 3). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 13. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 14. pin 3 on powertrain ECM connec- 2. If continuity is found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP all pins in powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4) from tors are reconnected. Verify corthe powertrain ECM. rect operation of machine (TM 52410-241-10). 14. Using a digital multimeter (WP 0296), test for continuity between pin 3 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and machine ground.

1. If continuity is NOT found, proceed to step 15. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

15. Using a digital multimeter (WP 0296), test for continuity between pin 3 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 33 on steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

16. Using a digital multimeter (WP 0296), test for continuity between pin 4 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 7 on steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 17. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

17. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 18. pin 3 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C3 (WP 0018, Figure 3) and steering control harness (WP pin 7 on parking brake switch con0178). Ensure all harness connecnector X-C6 (WP 0018, Figure 44). tors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-133

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 681-6 Parking Brake Solenoid Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

18. Remove rear floor plate (WP 0231). 19. Disconnect platform harness park brake dump solenoid connector MA-C4 (WP 0018, Figure 65) from park brake dump solenoid (WP 0018, Figure 66).

689-3 Left Brake Solenoid Voltage Above Normal

20. Using a digital multimeter (WP 0296), test for continuity between pin 1 on platform harness park brake dump solenoid connector MA-C4 (WP 0018, Figure 65) and pin 33 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

21. Using a digital multimeter (WP 0296), test for continuity between pin 33 on platform harness connector MA-C14 (WP 0018, Figure 33) and all pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 22. 2. If continuity is found, replace platform harness (WP 0209).Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

22. Using a digital multimeter (WP 0296), test for continuity between pin 33 on platform harness connector MA-C14 (WP 0018, Figure 33) and machine ground.

1. If continuity is NOT found, proceed to step 23. 2. If continuity is found, replace platform harness (WP 0209).Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

23. Using a digital multimeter (WP 0296), measure resistance between pin 1 and pin 2 on park brake dump solenoid (WP 0018, Figure 66).

1. If resistance of 39 to 44 ohms is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If resistance of 39 to 44 ohms is NOT found, replace park brake dump solenoid (WP 0147). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 689-3 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

0020-134

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 689-3 Left Brake Solenoid Voltage Above Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

2. Remove left platform access panel (WP 0207). 3. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from the powertrain ECM. 4. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from the powertrain ECM. 5. Disconnect platform harness connector MA-C14 (WP 0018, Figure 33) from steering control harness connector X-C1 (WP 0018, Figure 34. 6. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 7. pin 58 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all pins in powertrain ECM connec0178). Ensure all harness connector X-C2 (WP 0018, Figure 4). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 7. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 8. pin 58 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all pins in powertrain ECM connec0178). Ensure all harness connector X-C3 (WP 0018, Figure 3). tors are reconnected. Verify correct operation of machine (TM 52410-241-10). 8. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 9. pin 58 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 37 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, Figure tors are reconnected. Verify cor34). rect operation of machine (TM 52410-241-10). 9. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 10. pin 60 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 41 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, Figure tors are reconnected. Verify cor34). rect operation of machine (TM 52410-241-10).

0020-135

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 689-3 Left Brake Solenoid Voltage Above Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Remove rear floor plate (WP 0231). 11. Disconnect platform harness left brake solenoid connector MA-C12 (WP 0018, Figure 67) from left brake solenoid (WP 0018, Figure 68). 12. Using a digital multimeter (WP 0296), test for continuity between pin 1 on platform harness left brake solenoid connector MA-C12 (WP 0018, Figure 67) and pin 37 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

13. Using a digital multimeter (WP 0296), test for continuity between pin 2 on platform harness left brake solenoid connector MA-C12 (WP 0018, Figure 67) and pin 41 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 14. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

14. Using a digital multimeter (WP 0296), test for continuity between pin 37 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 15. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

15. Using a digital multimeter (WP 0296), measure resistance between pin 1 and pin 2 on left brake solenoid (WP 0018, Figure 68).

1. If resistance of 8 to 9 ohms is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If resistance of 8 to 9 ohms is NOT found, replace left brake solenoid (WP 0147). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-136

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 689-5 Left Brake Solenoid Voltage Below Normal

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 689-5 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Remove rear floor plate (WP 0231). 3. Disconnect platform harness left brake solenoid connector MA-C12 (WP 0018, Figure 67) from left brake solenoid (WP 0018, Figure 68). 4. Install a jumper wire between pins 1 and 2 on platform harness left brake solenoid connector MA-C12 (WP 0018, Figure 67). 5. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 689-6 code is present, Replace left brake solenoid (WP 0147). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 2. If active 689-5 is present, proceed to step 6.

6. Remove left platform access panel (WP 0207). 7. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from the powertrain ECM. 8. Disconnect platform harness connector MA-C14 (WP 0018, Figure 33) from steering control harness connector X-C1 (WP 0018, Figure 34). 9. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 10. pin 58 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 37 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10).

0020-137

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 689-5 Left Brake Solenoid Voltage Below Normal Continued

689-6 Left Brake Solenoid Current Above Normal

TEST OR INSPECTION

CORRECTIVE ACTION

10. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 11. pin 60 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 41 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 11. Using a digital multimeter (WP 0296), test for continuity between pin 1 on platform harness left brake solenoid connector MA-C12 (WP 0018, Figure 67) and pin 37 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 12. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

12. Using a digital multimeter (WP 0296), test for continuity between pin 2 on platform harness left brake solenoid connector MA-C12 (WP 0018, Figure 67) and pin 41 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace platform harness. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 689-6 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Remove rear floor plate (WP 0231). 3. Disconnect platform harness left brake solenoid connector MA-C12 (WP 0018, Figure 67) from left brake solenoid (WP 0018, Figure 68). 4. Check for Diagnostic Codes or Event Codes (WP 0013).

0020-138

1. If active 689-5 code is present, replace left brake solenoid (WP 0147). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 2. If active 689-6 is present, proceed to step 5.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 689-6 Left Brake Solenoid Current Above Normal Continued

TEST OR INSPECTION

CORRECTIVE ACTION

5. Remove left platform access panel (WP 0207). 6. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from the powertrain ECM. 7. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from the powertrain ECM. 8. Disconnect platform harness connector MA-C14 (WP 0018, Figure 33) from steering control harness connector X-C1 (WP 0018, Figure 34). 9. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 10. pin 58 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 37 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 10. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 11. pin 60 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 41 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 11. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 12. pin 58 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10). 12. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 13. pin 60 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10).

0020-139

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 689-6 Left Brake Solenoid Current Above Normal Continued

689-13 Left Brake Solenoid Out of Calibration

TEST OR INSPECTION

CORRECTIVE ACTION

13. Using a digital multimeter (WP 0296), test for continuity between pin 1 on platform harness left brake solenoid connector MA-C12 (WP 0018, Figure 67) and pin 37 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 14. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

14. Using a digital multimeter (WP 0296), test for continuity between pin 2 on platform harness left brake solenoid connector MA-C12 (WP 0018, Figure 67) and pin 41 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

15. Using a digital multimeter (WP 0296), test for continuity between pin 41 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 689-13 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Lift and support machine (WP 0294). Tracks must be raised off ground for rotation while lifted. 3. Select Powertrain D7 ECM on the left side of screen.

0020-140

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

689-13 Left Brake Solenoid Out of Calibration - Continued

4. Select Service (Figure 32, Item 1), Calibrations (Figure 32, Item 2), Brake Touch-Up Pressure Calibrations (Manual) (Figure 32, Item 3).

Figure 32. Calibration Selection.

0020-141

0020

CORRECTIVE ACTION

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 689-13 Left Brake Solenoid Out of Calibration - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

5. Select Begin (Figure 33, Item 1).

Figure 33. Test Startup. 6. Set up Calibration conditions: a. Elevate machine off the ground (WP 0294). This calibration should not be performed with machine on the ground (Figure 34, Item 1). b. Warm transmission oil to 140ºF (60ºC) (Figure 34, Item 1) (TM 5-2410-241-10).

0020-142

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

689-13 Left Brake Solenoid Out of Calibration - Continued

c.

0020

CORRECTIVE ACTION

Release the parking brake (Figure 34, Item 1) (TM 52410-241-10).

d. Set engine speed to low idle (Figure 34, Item 1) (TM 52410-241-10). e. Shift transmission to 3rd forward (Figure 34, Item 1) (TM 5-2410-241-10). f.

Rotate tracks several times (Figure 34, Item 1) (TM 52410-241-10).

NOTE Read steps 7 through 9 thoroughly before starting test. 7. When setup conditions are met, select NEXT (Figure 34, Item 2) button.

Figure 34. Calibration Setup.

0020-143

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 689-13 Left Brake Solenoid Out of Calibration - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

NOTE • Clicking on the left arrow button (Figure 35, Item 4) will cause the ECM to apply a test current to the left brake solenoid. The test current will stop automatically after 20 seconds. Do not click on the left arrow button more than one time during the same test. • To stop the test current at any time during this test (Figure 35, Item 1), click on the right arrow button (Figure 35, Item 3). 8. Click on the left arrow button (Fig- 1. If track functions as specified, proure 35, Item 4) one time. Observe ceed to step 9. the left track. Track rotation should 2. If track rotation stops any time slow but not come to a stop and before track speed returns to northen return to normal after approxmal, increase the calibration value imately 20 seconds. by 5 units (Figure 35, Item 2). To increase the calibration value, click on the right arrow button (Figure 35, Item 3) until the desired value displays. Then, repeat test step 8 9. Click on the left arrow button (Figure 35, Item 4) to decrease the calibration value one unit lower (Figure 35, Item 2). The 20 second test will begin again. Observe the left track. Track rotation should stop and then return to normal after 20 seconds.

0020-144

1. If track functions as specified, calibration is complete. Proceed to step 10. 2. If track does not function as specified, repeat step 9.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 689-13 Left Brake Solenoid Out of Calibration - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

Select NEXT (Figure 35, Item 5) button.

Figure 35. Calibration Controls.

0020-145

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

689-13 Left Brake Solenoid Out of Calibration - Continued

10. Select FINISH (Figure 36, Item 1) button.

Figure 36. Calibration Finish. 11. Shift transmission to Neutral (TM 5-2410-241-10). 12. Engage parking brake (TM 52410-241-10). 13. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 14. Remove MSD (WP 0016). Verify correct operation of machine (TM 5-2410-241-10). 15. Set machine back on ground.

0020-146

0020

CORRECTIVE ACTION

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

722-3 Service Brake Solenoid Voltage Above Normal

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 722-3 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

0020

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect dash harness brake switch connector E-C23 (WP 0018, Figure 47) from service brake switch harness connector KK-C1 (WP 0018, Figure 48) (WP 0174). 4. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 5. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 722-3 code is present, proceed to step 11. 2. If no active codes are present, proceed to step 6.

6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Connect dash harness brake switch connector E-C23 (WP 0018, Figure 47) on service brake switch harness connector KK-C1 (WP 0018, Figure 48) (WP 0174). 8. Adjust service brake pedal switch (WP 0174). 9. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 10. Check for Diagnostic Codes or Event Codes (WP 0013).

0020-147

1. If active 722-3 code is present, replace service brake switch (WP 0037). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 2. If no active code is present, verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

722-3 Service Brake Solenoid Voltage Above Normal - Continued

11. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

CORRECTIVE ACTION

12. Disconnect dash harness brake switch connector E-C23 (WP 0018, Figure 47) from service brake switch harness connector KK-C1 (WP 0018, Figure 48) (WP 0174). 13. Remove left platform access panel (WP 0207). 14. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 15. Remove rear floor plate (WP 0231). 16. Disconnect service brake dump solenoid connector MA-C6 (WP 0018, Figure 69) from service brake dump solenoid (WP 0018, Figure 70). 17. Using a digital multimeter (WP 0296), test for continuity between pin 1 on dash harness brake switch connector E-C23 (WP 0018, Figure 47) and pin 17 on platform harness connector MAC14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 18. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

18. Using a digital multimeter (WP 0296), test for continuity between pin 17 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 19. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

19. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM.

0020-148

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

722-3 Service Brake Solenoid Voltage Above Normal - Continued

20. Disconnect ECM harness connector X-C3 (WP 0018, Figure 3) from powertrain ECM.

722-5 Service Brake Solenoid Voltage Below Normal

CORRECTIVE ACTION

21. Using a digital multimeter (WP 0296), test for continuity between pin 5 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 17 on steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 22. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

22. Using a digital multimeter (WP 0296), test for continuity between pin 5 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 23. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

23. Using a digital multimeter (WP 0296), test for continuity between pin 5 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 722-5 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove rear floor plate (WP 0231). 4. Disconnect service brake dump solenoid connector MA-C6 (WP 0018, Figure 69) from service brake dump solenoid (WP 0018, Figure 70).

0020-149

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

722-5 Service Brake Solenoid Voltage Below Normal - Continued

5. Install a jumper wire between pins 1 and 2 on service brake dump solenoid connector MA-C6 (WP 0018, Figure 69). 6. Check for Diagnostic Codes (WP 0013).

CORRECTIVE ACTION

1. If active 722-6 code is present, replace service brake dump solenoid (WP 0147). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 722-5 code is present, proceed to step 7.

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Remove left platform access panel (WP 0207). 9. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 10. Using a digital multimeter (WP 0296), test for continuity between pin 17 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin 1 on service brake dump solenoid connector MA-C6 (WP 0018, Figure 69).

1. If continuity is found, proceed to step 11. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

11. Using a digital multimeter (WP 0296), test for continuity between pin 7 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin 2 on service brake dump solenoid connector MA-C6 (WP 0018, Figure 69).

1. If continuity is found, proceed to step 12. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

12. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM.

0020-150

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

722-5 Service Brake Solenoid Voltage Below Normal - Continued

13. Using a digital multimeter (WP 0296), test for continuity between pin 4 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 7 on steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 14. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

14. Using a digital multimeter (WP 0296), test for continuity between pin 5 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 17 on steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 722-6 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

722-6 Service Brake Solenoid Current Above Normal

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove rear floor plate (WP 0231). 4. Disconnect service brake dump solenoid connector MA-C6 (WP 0018, Figure 69) from service brake dump solenoid (WP 0018, Figure 70). 5. Check for Diagnostic Codes (WP 0013).

6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Remove left platform access panel (WP 0207).

0020-151

1. If active 722-5 code is present, replace service brake dump solenoid (WP 0147). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 722-6 code is present, proceed to step 6.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

722-6 Service Brake Solenoid Current Above Normal - Continued

8. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33).

CORRECTIVE ACTION

9. Using a digital multimeter (WP 0296), test for continuity between pin 17 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin 1 on service brake dump solenoid connector MA-C6 (WP 0018, Figure 69).

1. If continuity is found, proceed to step 10. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

10. Using a digital multimeter (WP 0296), test for continuity between pin 7 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin 2 on service brake dump solenoid connector MA-C6 (WP 0018, Figure 69).

1. If continuity is found, proceed to step 11. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

11. Using a digital multimeter (WP 0296), test for continuity between pin 17 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 12. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

12. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 13. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 14. Using a digital multimeter (WP 0296), test for continuity between pin 4 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 7 on steering control harness connector X-C1 (WP 0018, Figure 34).

0020-152

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

722-6 Service Brake Solenoid Current Above Normal - Continued

15. Using a digital multimeter (WP 0296), test for continuity between pin 5 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 17 on steering control harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

16. Using a digital multimeter (WP 0296), test for continuity between pin 5 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 17. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

17. Using a digital multimeter (WP 0296), test for continuity between pin 5 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, proceed to step 18. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

18. Using a digital multimeter (WP 0296), test for continuity between pin 4 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 19. 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

19. Using a digital multimeter (WP 0296), test for continuity between pin 4 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110). 2. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 1326-2 code is present, proceed to step 3. 2. If active 1326-2 code is NOT present, proceed to step 2.

1326-2 ECM Location Code Data Erratic, Intermittent, or Incorrect

0020-153

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1326-2 ECM Location Code Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

2. Check for proper software in powertrain ECM. Refer to ECM programming (WP 0017).

1. If software in powertrain ECM is wrong, install proper software (WP 0017). Verify correct operation of machine (TM 5-2410-241-10). 2. If software in powertrain ECM is OK, proceed to step 3.

3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Remove left platform access panel (WP 0207). 5. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 6. Using a digital multimeter (WP 1. If continuity is found, replace pow0296), test for continuity between ertrain ECM (WP 0175). Ensure all pin 32 on powertrain ECM connecharness connectors are recontor X-C3 (WP 0018, Figure 3) and nected. Verify correct operation of machine ground. machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 1401-3 Transmission Solenoid Valve #1 Voltage Above Normal

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove left platform access panel (WP 0207). 4. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 5. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 6. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM.

0020-154

1. If active 1401-3 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1401-3 Transmission Solenoid Valve #1 Voltage Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

7. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 8. pin 65 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 28 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, Figure tors are reconnected. Verify cor34). rect operation of machine (TM 52410-241-10). 8. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 9. pin 65 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10). 9. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 10. pin 65 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10). 10. Remove rear floor plate (WP 0231). 11. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54). 12. Using a digital multimeter (WP 0296), test for continuity between pin 1 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 28 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

13. Using a digital multimeter (WP 0296), test for continuity between pin 28 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 14. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-155

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1401-3 Transmission Solenoid Valve #1 Voltage Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

14. Remove four bolts (Figure 37, Item 2), washers (Figure 37, Item 3), and guard (Figure 37, Item 1) from machine.

Figure 37. Guard and Retaining Hardware.

0020

15. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 16. Using a digital multimeter (WP 0296), test for continuity between pin 1 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin E on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 17. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

17. Using a digital multimeter (WP 0296), test for continuity between pin 1 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and all other pins in transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

1. If continuity is NOT found, proceed to step 18. 2. If continuity is found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-156

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

1401-3 Transmission Solenoid Valve #1 Voltage Above Normal - Continued

0020

CORRECTIVE ACTION

NOTE It may be necessary to remove winch (if equipped) to access transmission solenoid valves. 18. Remove two bolts (Figure 38, Item 3) and guard (Figure 38, Item 4) from machine. 19. Remove 15 bolts (Figure 38, Item 1) and plate (Figure 38, Item 2) from machine.

Figure 38. Guard, Plate, and Retaining Hardware.

0020

20. Disconnect transmission solenoid valve #1 connector P-C4 (WP 0018, Figure 71) from transmission solenoid valve #1 (WP 0145). 21. Using a digital multimeter (WP 0296), test for continuity between pin E on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 1 on transmission solenoid valve #1 connector P-C4 (WP 0018, Figure 71).

0020-157

1. If continuity is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1401-5 Transmission Solenoid Valve #1 Voltage Below Normal

0020

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 1401-5 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove four bolts (Figure 39, Item 2), washers (Figure 39, Item 3), and guard (Figure 39, Item 1) from machine.

Figure 39. Guard and Retaining Hardware.

0020-158

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1401-5 Transmission Solenoid Valve #1 Voltage Below Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

4. Remove two bolts (Figure 40, Item 3) and guard (Figure 40, Item 4) from machine. 5. Remove 15 bolts (Figure 40, Item 1) and plate (Figure 40, Item 2) from machine.

Figure 40. Guard, Plate, and Retaining Hardware.

0020

6. Disconnect transmission solenoid valve #1 connector P-C4 (WP 0018, Figure 71) from transmission solenoid valve #1 (WP 0145). 7. Insert a jumper wire between pins 1 and 2 on transmission solenoid valve #1 connector P-C4 (WP 0018, Figure 71). 8. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 9. Check for Diagnostic Codes (WP 0013).

0020-159

1. If active 1401-6 code is present, replace transmission solenoid valve #1 (WP 0145). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 1401-5 code is present, proceed to step 10.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1401-5 Transmission Solenoid Valve #1 Voltage Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 11. Remove jumper wire between pins 1 and 2 on transmission solenoid valve #1 connector P-C4 (WP 0018, Figure 71). 12. Remove left platform access panel (WP 0207). 13. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 14. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 65 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 28 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 16. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 17. pin 55 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 30 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 17. Remove rear floor plate (WP 0231). 18. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

0020-160

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1401-5 Transmission Solenoid Valve #1 Voltage Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

19. Using a digital multimeter (WP 0296), test for continuity between pin 1 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 28 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 20. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

20. Using a digital multimeter (WP 0296), test for continuity between pin 6 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 30 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

21. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 22. Using a digital multimeter (WP 0296), test for continuity between pin 1 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin E on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 23. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

23. Using a digital multimeter (WP 0296), test for continuity between pin 6 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin J on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 24. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

24. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 25. pin J on transmission harness con- 2. If continuity is NOT found, replace nector P-C1 (WP 0018, Figure 56) transmission sensor harness (WP and pin 2 on transmission solenoid 0173). Ensure all harness connecvalve #1 connector P-C4 (WP tors are reconnected. Verify cor0018, Figure 71). rect operation of machine (TM 52410-241-10).

0020-161

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

0020

TEST OR INSPECTION

CORRECTIVE ACTION

1401-5 Transmission Solenoid Valve #1 Voltage Below Normal - Continued

25. Using a digital multimeter (WP 0296), test for continuity between pin E on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 1 on transmission solenoid valve #1 connector P-C4 (WP 0018, Figure 71).

1. If continuity is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

1401-6 Transmission Solenoid Valve #1 Current Above Normal

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 1401-6 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

3.

3. Remove four bolts (Figure 41, Item 2), washers (Figure 41, Item 3), and guard (Figure 41, Item 1) from machine.

Figure 41. Guard and Retaining Hardware.

0020-162

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1401-6 Transmission Solenoid Valve #1 Current Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

4. Remove two bolts (Figure 42, Item 3) and guard (Figure 42, Item 4) from machine. 5. Remove 15 bolts (Figure 42, Item 1) and plate (Figure 42, Item 2) from machine.

Figure 42. Guard, Plate, and Retaining Hardware.

0020

6. Disconnect transmission solenoid valve #1 connector P-C4 (WP 0018, Figure 71) from transmission solenoid valve #1 (WP 0145). 7. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 8. Check for Diagnostic Codes (WP 0013).

9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0020-163

1. If active 1401-5 code is present, replace transmission solenoid valve #1 (WP 0145). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 1401-6 code is present, proceed to step 9.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1401-6 Transmission Solenoid Valve #1 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Remove left platform access panel (WP 0207).

11. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 12. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 13. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 14. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 15. pin 65 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 28 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 55 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 30 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 16. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 17. pin 65 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10). 17. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 18. pin 65 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10).

0020-164

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1401-6 Transmission Solenoid Valve #1 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

18. Remove rear floor plate (WP 0231).

19. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54). 20. Using a digital multimeter (WP 0296), test for continuity between pin 1 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 28 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

21. Using a digital multimeter (WP 0296), test for continuity between pin 6 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 30 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 22. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

22. Using a digital multimeter (WP 0296), test for continuity between pin 28 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MAC14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 23. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

23. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 24. Using a digital multimeter (WP 0296), test for continuity between pin 1 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin E on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

0020-165

1. If continuity is found, proceed to step 25. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1401-6 Transmission Solenoid Valve #1 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

25. Using a digital multimeter (WP 0296), test for continuity between pin 6 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin J on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 26. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

26. Using a digital multimeter (WP 0296), test for continuity between pin 1 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and all other pins in transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

1. If continuity is NOT found, proceed to step 27. 2. If continuity is found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

27. Using a digital multimeter (WP 1. If continuity is found, proceed step 0296), test for continuity between 28. pin J on transmission harness con- 2. If continuity is NOT found, replace nector P-C1 (WP 0018, Figure 56) transmission sensor harness (WP and pin 2 on transmission solenoid 0173). Ensure all harness connecvalve #1 connector P-C4 (WP tors are reconnected. Verify cor0018, Figure 71). rect operation of machine (TM 52410-241-10). 28. Using a digital multimeter (WP 0296), test for continuity between pin E on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 1 on transmission solenoid valve #1 connector P-C4 (WP 0018, Figure 71).

1. If continuity is found, proceed to step 29. 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

29. Using a digital multimeter (WP 0296), test for continuity between pin E on transmission harness connector P-C1 (WP 0018, Figure 56) and all other pins in transmission harness connector P-C1 (WP 0018, Figure 56).

1. If continuity is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-166

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

1401-13 Transmission Sole1. Connect MSD (WP 0016), select noid Valve #1 Out of CaliPowertrain D7 ECM, and check for bration Diagnostic Codes or Event Codes (WP 0013).

0020

CORRECTIVE ACTION 1. If active 1401-13 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Select Powertrain D7 ECM on the left side of screen. 3. Select Service (Figure 43, Item 1), Calibrations (Figure 43, Item 2), Transmission Fill Calibration (Figure 43, Item 3).

Figure 43. ECM Selection. 4. Set up Calibration Requirements.

0020-167

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

0020

CORRECTIVE ACTION

1401-13 Transmission Sole5. Select NEXT (Figure 44, Item 1) noid Valve #1 Out of Calibutton. bration - Continued 8

Figure 44. Select Calibration. 6. Select FINISH (Figure 45, Item 1) button.

0020

Verify correct operation of machine (TM 5-2410-241-10).

7. Remove MSD (WP 0016).

Figure 45. Calibration Finish.

0020-168

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1402-3 Transmission Solenoid Valve #2 Voltage Above Normal

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 1402-3 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove left platform access panel (WP 0207). 4. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 5. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 6. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 7. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 8. pin 66 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 29 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, Figure tors are reconnected. Verify cor34). rect operation of machine (TM 52410-241-10). 8. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 9. pin 66 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, Figure tors are reconnected. Verify cor4). rect operation of machine (TM 52410-241-10). 9. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 10. pin 66 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10).

0020-169

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1402-3 Transmission Solenoid Valve #2 Voltage Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Remove rear floor plate (WP 0231).

11. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54). 12. Using a digital multimeter (WP 0296), test for continuity between pin 2 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 29 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

13. Using a digital multimeter (WP 0296), test for continuity between pin 29 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 14. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-170

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1402-3 Transmission Solenoid Valve #2 Voltage Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

14. Remove four bolts (Figure 46, Item 2), washers (Figure 46, Item 3), and guard (Figure 46, Item 1) from machine.

Figure 46. Guard and Retaining Hardware.

0020

15. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 16. Using a digital multimeter (WP 0296), test for continuity between pin 2 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin F on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 17. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

17. Using a digital multimeter (WP 0296), test for continuity between pin 2 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and all other pins in transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

1. If continuity is NOT found, proceed to step 18. 2. If continuity is found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-171

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1402-3 Transmission Solenoid Valve #2 Voltage Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

NOTE It may be necessary to remove winch (if equipped) to access transmission solenoid valves. 18. Remove two bolts (Figure 47, Item 3) and guard (Figure 47, Item 4) from machine. 19. Remove 15 bolts (Figure 47, Item 1) and plate (Figure 47, Item 2) from machine.

Figure 47. Guard, Plate, and Retaining Hardware.

0020

20. Disconnect transmission solenoid valve #2 connector P-C3 (WP 0018, Figure 72) from transmission solenoid valve #2 (WP 0145). 21. Using a digital multimeter (WP 0296), test for continuity between pin F on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 1 on transmission solenoid valve #2 connector P-C3 (WP 0018, Figure 72).

0020-172

1. If continuity is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1402-5 Transmission Solenoid Valve #2 Current Below Normal

0020

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 1402-5 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove four bolts (Figure 48, Item 2), washers (Figure 48, Item 3), and guard (Figure 48, Item 1) from machine.

Figure 48. Guard and Retaining Hardware.

0020-173

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1402-5 Transmission Solenoid Valve #2 Current Below Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

4. Remove two bolts (Figure 49, Item 3) and guard (Figure 49, Item 4) from machine. 5. Remove 15 bolts (Figure 49, Item 1) and plate (Figure 49, Item 2) from machine

Figure 49. Guard, Plate, and Retaining Hardware.

0020

6. Disconnect transmission solenoid valve #2 connector P-C3 (WP 0018, Figure 72) from transmission solenoid valve #2 (WP 0145). 7. Insert a jumper wire between pins 1 and 2 on transmission solenoid valve #2 connector P-C3 (WP 0018, Figure 72). 8. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 9. Check for Diagnostic Codes (WP 0013).

0020-174

1. If active 1402-6 code is present, replace transmission solenoid valve #2 (WP 0145). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 1402-5 code is present, proceed to step 10.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1402-5 Transmission Solenoid Valve #2 Current Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 11. Remove jumper wire between pins 1 and 2 on transmission solenoid valve #2 connector P-C3 (WP 0018, Figure 72). 12. Remove left platform access panel (WP 0207). 13. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 14. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 66 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 29 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, Figure tors are reconnected. Verify cor34). rect operation of machine (TM 52410-241-10). 16. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 17. pin 55 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 30 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, Figure tors are reconnected. Verify cor34). rect operation of machine (TM 52410-241-10). 17. Remove rear floor plate (WP 0231). 18. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

0020-175

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1402-5 Transmission Solenoid Valve #2 Current Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

19. Using a digital multimeter (WP 0296), test for continuity between pin 2 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 29 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 20. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

20. Using a digital multimeter (WP 0296), test for continuity between pin 6 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 30 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

21. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 22. Using a digital multimeter (WP 0296), test for continuity between pin 2 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin F on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 23. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

23. Using a digital multimeter (WP 0296), test for continuity between pin 6 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin J on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 24. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

24. Using a digital multimeter (WP 1. If continuity is found, proceed 0296), test for continuity between step 25. pin J on transmission harness con- 2. If continuity is NOT found, replace nector P-C1 (WP 0018, Figure 56) transmission sensor harness (WP and pin 2 on transmission solenoid 0173). Ensure all harness connecvalve #2 connector P-C3 (WP tors are reconnected. Verify cor0018, Figure 72). rect operation of machine (TM 52410-241-10).

0020-176

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

0020

TEST OR INSPECTION

CORRECTIVE ACTION

1402-5 Transmission Solenoid Valve #2 Current Below Normal - Continued

25. Using a digital multimeter (WP 0296), test for continuity between pin F on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 1 on transmission solenoid valve #2 connector P-C3 (WP 0018, Figure 72).

1. If continuity is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

1402-6 Transmission Solenoid Valve #2 Current Above Normal

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 1402-6 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove four bolts (Figure 50, Item 2), washers (Figure 50, Item 3), and guard (Figure 50, Item 1) from machine.

Figure 50. Guard and Retaining Hardware.

0020-177

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1402-6 Transmission Solenoid Valve #2 Current Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

4. Remove two bolts (Figure 51, Item 3) and guard (Figure 51, Item 4) from machine. 5. Remove 15 bolts (Figure 51, Item 1) and plate (Figure 51, Item 2) from machine.

Figure 51. Guard, Plate, and Retaining Hardware.

0020

6. Disconnect transmission solenoid valve #2 connector P-C3 (WP 0018, Figure 72) from transmission solenoid valve #2 (WP 0145). 7. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 8. Check for Diagnostic Codes (WP 0013).

9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0020-178

1. If active 1402-5 code is present, replace transmission solenoid valve #2 (WP 0145). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 1402-6 code is present, proceed to step 9.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1402-6 Transmission Solenoid Valve #2 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Remove left platform access panel (WP 0207).

11. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 12. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 13. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 14. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 15. pin 66 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 29 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 55 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 30 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 16. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 17. pin 66 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10). 17. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 18. pin 66 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10).

0020-179

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1402-6 Transmission Solenoid Valve #2 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

18. Remove rear floor plate (WP 0231).

19. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54). 20. Using a digital multimeter (WP 0296), test for continuity between pin 2 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 29 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

21. Using a digital multimeter (WP 0296), test for continuity between pin 6 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 30 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 22. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

22. Using a digital multimeter (WP 0296), test for continuity between pin 29 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 23. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

23. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 24. Using a digital multimeter (WP 0296), test for continuity between pin 2 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin F on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

0020-180

1. If continuity is found, proceed to step 25. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1402-6 Transmission Solenoid Valve #2 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

25. Using a digital multimeter (WP 0296), test for continuity between pin 6 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin J on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 26. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

26. Using a digital multimeter (WP 0296), test for continuity between pin 2 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and all other pins in transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

1. If continuity is NOT found, proceed to step 27. 2. If continuity is found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

27. Using a digital multimeter (WP 1. If continuity is found, proceed step 0296), test for continuity between 28. pin J on transmission harness con- 2. If continuity is NOT found, replace nector P-C1 (WP 0018, Figure 56) transmission sensor harness (WP and pin 2 on transmission solenoid 0173). Ensure all harness connecvalve #2 connector P-C3 (WP tors are reconnected. Verify cor0018, Figure 72). rect operation of machine (TM 52410-241-10). 28. Using a digital multimeter (WP 0296), test for continuity between pin F on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 1 on transmission solenoid valve #2 connector P-C3 (WP 0018, Figure 72).

1. If continuity is found, proceed to step 29. 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

29. Using a digital multimeter (WP 0296), test for continuity between pin F on transmission harness connector P-C1 (WP 0018, Figure 56) all other pins in transmission harness connector P-C1 (WP 0018, Figure 56).

1. If continuity is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-181

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

1402-13 Transmission Sole1. Connect MSD (WP 0016), select noid Valve #2 Out of CaliPowertrain D7 ECM, and check for bration Diagnostic Codes or Event Codes (WP 0013).

0020

CORRECTIVE ACTION 1. If active 1402-13 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Select Powertrain D7 ECM on the left side of screen. 3. Select Service (Figure 52, Item 1), Calibrations (Figure 52, Item 2), Transmission Fill Calibration (Figure 52, Item 3).

Figure 52. ECM Selection. 4. Set Up Calibration Requirements.

0020-182

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

0020

CORRECTIVE ACTION

1402-13 Transmission Sole5. Select NEXT (Figure 53, Item 1) noid Valve #2 Out of Calibutton. bration - Continued

Figure 53. Select Calibration. 6. Select FINISH (Figure 54, Item 1) button. 7. Remove MSD (WP 0016).

Figure 54. Calibration Finish.

0020-183

0020

Verify correct operation of machine (TM 5-2410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1403-3 Transmission Solenoid Valve #3 Voltage Above Normal

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 1403-3 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove left platform access panel (WP 0207). 4. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 5. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 6. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 7. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 8. pin 51 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 26 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, Figure tors are reconnected. Verify cor34). rect operation of machine (TM 52410-241-10). 8. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 9. pin 51 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10). 9. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 10. pin 51 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10).

0020-184

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1403-3 Transmission Solenoid Valve #3 Voltage Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

10. Remove rear floor plate (WP 0231).

11. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54). 12. Using a digital multimeter (WP 0296), test for continuity between pin 3 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 26 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

13. Using a digital multimeter (WP 0296), test for continuity between pin 26 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 14. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

14. Remove four bolts (Figure 55, Item 2), washers (Figure 55, Item 3), and guard (Figure 55, Item 1) from machine.

Figure 55. Guard and Retaining Hardware.

0020-185

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1403-3 Transmission Solenoid Valve #3 Voltage Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

15. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 16. Using a digital multimeter (WP 0296), test for continuity between pin 3 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin G on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 17. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

17. Using a digital multimeter (WP 0296), test for continuity between pin 3 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and all other pins in transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

1. If continuity is NOT found, proceed to step 18. 2. If continuity is found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-186

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

1403-3 Transmission Solenoid Valve #3 Voltage Above Normal - Continued

0020

CORRECTIVE ACTION

NOTE It may be necessary to remove winch (if equipped) to access transmission solenoid valves. 18. Remove two bolts (Figure 56, Item3) and guard (Figure 56, Item4) from machine. 19. Remove 15 bolts (Figure 56, Item1) and plate (Figure 56, Item 2) from machine.

Figure 56. Guard, Plate, and Retaining Hardware.

0020

20. Disconnect transmission solenoid valve #3 connector P-C7 (WP 0018, Figure 73) from transmission solenoid valve #3 (WP 0145). 21. Using a digital multimeter (WP 0296), test for continuity between pin G on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 1 on transmission solenoid valve #3 connector P-C7 (WP 0018, Figure 73).

0020-187

1. If continuity is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1403-5 Transmission Solenoid Valve #3 Current Below Normal

0020

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 1403-5 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove four bolts (Figure 57, Item 2), washers (Figure 57, Item 3), and guard (Figure 57, Item 1) from machine.

Figure 57. Guard and Retaining Hardware.

0020-188

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1403-5 Transmission Solenoid Valve #3 Current Below Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

4. Remove two bolts (Figure 58, Item 3) and guard (Figure 58, Item 4) from machine. 5. Remove 15 bolts (Figure 58, Item 1) and plate (Figure 58, Item 2) from machine.

Figure 58. Guard, Plate, and Retaining Hardware. 6. Disconnect transmission solenoid valve #3 connector P-C7 (WP 0018, Figure 73) from transmission solenoid valve #3 (WP 0145). 7. Insert a jumper wire between pins 1 and 2 on transmission solenoid valve #3 connector P-C7 (WP 0018, Figure 73). 8. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10).

0020-189

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1403-5 Transmission Solenoid Valve #3 Current Below Normal - Continued

TEST OR INSPECTION 9. Check for Diagnostic Codes (WP 0013).

CORRECTIVE ACTION 1. If active 1403-6 code is present, replace transmission solenoid valve #3 (WP 0145). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 1403-5 code is present, proceed to step 10.

10. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 11. Remove jumper wire between pins 1 and 2 on transmission solenoid valve #3 connector P-C7 (WP 0018, Figure 73). 12. Remove left platform access panel (WP 0207). 13. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 14. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 51 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 26 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 16. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 17. pin 50 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 31 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 17. Remove rear floor plate (WP 0231).

0020-190

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1403-5 Transmission Solenoid Valve #3 Current Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

18. Disconnect platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54). 19. Using a digital multimeter (WP 0296), test for continuity between pin 3 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 26 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 20. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

20. Using a digital multimeter (WP 0296), test for continuity between pin 7 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 31 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

21. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 22. Using a digital multimeter (WP 0296), test for continuity between pin 3 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin G on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 23. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

23. Using a digital multimeter (WP 0296), test for continuity between pin 7 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin L on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 24. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-191

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1403-5 Transmission Solenoid Valve #3 Current Below Normal - Continued

1403-6 Transmission Solenoid Valve #3 Current Above Normal

TEST OR INSPECTION

CORRECTIVE ACTION

24. Using a digital multimeter (WP 0296), test for continuity between pin L on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 2 on transmission solenoid valve #3 connector P-C7 (WP 0018, Figure 73).

1. If continuity is found, proceed step 25. 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

25. Using a digital multimeter (WP 0296), test for continuity between pin G on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 1 on transmission solenoid valve #3 connector P-C7 (WP 0018, Figure 73).

1. If continuity is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 1403-6 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0020-192

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1403-6 Transmission Solenoid Valve #3 Current Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

3. Remove four bolts (Figure 59, Item 2), washers (Figure 59, Item 3), and guard (Figure 59, Item 1) from machine.

Figure 59. Guard and Retaining Hardware.

0020-193

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1403-6 Transmission Solenoid Valve #3 Current Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

4. Remove two bolts (Figure 60, Item 3) and guard (Figure 60, Item 4) from machine. 5. Remove 15 bolts (Figure 60, Item 1) and plate (Figure 60, Item 2) from machine.

Figure 60. Guard, Plate, and Retaining Hardware.

0020

6. Disconnect transmission solenoid valve #3 connector P-C7 (WP 0018, Figure 73) from transmission solenoid valve #3 (WP 0145). 7. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 8. Check for Diagnostic Codes (WP 0013).

9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0020-194

1. If active 1403-5 code is present, replace transmission solenoid valve #1 (WP 0145). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 1403-6 code is present, proceed to step 9.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1403-6 Transmission Solenoid Valve #3 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Remove left platform access panel (WP 0207).

11. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 12. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 13. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 14. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 15. pin 51 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 26 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 50 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 31 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 16. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 17. pin 51 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10). 17. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 18. pin 51 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10).

0020-195

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1403-6 Transmission Solenoid Valve #3 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

18. Remove rear floor plate (WP 0231).

19. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54). 20. Using a digital multimeter (WP 0296), test for continuity between pin 3 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 26 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

21. Using a digital multimeter (WP 0296), test for continuity between pin 7 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 31 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 22. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

22. Using a digital multimeter (WP 0296), test for continuity between pin 26 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 23. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

23. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 24. Using a digital multimeter (WP 0296), test for continuity between pin 3 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin G on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

0020-196

1. If continuity is found, proceed to step 25. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1403-6 Transmission Solenoid Valve #3 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

25. Using a digital multimeter (WP 0296), test for continuity between pin 7 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin L on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 26. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

26. Using a digital multimeter (WP 0296), test for continuity between pin 3 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and all other pins in transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

1. If continuity is NOT found, proceed to step 27. 2. If continuity is found, replace transmission jumper harness (WP 0169). Proceed to step 30. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

27. Using a digital multimeter (WP 0296), test for continuity between pin L on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 2 on transmission solenoid valve #3 connector P-C7 (WP 0018, Figure 73).

1. If continuity is found, proceed step 28. 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

28. Using a digital multimeter (WP 0296), test for continuity between pin G on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 1 on transmission solenoid valve #3 connector P-C7 (WP 0018, Figure 73).

1. If continuity is found, proceed to step 29. 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

29. Using a digital multimeter (WP 0296), test for continuity between pin G on transmission harness connector P-C1 (WP 0018, Figure 56) and all other pins in transmission harness connector P-C1 (WP 0018, Figure 56).

1. If continuity is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-197

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

1403-13 Transmission Sole1. Connect MSD (WP 0016), select noid Valve #3 Out of CaliPowertrain D7 ECM, and check for bration Diagnostic Codes or Event Codes (WP 0013).

0020

CORRECTIVE ACTION 1. If active 1403-13 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Select Powertrain D7 ECM on the left side of screen. 3. Select Service (Figure 61, Item 1), Calibrations (Figure 61, Item 2), Transmission Fill Calibration (Figure 61, Item 3).

Figure 61. ECM Selection.

0020-198

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

0020

CORRECTIVE ACTION

1403-13 Transmission Sole4. Set up Calibration Requirements. noid Valve #3 Out of Calibration - Continued 5. Select NEXT (Figure 62, Item 1) button.

Figure 62. Select Calibration. 6. Select FINISH (Figure 63, Item 1) button.

0020

Verify correct operation of machine (TM 5-2410-241-10).

7. Remove MSD (WP 0016).

Figure 63. Calibration Finish.

0020-199

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1404-3 Transmission Solenoid Valve #4 Voltage Above Normal

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 1404-3 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove left platform access panel (WP 0207). 4. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 5. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 6. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 7. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 8. pin 49 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 25 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 8. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 9. pin 49 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10). 9. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 10. pin 49 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10).

0020-200

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1404-3 Transmission Solenoid Valve #4 Voltage Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Remove rear floor plate (WP 0231).

11. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54). 12. Using a digital multimeter (WP 0296), test for continuity between pin 4 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 25 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

13. Using a digital multimeter (WP 0296), test for continuity between pin 25 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 14. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-201

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1404-3 Transmission Solenoid Valve #4 Voltage Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

14. Remove four bolts (Figure 64, Item 2), washers (Figure 64, Item 3), and guard (Figure 64, Item 1) from machine.

Figure 64. Guard and Retaining Hardware.

0020

15. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 16. Using a digital multimeter (WP 0296), test for continuity between pin 4 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin D on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 17. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

17. Using a digital multimeter (WP 0296), test for continuity between pin 4 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and all other pins in transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

1. If continuity is NOT found, proceed to step 18. 2. If continuity is found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-202

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1404-3 Transmission Solenoid Valve #4 Voltage Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

NOTE It may be necessary to remove winch (if equipped) to access transmission solenoid valves. 18. Remove two bolts (Figure 65, Item 3) and guard (Figure 65, Item 4) from machine. 19. Remove 15 bolts (Figure 65, Item 1) and plate (Figure 65, Item 2) from machine.

Figure 65. Guard, Plate, and Retaining Hardware.

0020

20. Disconnect transmission solenoid valve #4 connector P-C6 (WP 0018, Figure 74) from transmission solenoid valve #4 (WP 0145). 21. Using a digital multimeter (WP 0296), test for continuity between pin D on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 1 on transmission solenoid valve #4 connector P-C6 (WP 0018, Figure 74).

0020-203

1. If continuity is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1404-5 Transmission Solenoid Valve #4 Current Below Normal

0020

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 1404-5 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove four bolts (Figure 66, Item 2), washers (Figure 66, Item 3), and guard (Figure 66, Item 1) from machine.

Figure 66. Guard and Retaining Hardware.

0020-204

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1404-5 Transmission Solenoid Valve #4 Current Below Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

4. Remove two bolts (Figure 67, Item 3) and guard (Figure 67, Item 4) from machine. 5. Remove 15 bolts (Figure 67, Item 1) and plate (Figure 67, Item 2) from machine.

Figure 67. Guard, Plate, and Retaining Hardware.

0020

6. Disconnect transmission solenoid valve #4 connector P-C6 (WP 0018, Figure 74) from transmission solenoid valve #4 (WP 0145). 7. Insert a jumper wire between pins 1 and 2 on transmission solenoid valve #4 connector P-C6 (WP 0018, Figure 74). 8. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 9. Check for Diagnostic Codes (WP 0013).

0020-205

1. If active 1405-6 code is present, replace transmission solenoid valve #1 (WP 0145). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 1405-5 code is present, proceed to step 10.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1404-5 Transmission Solenoid Valve #4 Current Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 11. Remove jumper wire between pins 1 and 2 on transmission solenoid valve #4 connector P-C6 (WP 0018, Figure 74). 12. Remove left platform access panel (WP 0207). 13. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 14. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 49 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 25 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 16. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 17. pin 50 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 31 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 17. Remove rear floor plate (WP 0231). 18. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

0020-206

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1404-5 Transmission Solenoid Valve #4 Current Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

19. Using a digital multimeter (WP 0296), test for continuity between pin 4 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 25 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 20. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

20. Using a digital multimeter (WP 0296), test for continuity between pin 7 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 31 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

21. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 22. Using a digital multimeter (WP 0296), test for continuity between pin 4 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin D on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 23.

23. Using a digital multimeter (WP 0296), test for continuity between pin 7 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin L on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 24. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

24. Using a digital multimeter (WP 0296), test for continuity between pin L on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 2 on transmission solenoid valve #4 connector P-C6 (WP 0018, Figure 74).

1. If continuity is found, proceed step 25. 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-207

2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

0020

TEST OR INSPECTION

CORRECTIVE ACTION

1404-5 Transmission Solenoid Valve #4 Current Below Normal - Continued

25. Using a digital multimeter (WP 0296), test for continuity between pin D on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 1 on transmission solenoid valve #4 connector P-C6 (WP 0018, Figure 74).

1. If continuity is found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

1404-6 Transmission Solenoid Valve #4 Current Above Normal

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 1404-6 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove four bolts (Figure 68, Item 2), washers (Figure 68, Item 3), and guard (Figure 68, Item 1) from machine.

Figure 68. Guard and Retaining Hardware.

0020-208

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

1404-6 Transmission Solenoid Valve #4 Current Above Normal - Continued

0020

CORRECTIVE ACTION

4. Remove two bolts (Figure 69, Item 3) and guard (Figure 69, Item 4) from machine. 5. Remove 15 bolts (Figure 69, Item 1) and plate (Figure 69, Item 2) from machine.

Figure 69. Guard, Plate, and Retaining Hardware.

0020

6. Disconnect transmission solenoid valve #4 connector P-C6 (WP 0018, Figure 74) from transmission solenoid valve #4 (WP 0145). 7. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 8. Check for Diagnostic Codes (WP 0013).

9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0020-209

1. If active 1404-5 code is present, replace transmission solenoid valve #1 (WP 0145). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 1404-6 code is present, proceed to step 9.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1404-6 Transmission Solenoid Valve #4 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Remove left platform access panel (WP 0207).

11. Disconnect powertrain steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 12. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 13. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 14. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 15. pin 49 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 25 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 50 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 31 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 16. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 17. pin 49 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10). 17. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 18. pin 49 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10).

0020-210

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1404-6 Transmission Solenoid Valve #4 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

18. Remove rear floor plate (WP 0231).

19. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54). 20. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 21. pin 4, on platform harness connec- 2. If continuity is NOT found, replace tor to transmission jumper harness platform harness (WP 0209). MA-C7 (WP 0018, Figure 53) and Ensure all harness connectors are pin 25 on platform harness conreconnected. Verify correct operanector MA-C14 (WP 0018, tion of machine (TM 5-2410-241Figure 33). 10). 21. Using a digital multimeter (WP 0296), test for continuity between pin 7 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 31 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 22. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

22. Using a digital multimeter (WP 0296), test for continuity between pin 25 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MAC14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 23. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

23. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 24. Using a digital multimeter (WP 0296), test for continuity between pin 4 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin D on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

0020-211

1. If continuity is found, proceed to step 25. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1404-6 Transmission Solenoid Valve #4 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

25. Using a digital multimeter (WP 0296), test for continuity between pin 7 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin L on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 26. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

26. Using a digital multimeter (WP 0296), test for continuity between pin 4 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and all other pins in transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

1. If continuity is NOT found, proceed to step 27. 2. If continuity is found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

27. Using a digital multimeter (WP 0296), test for continuity between pin L on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 2 on transmission solenoid valve #4 connector P-C6 (WP 0018, Figure 74).

1. If continuity is found, proceed step 28. 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

28. Using a digital multimeter (WP 0296), test for continuity between pin D on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 1 on transmission solenoid valve #4 connector P-C6 (WP 0018, Figure 74).

1. If continuity is found, proceed to step 29. 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

29. Using a digital multimeter (WP 1. If continuity is found, replace pow0296), test for continuity between ertrain ECM (WP 0175). Ensure all pin D on transmission harness harness connectors are reconconnector P-C1 (WP 0018, nected. Verify correct operation of Figure 56) and all other pins in machine (TM 5-2410-241-10). transmission harness connector P- 2. If continuity is NOT found, replace C1 (WP 0018, Figure 56). transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-212

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

1404-13 Transmission Sole1. Connect MSD (WP 0016), select noid Valve #4 Out of CaliPowertrain D7 ECM, and check for bration Diagnostic Codes or Event Codes (WP 0013).

0020

CORRECTIVE ACTION 1. If active 1404-13 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Select Powertrain D7 ECM on the left side of screen. 3. Select Service (Figure 70, Item 1), Calibrations (Figure 70, Item 2), Transmission Fill Calibration (Figure 70, Item 3).

Figure 70. ECM Selection.

0020-213

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

0020

CORRECTIVE ACTION

1404-13 Transmission Sole4. Set up Calibration Requirements. noid Valve #4 Out of Cali- 5. Select NEXT (Figure 71, Item 1) bration - Continued button.

Figure 71. Select Calibration. 6. Select FINISH (Figure 72, Item 1) button. 7. Remove MSD (WP 0016).

Figure 72. Calibration Finish.

0020-214

0020

Verify correct operation of machine (TM 5-2410-241-10)

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1405-3 Transmission Solenoid Valve #5 Voltage Above Normal

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 1405-3 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove left platform access panel (WP 0207). 4. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 5. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 6. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 7. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 8. pin 48 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 24 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 8. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 9. pin 48 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10).

0020-215

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1405-3 Transmission Solenoid Valve #5 Voltage Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

9. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 10. pin 48 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10). 10. Remove rear floor plate (WP 0231). 11. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54). 12. Using a digital multimeter (WP 0296), test for continuity between pin 5 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 24 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

13. Using a digital multimeter (WP 0296), test for continuity between pin 24 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MAC14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 14. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020-216

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1405-3 Transmission Solenoid Valve #5 Voltage Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

14. Remove four bolts (Figure 73, Item 2), washers (Figure 73, Item 3), and guard (Figure 73, Item 1) from machine.

Figure 73. Guard and Retaining Hardware.

0020

15. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 16. Using a digital multimeter (WP 0296), test for continuity between pin 5 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin I on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 17. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

17. Using a digital multimeter (WP 0296), test for continuity between pin 5 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and all other pins in transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

1. If continuity is NOT found, proceed to step 18. 2. If continuity is found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-217

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1405-3 Transmission Solenoid Valve #5 Voltage Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

NOTE It may be necessary to remove winch (if equipped) to access transmission solenoid valves. 18. Remove two bolts (Figure 74, Item 3) and guard (Figure 74, Item 4) from machine. 19. Remove 15 bolts (Figure 74, Item 1) and plate (Figure 74, Item 2) from machine.

Figure 74. Guard, Plate, and Retaining Hardware.

0020

20. Disconnect transmission solenoid valve #5 connector P-C5 (WP 0018, Figure 75) from transmission solenoid valve #5 (WP 0145). 21. Using a digital multimeter (WP 1. If continuity is found, replace pow0296), test for continuity between ertrain ECM (WP 0175). Ensure all pin I on transmission harness conharness connectors are reconnector P-C1 (WP 0018, Figure 56) nected. Verify correct operation of and pin 1 on transmission solenoid machine (TM 5-2410-241-10). valve #5 connector P-C5 (WP 2. If continuity is NOT found, replace 0018, Figure 75). transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 22. Ensure all harness connectors are reconnected.

0020-218

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1405-5 Transmission Solenoid Valve #5 Current Below Normal

0020

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 1405-5 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove four bolts (Figure 75, Item 2), washers (Figure 75, Item 3), and guard (Figure 75, Item 1) from machine.

Figure 75. Guard and Retaining Hardware.

0020-219

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

1405-5 Transmission Solenoid Valve #5 Current Below Normal - Continued

0020

CORRECTIVE ACTION

4. Remove two bolts (Figure 76, Item 3) and guard (Figure 76, Item 4) from machine. 5. Remove 15 bolts (Figure 76, Item 1) and plate (Figure 76, Item 2) from machine.

Figure 76. Guard, Plate, and Retaining Hardware.

0020

6. Disconnect transmission solenoid valve #5 connector P-C5 (WP 0018, Figure 75) from transmission solenoid valve #5 (WP 0145). 7. Insert a jumper wire between pins 1 and 2 on transmission solenoid valve #5 connector P-C5 (WP 0018, Figure 75). 8. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 9. Check for Diagnostic Codes (WP 0013).

0020-220

1. If active 1405-6 code is present, replace transmission solenoid valve #5 (WP 0145). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 1405-5 code is present, proceed to step 10.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1405-5 Transmission Solenoid Valve #5 Current Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 11. Remove jumper wire between pins 1 and 2 on transmission solenoid valve #5 connector P-C5 (WP 0018, Figure 75). 12. Remove left platform access panel (WP 0207). 13. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 14. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 48 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 24 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 16. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 17. pin 50 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 31 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 17. Remove rear floor plate (WP 0231). 18. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

0020-221

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1405-5 Transmission Solenoid Valve #5 Current Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

19. Using a digital multimeter (WP 0296), test for continuity between pin 5 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 24 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 20. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

20. Using a digital multimeter (WP 0296), test for continuity between pin 7 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 31 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

21. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56). 22. Using a digital multimeter (WP 0296), test for continuity between pin 5 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 23. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

23. Using a digital multimeter (WP 0296), test for continuity between pin 7 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin L on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 24. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

24. Using a digital multimeter (WP 0296), test for continuity between pin L on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 2 on transmission solenoid valve #5 connector P-C5 (WP 0018, Figure 75).

1. If continuity is found, proceed step 25. 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0020-222

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

0020

CORRECTIVE ACTION

1405-5 Transmission Solenoid Valve #5 Current Below Normal - Continued

25. Using a digital multimeter (WP 1. If continuity is found, replace pow0296), test for continuity between ertrain ECM (WP 0175). Ensure all pin I on transmission harness conharness connectors are reconnector P-C1 (WP 0018, Figure 56) nected. Verify correct operation of and pin 1 on transmission solenoid machine (TM 5-2410-241-10). valve #5 connector P-C5 (WP 2. If continuity is NOT found, replace 0018, Figure 75). transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

1405-6 Transmission Solenoid Valve #5 Current Above Normal

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes (WP 0013).

1. If active 1405-6 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

3.

3. Remove four bolts (Figure 77, Item 2), washers (Figure 77, Item 3), and guard (Figure 77, Item 1) from machine.

Figure 77. Guard and Retaining Hardware.

0020-223

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

1405-6 Transmission Solenoid Valve #5 Current Above Normal - Continued

0020

CORRECTIVE ACTION

4. Remove two bolts (Figure 78, Item 3) and guard (Figure 78, Item 4) from machine. 5. Remove 15 bolts (Figure 78, Item 1) and plate (Figure 78, Item 2) from machine.

Figure 78. Guard, Plate, and Retaining Hardware.

0020

6. Disconnect transmission solenoid valve # 5 connector P-C5 (WP 0018, Figure 75) from transmission solenoid valve # 5 (WP 0145). 7. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 8. Check for Diagnostic Codes (WP 0013)

0020-224

1. If active 1405-5 code is present, replace transmission solenoid valve # 5 (WP 0145). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 1405-6 code is present, proceed to step 9.

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1405-6 Transmission Solenoid Valve #5 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 10. Remove left platform access panel (WP 0207). 11. Disconnect steering control harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 12. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 13. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 14. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 15. pin 48 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 24 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 15. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 16. pin 50 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin 31 on steering control harness 0178). Ensure all harness connecconnector X-C1 (WP 0018, tors are reconnected. Verify corFigure 34). rect operation of machine (TM 52410-241-10). 16. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 17. pin 48 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10).

0020-225

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1405-6 Transmission Solenoid Valve #5 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

17. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 18. pin 48 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10). 18. Remove rear floor plate (WP 0231). 19. Disconnect platform harness connector MA-C7 (WP 0018, Figure 53) from transmission jumper harness connector MP-C2 (WP 0018, Figure 54). 20. Using a digital multimeter (WP 0296), test for continuity between pin 5 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 24 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

21. Using a digital multimeter (WP 0296), test for continuity between pin 7 on platform harness connector to transmission jumper harness MA-C7 (WP 0018, Figure 53) and pin 31 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 22. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-24110).

22. Using a digital multimeter (WP 0296), test for continuity between pin 24 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MAC14 (WP 0018, Figure 33)

1. If continuity is NOT found, proceed to step 23. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

23. Disconnect transmission jumper harness connector MP-C1 (WP 0018, Figure 55) from transmission harness connector P-C1 (WP 0018, Figure 56).

0020-226

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1405-6 Transmission Solenoid Valve #5 Current Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

24. Using a digital multimeter (WP 0296), test for continuity between pin 5 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin I on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 25. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

25. Using a digital multimeter (WP 0296), test for continuity between pin 7 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and pin L on transmission jumper harness connector MP-C1 (WP 0018, Figure 55).

1. If continuity is found, proceed to step 26. 2. If continuity is NOT found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

26. Using a digital multimeter (WP 0296), test for continuity between pin 5 on transmission jumper harness connector MP-C2 (WP 0018, Figure 54) and all other pins in transmission jumper harness connector MP-C2 (WP 0018, Figure 54).

1. If continuity is NOT found, proceed to step 27. 2. If continuity is found, replace transmission jumper harness (WP 0169). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

27. Using a digital multimeter (WP 0296), test for continuity between pin L on transmission harness connector P-C1 (WP 0018, Figure 56) and pin 2 on transmission solenoid valve #5 connector P-C5 (WP 0018, Figure 75).

1. If continuity is found, proceed step 28. 2. If continuity is NOT found, replace transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

28. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 29. pin I on transmission harness con- 2. If continuity is NOT found, replace nector P-C1 (WP 0018, Figure 56) transmission sensor harness (WP and pin 1 on transmission solenoid 0173). Ensure all harness connecvalve #5 connector P-C5 (WP tors are reconnected. Verify cor0018, Figure 75). rect operation of machine (TM 52410-241-10).

0020-227

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 1405-6 Transmission Solenoid Valve #5 Current Above Normal - Continued

TEST OR INSPECTION

0020

CORRECTIVE ACTION

29. Using a digital multimeter (WP 1. If continuity is found, replace pow0296), test for continuity between ertrain ECM (WP 0175). Ensure all pin I on transmission harness conharness connectors are reconnector P-C1 (WP 0018, Figure 56) nected. Verify correct operation of all other pins in transmission harmachine (TM 5-2410-241-10). ness connector P-C1 (WP 0018, 2. If continuity is NOT found, replace Figure 56). transmission sensor harness (WP 0173). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

1405-13 Transmission Sole1. Connect MSD (WP 0016), select noid Valve #5 Out of CaliPowertrain D7 ECM, and check for bration Diagnostic Codes or Event Codes (WP 0013).

1. If active 1405-13 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Select Powertrain D7 ECM on the left side of screen. 3. Select Service (Figure 79, Item 1), Calibrations (Figure 79, Item 2), Transmission Fill Calibration (Figure 79, Item 3).

Figure 79. ECM Selection.

0020-228

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

0020

CORRECTIVE ACTION

1405-13 Transmission Sole4. Set up Calibration Requirements. noid Valve #5 Out of Calibration - Continued 5. Select NEXT (Figure 80, Item 1) button.

Figure 80. Select Calibration. 6. Select FINISH (Figure 81, Item 1) button. 7. Remove MSD (WP 0016).

Figure 81. Calibration Finish.

0020-229

0020

Verify correct operation of machine (TM 5-2410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 2122-2 Reverse Switch Data Erratic, Intermittent, or Incorrect

TEST OR INSPECTION

CORRECTIVE ACTION

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 2122-2 code is present, proceed to step 4. 2. If active 2122-2 code is NOT present, proceed to step 2.

2. Position transmission control handle in REVERSE (TM 5-2410-24110). 3. Check for Diagnostic Codes (WP 0013).

1. If active 2122-2 code is present, proceed to step 4. 2. If no active codes are present, the problem does not exist at this time. Resume normal operation.

4. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 5. Remove left platform access panel (WP 0207). 6. Disconnect steering harness reverse switch connector X-C5 (WP 0018, Figure 76) from reverse switch connector RT-C1 (WP 0018, Figure 77). 7. Position transmission control handle in REVERSE (TM 5-2410-24110). 8. Using a digital multimeter (WP 0296), test for continuity between pin A and pin C in reverse switch connector RT-C1 (WP 0018, Figure 77).

1. If continuity is found, proceed to step 9. 2. If continuity is NOT found, replace reverse switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

9. Position transmission control handle in NEUTRAL (TM 5-2410-24110). 10. Using a digital multimeter (WP 0296), test for continuity between pin A and pin C in reverse switch connector RT-C1 (WP 0018, Figure 77).

11. Position transmission control handle in REVERSE (TM 5-2410-24110).

0020-230

1. If continuity is NOT found, proceed to step 11. 2. If continuity is found, replace reverse switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 2122-2 Reverse Switch Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

12. Using a digital multimeter (WP 0296), test for continuity between pin B and pin C in reverse switch connector RT-C1 (WP 0018, Figure 77).

1. If continuity is NOT found, proceed to step 13. 2. If continuity is found, replace reverse switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

13. Position transmission control handle in NEUTRAL (TM 5-2410-24110). 14. Using a digital multimeter (WP 0296), test for continuity between pin B and pin C in reverse switch connector RT-C1 (WP 0018, Figure 77).

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace reverse switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

15. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from ECM. 16. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from ECM. 17. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 18. pin 33 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin A on steering harness reverse 0178). Ensure all harness connecswitch connector X-C5 (WP 0018, tors are reconnected. Verify corFigure 76). rect operation of machine (TM 52410-241-10). 18. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 19. pin 34 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin B on steering harness reverse 0178). Ensure all harness connecswitch connector X-C5 (WP 0018, tors are reconnected. Verify corFigure 76). rect operation of machine (TM 52410-241-10). 19. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 20. pin 33 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10).

0020-231

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 2122-2 Reverse Switch Data Erratic, Intermittent, or Incorrect - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

20. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 21. pin 33 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, Figure tors are reconnected. Verify cor3). rect operation of machine (TM 52410-241-10). 21. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 22. pin 34 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10). 22. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 23. pin 34 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10). 23. Using a digital multimeter (WP 1. If continuity is found, replace pow0296), test for continuity between ertrain ECM (WP 0175). Ensure all pin 13 on powertrain ECM connecharness connectors are recontor X-C2 (WP 0018, Figure 4) and nected. Verify correct operation of pin C on steering harness reverse machine (TM 5-2410-241-10). switch connector X-C5 (WP 0018, 2. If continuity is found, replace Figure 76). steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

2122-7 Reverse Switch Mechanical System Not Responding

1. Connect MSD (WP 0016), select Powertrain D7 ECM, and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 2122-7 code is present, proceed to step 4. 2. If active 2122-7 code is NOT present, proceed to step 2.

2. Position transmission control handle in REVERSE (TM 5-2410-24110). 3. Check for Diagnostic Codes (WP 0013)

0020-232

1. If active 2122-7 code is present, proceed to step 4. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

2122-7 Reverse Switch Mechanical System Not Responding - Continued

4. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

CORRECTIVE ACTION

5. Remove left platform access panel (WP 0207). 6. Disconnect steering harness reverse switch connector X-C5 (WP 0018, Figure 76) from reverse switch connector RT-C1 (WP 0018, Figure 77). 7. Position transmission control handle in REVERSE (TM 5-2410-24110). 8. Using a digital multimeter (WP 0296), test for continuity between pin A and pin C in reverse switch connector RT-C1 (WP 0018, Figure 77).

1. If continuity is found, proceed to step 9. 2. If continuity is NOT found, replace reverse switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

9. Position transmission control handle in NEUTRAL (TM 5-2410-24110). 10. Using a digital multimeter (WP 0296), test for continuity between pin A and pin C in reverse switch connector RT-C1 (WP 0018, Figure 77).

1. If continuity is NOT found, proceed to step 11. 2. If continuity is found, replace reverse switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

11. Position transmission control handle in REVERSE (TM 5-2410-24110). 12. Using a digital multimeter (WP 0296), test for continuity between pin B and pin C in reverse switch connector RT-C1 (WP 0018, Figure 77).

0020-233

1. If continuity is NOT found, proceed to step 13. 2. If continuity is found, replace reverse switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

2122-7 Reverse Switch Mechanical System Not Responding - Continued

13. Position transmission control handle in NEUTRAL (TM 5-2410-24110). 14. Using a digital multimeter (WP 0296), test for continuity between pin B and pin C in reverse switch connector RT-C1 (WP 0018, Figure 77).

CORRECTIVE ACTION

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace reverse switch (WP 0237). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

15. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from ECM. 16. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from ECM. 17. Using a digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 18. pin 33 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin A on steering harness reverse 0178). Ensure all harness connecswitch connector X-C5 (WP 0018, tors are reconnected. Verify corFigure 76). rect operation of machine (TM 52410-241-10). 18. Using a digital multimeter (WP 1. If continuity is found, proceed, to 0296), test for continuity between step 19. pin 34 on powertrain ECM connec- 2. If continuity is NOT found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP pin B on steering harness reverse 0178). Ensure all harness connecswitch connector X-C5 (WP 0018, tors are reconnected. Verify corFigure 76). rect operation of machine (TM 52410-241-10). 19. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 20. pin 33 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10).

0020-234

0020

TM 5-2410-241-23-1

0020

Table 1. Powertrain Troubleshooting Procedures - Continued. MALFUNCTION 2122-7 Reverse Switch Mechanical System Not Responding - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

20. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 21. pin 33 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10). 21. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 22. pin 34 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C2 (WP 0018, tors are reconnected. Verify corFigure 4). rect operation of machine (TM 52410-241-10). 22. Using a digital multimeter (WP 1. If continuity is NOT found, proceed 0296), test for continuity between to step 23. pin 34 on powertrain ECM connec- 2. If continuity is found, replace tor X-C2 (WP 0018, Figure 4) and steering control harness (WP all other pins in powertrain ECM 0178). Ensure all harness connecconnector X-C3 (WP 0018, tors are reconnected. Verify corFigure 3). rect operation of machine (TM 52410-241-10). 23. Using a digital multimeter (WP 1. If continuity is found, replace pow0296), test for continuity between ertrain ECM (WP 0175). Ensure all pin 13 on powertrain ECM connecharness connectors are recontor X-C2 (WP 0018, Figure 4) and nected. Verify correct operation of pin C on steering harness reverse machine (TM 5-2410-241-10). switch connector X-C5 (WP 0018, 2. If continuity is found, replace Figure 76). steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

END OF WORK PACKAGE

0020-235/(236 blank)

0020

50 TM 5-2410-241-23-1

0021

FIELD MAINTENANCE 0 0 2 1

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CHASSIS AND IMPLEMENT TROUBLESHOOTING PROCEDURES

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Adapter Kit Test (WP 0302, Item 5) Needle Tip (Tip G), (Multimeter) (WP 0302, Item 39) Test Set, Electronic (MSD) (WP 0302, Item 62) 0

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Materials/Parts Rag, Wiping (WP 0303, Item 24) Tiedown Strap (WP 0303, Item 36) Personnel Required Two References WP 0013 WP 0016 WP 0018 WP 0032 WP 0033 WP 0034 WP 0035 WP 0041 WP 0055 WP 0103 WP 0112 WP 0124 WP 0140 WP 0146 WP 0147 WP 0170 WP 0171

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References - Continued WP 0172 WP 0175 WP 0178 WP 0179 WP 0181 WP 0183 WP 0207 WP 0208 WP 0209 WP 0211 WP 0212 WP 0213 WP 0214 WP 0216 WP 0218 WP 0222 WP 0223 WP 0230 WP 0231 WP 0238 WP 0259 WP 0260 WP 0262 WP 0266 WP 0267 WP 0277 WP 0278 WP 0296 Equipment Condition Machine parked (TM 5-2410-241-10)

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GENERAL

0021

This work package contains troubleshooting information for the D7R Dozer. Each malfunction or symptom listed is followed by the possible cause(s) and suggested remedy or remedies. This work package should be used as an aid in the isolation and correction of system problems.

0021-1

TM 5-2410-241-23-1

0021

Table 1. Chassis and Implement Troubleshooting Procedures. MALFUNCTION Hydraulic Oil Temperature is Too High

TEST OR INSPECTION 1. Verify hydraulic oil is at correct level (TM 5-2410-241-10).

1. Hydraulic Oil Level Is Not Correct - Add hydraulic oil to proper level (TM 5-2410-241-10). 2. Hydraulic Oil Level Is OK - Proceed to step 2.

2. Inspect hydraulic oil cooler core for bent fins, air flow restrictions, dirt, or blockage (WP 0042).

1. Hydraulic Oil Cooler Core Fins Bent - Straighten cooler fins or replace hydraulic oil cooler core (WP 0041). 2. Hydraulic Oil Cooler Blocked With Dirt or Foreign Object - Clean dirt and remove foreign object. 3. Hydraulic Oil Cooler Core Is OK Proceed to step 3.

3. Perform Implement Pump Discharge Pressure - Test (WP 0033).

1. Problem Is Not Resolved Replace implement pump (WP 0112). 2. Implement Pump Cutoff Pressures OK - Resume normal operation.

Machine Has Low Turning 1. Perform Steering Hydraulic Circuit Force in Both Directions Pressure - Test (WP 0035).

2. Perform Cylinder Cycle Tests. Blade Lift (WP 0032) Blade Tilt (WP 0032) Ripper Lift (WP 0032) Ripper Tilt (WP 0032) Machine Has Low Turning Force in One Direction

CORRECTIVE ACTION

1. Steering Hydraulic Circuit Test OK - Resume normal operation. 2. Steering Hydraulic Circuit Test NOT OK - Proceed to step 2. 1. ALL Cylinder Cycle Tests Fail Replace implement pump (WP 0112). 2. ALL Cylinder Cycle Tests Pass Replace the steering motor (WP 0140).

1. Perform Steering Hydraulic Circuit Pressure - Test (WP 0035).

1. Steering Hydraulic Circuit Test OK - Resume normal operation. 2. Steering Hydraulic Circuit - Test NOT OK - Proceed to step 2.

2. Check steering control linkage for correct adjustment. Perform Steering Checks (WP 0238).

1. Steering Control Linkage NOT OK - Replace or repair linkage as necessary (WP 0238). 2. Steering Control Linkage OK Replace steering control valve (WP 0147).

0021-2

0021

TM 5-2410-241-23-1

0021

Table 1. Chassis and Implement Troubleshooting Procedures - Continued. MALFUNCTION Machine Will Not Turn in Either Direction

TEST OR INSPECTION

CORRECTIVE ACTION

1. Perform Steering Hydraulic Circuit Pressure - Test (WP 0035).

1. Steering Hydraulic Circuit Test OK - Resume normal operation. 2. Steering Hydraulic Circuit Test NOT OK - Proceed to step 2.

2. Perform Cylinder Cycle Tests. Blade Lift (WP 0032)

1. ALL Cylinder Cycle Tests Fails Replace implement pump (WP 0112). 2. ALL Cylinder Cycle Tests Pass Replace the steering motor (WP 0140).

Blade Tilt (WP 0032) Ripper Lift (WP 0032) Ripper Tilt (WP 0032) Steering is Jerky or Unstable

Machine Continues to Turn When Steering Control Lever is Returned to NEUTRAL

1. Verify hydraulic oil is at correct level (TM 5-2410-241-10).

1. Hydraulic Oil Level Is Not Correct - Add hydraulic oil to proper level (TM 5-2410-241-10). 2. Hydraulic Oil Level Is OK - Proceed to step 2.

2. Check steering control linkage for correct adjustment. Perform Steering Checks (WP 0238).

1. Steering Control Linkage NOT OK - Replace or repair linkage as necessary (WP 0238). 2. Steering Control Linkage OK Proceed to step 3.

3. Perform Steering Hydraulic Circuit Pressure - Test (WP 0035).

1. Steering Hydraulic Circuit Test OK - Resume normal operation. 2. Steering Hydraulic Circuit Test NOT OK - Replace steering control valve (WP 0147).

Check steering control linkage for cor- 1. Steering Control Linkage NOT OK rect adjustment (WP 0238). - Replace or repair linkage as necessary (WP 0238). 2. Steering Control Linkage OK Replace steering control valve (WP 0147).

0021-3

TM 5-2410-241-23-1

0021

Table 1. Chassis and Implement Troubleshooting Procedures - Continued. MALFUNCTION Machine Will Not Turn or Steering Radius is Very Large

TEST OR INSPECTION 1. Verify hydraulic oil is at correct level (TM 5-2410-241-10).

1. Hydraulic Oil Level Is Not Correct - Add hydraulic oil to proper level (TM 5-2410-241-10). 2. Hydraulic Oil Level Is OK - Proceed to step 2.

2. Perform Steering Hydraulic Circuit Pressure - Test (WP 0035).

1. Steering Hydraulic Circuit Test OK - Resume normal operation. 2. Steering Hydraulic Circuit Test NOT OK - Proceed to step 3.

3. Perform Cylinder Cycle Tests. Blade Lift (WP 0032)

1. ALL Cylinder Cycle Tests Fail Replace implement pump (WP 0112). 2. ALL Cylinder Cycle Tests Pass Replace the steering motor (WP 0140).

Blade Tilt (WP 0032) Ripper Lift (WP 0032) Ripper Tilt (WP 0032) All Implement Cycle Times are Too Slow

CORRECTIVE ACTION

1. Perform Cylinder Cycle Tests. Blade Lift (WP 0032) Blade Tilt (WP 0032) Ripper Lift (WP 0032)

1. ALL Cylinder Cycle Tests Pass Resume normal operation. 2. ALL Cylinder Cycle Tests Fail Proceed to step 2.

Ripper Tilt (WP 0032) 2. Perform Implement Pump Discharge Pressure - Test (WP 0033).

1. Pump Discharge Pressure Test Failed - Replace implement pump (WP 0112). 2. Pump Discharge Pressure Test OK - Proceed to step 3.

3. Perform Pilot System Pressure (WP 0034).

1. Pilot Pressure Test Failed Replace implement control valve. Valve 5 With Ripper (WP 0211) Valve 4 With Winch (WP 0212) 2. Pilot Pressure Test Passed Resume normal operation.

Implement Droops When Control Lever is Moved from HOLD to LIFT

Load check valve in affected implement's control valve is not closing.

0021-4

Replace Affected Implement's Control Valve - Bulldozer Lift Control Valve w/Ripper (WP 0211), Bulldozer Tilt Control Valve w/Ripper (WP 0211), Bulldozer Lift Control Valve w/Winch (WP 0212), Bulldozer Tilt Control Valve w/Winch (WP 0212).

TM 5-2410-241-23-1

0021

Table 1. Chassis and Implement Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

Implement Drift Is Excessive 1. Inspect affected cylinder for Class III leak at cylinder seal.

Hydraulic Circuits Have Weak Response

CORRECTIVE ACTION 1. Cylinder Seal Leak (external hose leakage) - Replace the O-ring seals or cylinder: Bulldozer Lift Cylinder (WP 0266), Bulldozer Tilt Cylinder (WP 0267), Ripper Lift Cylinder (WP 0277), Ripper Tilt Cylinder (WP 0278). 2. No External Seal Leakage - Proceed to step 2.

2. Check drift of the affected cylinder. Perform Cylinder Drift Test (WP 0032).

Resume normal operation.

1. Perform the Implement Pump Discharge Pressure - Test (WP 0033).

1. Pump Discharge Pressure Test Fails - Replace implement pump (WP 0104). 2. Pump Discharge Pressure Test OK - Proceed to step 2.

2. Perform Pilot System Pressure Test (WP 0034).

1. Pilot Pressure Test Fails Replace manifold. With Ripper (WP 0213) With Winch (WP 0214) 2. Pilot Pressure Test OK - Proceed to step 3.

3. Perform Cylinder Cycle Tests. Blade Lift (WP 0032) Blade Tilt (WP 0032) Ripper Lift (WP 0032) Ripper Tilt (WP 0032)

0021-5

Resume normal operation.

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

96-3 Fuel Level Sender Voltage Above Normal

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 96-3 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect fuel tank harness fuel level sender connector TW-C2 (WP 0018, Figure 78) from fuel level sender. 4. Install jumper wire in pin 1 and 2 of fuel tank harness fuel level sender connector TW-C2 (WP 0018, Figure 78). 5. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 6. Check for diagnostic codes or Event Codes (WP 0013).

1. If active 96-3 code is present, proceed to step 7. 2. If active 96-3 code is NOT present, replace fuel level sender (WP 0171). Remove jumper wire in pin 1 and 2 of connector TW-C2 (WP 0018, Figure 78). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Remove jumper wire in pin 1 and 2 of fuel tank harness fuel level sender connector TW-C2 (WP 0018, Figure 78). 9. Remove rear floor plate (WP 0240). 10. Disconnect fuel tank harness to platform harness connector TWC7 (WP 0018, Figure 80) from platform harness to fuel tank harness connector MA-C23 (WP 0018, Figure 79).

0021-6

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

96-3 Fuel Level Sender Voltage Above Normal Continued

11. Using digital multimeter (WP 0296), test for continuity between pin 7 on fuel tank harness to platform harness connector TW-C7 (WP 0018, Figure 80) and pin 1 on fuel tank harness fuel level sender connector TW-C2 (WP 0018, Figure 78).

1. If continuity is found, proceed to step 12. 2. If continuity is NOT found, replace fuel tank harness (WP 0170). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

12. Using digital multimeter (WP 0296), test for continuity between pin 8 on fuel tank harness to platform harness connector TW-C7 (WP 0018, Figure 80) and pin 2 on fuel tank harness fuel level sender connector TW-C2 (WP 0018, Figure 78).

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace fuel tank harness (WP 0170). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

13. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from dash monitor.

248-2 Display Data Link Data Erratic, Intermittent, or Incorrect

14. Using digital multimeter (WP 0296), test for continuity between pin 7 on platform harness to fuel tank harness connector MA-C23 (WP 0018, Figure 79) and pin 9 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace fuel tank harness (WP 0170). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

15. Using digital multimeter (WP 0296), test for continuity between pin 8 on platform harness to fuel tank harness connector MA-C23 (WP 0018, Figure 79) and pin 2 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is found, replace dash monitor ECM (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace fuel tank harness (WP 0170). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 248-2 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0021-7

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

248-2 Display Data Link Data Erratic, Intermittent, or Incorrect - Continued

3. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from ECM.

CORRECTIVE ACTION

4. Disconnect platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) from engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) (WP 0055). 5. Using digital multimeter (WP 0296), test for continuity between pin 40 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and pin 8 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 6. 2. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

6. Using digital multimeter (WP 0296), test for continuity between pin 39 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and pin 9 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 7. 2. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

7. Using digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between engine main harness (WP 0055). pin 8 on engine ECM connector Ensure all harness connectors V-C4 (WP 0018, Figure 1) to all are reconnected. Verify correct other pins in engine ECM connecoperation of machine (TM 5-2410tor V-C4 (WP 0018, Figure 1). 241-10). 2. If continuity is NOT found, proceed to step 8. 8. Using digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between engine main harness (WP 0055). pin 9 on engine ECM connector Ensure all harness connectors V-C4 (WP 0018, Figure 1) and all are reconnected. Verify correct other pins in engine ECM connecoperation of machine (TM 5-2410tor V-C4 (WP 0018, Figure 1). 241-10). 2. If continuity is NOT found, proceed to step 9. 9. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262). 10. Remove left platform access panel (WP 0212).

0021-8

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

248-2 Display Data Link Data Erratic, Intermittent, or Incorrect - Continued

11. Disconnect powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33).

CORRECTIVE ACTION

12. Remove MSD (WP 0016). 13. Using digital multimeter (WP 0296), test for continuity between pin 40 on platform harness (platform to engine) connector MAC22 (WP 0018, Figure 11) and pin 23 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 14. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

14. Using digital multimeter (WP 0296), test for continuity between pin 39 on platform harness (platform to engine) connector MAC22 (WP 0018, Figure 11) and pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

15. Using digital multimeter (WP 0296), test for continuity between pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MAC14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 16.

16. Using digital multimeter (WP 0296), test for continuity between pin 23 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 17.

17. Using digital multimeter (WP 0296), test for continuity between pin 23 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin 5 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 18.

0021-9

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

248-2 Display Data Link Data Erratic, Intermittent, or Incorrect - Continued

18. Using digital multimeter (WP 0296), test for continuity between pin 22 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin 14 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 19.

19. Using digital multimeter (WP 1. If continuity is found, replace plat0296), test for continuity between form harness (WP 0209) and pin 5 on dash monitor connector instrument panel harness E-C7 (WP 0018, Figure 5) and all (WP 0260). Ensure all harness other pins in dash monitor conconnectors are reconnected. Vernector E-C7 (WP 0018, Figure 5). ify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 20. 20. Using digital multimeter (WP 1. If continuity is found, replace plat0296), test for continuity between form harness (WP 0209) and pin 14 on dash monitor connector instrument panel harness E-C7 (WP 0018, Figure 5) and all (WP 0260). Ensure all harness other pins in dash monitor conconnectors are reconnected. Vernector E-C7 (WP 0018, Figure 5). ify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 21. 21. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 22. Using digital multimeter (WP 0296), test for continuity between pin 23 on powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34) and pin 10 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 23. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

23. Using digital multimeter (WP 0296), test for continuity between pin 22 on powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34) and pin 20 on powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, proceed to step 24. 2. If continuity is NOT found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0021-10

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

248-2 Display Data Link Data Erratic, Intermittent, or Incorrect - Continued

24. Using digital multimeter (WP 0296), test for continuity between pin 10 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 25.

25. Using digital multimeter (WP 0296), test for continuity between pin 20 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is found, replace steering control harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace dash monitor ECM (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 271-3 code is present, proceed to step 2. 2. If no active codes are present, problem does NOT exist at this time. Resume normal operation.

271-3 Action Alarm Voltage Above Normal

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262). 4. Disconnect instrument panel harness action alarm connector E-C3 (WP 0018, Figure 81) from action alarm (WP 0183). 5. Using digital multimeter (WP 0296), test for continuity between pin 1 on instrument panel harness action alarm connector E-C3 (WP 0018, Figure 81) and pin 4 on dash monitor connector E-C7 (WP 0018, Figure 5).

0021-11

1. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 6.

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

271-3 Action Alarm Voltage Above Normal - Continued

6. Using digital multimeter (WP 0296), test for continuity between pin 4 on dash monitor connector E-C7 (WP 0018, Figure 5) and all other pins in dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace dash monitor ECM (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

271-5 Action Alarm Voltage Below Normal

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 271-5 code is present, proceed to step 2. 2. If no active codes are present, problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect instrument panel harness action alarm connector E-C3 (WP 0018, Figure 81) from action alarm (WP 0183). 4. Install jumper wire between pin 1 and 2 on instrument panel harness action alarm connector E-C3 (WP 0018, Figure 81). 5. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 6. Check for Diagnostic Codes or Event Codes (WP 0013).

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0021-12

1. If active 271-5 code is present, proceed to step 7. 2. If active 271-5 code is NOT present, replace action alarm (WP 0183). Remove jumper wire between pin 1 and 2 on connector E-C3 (WP 0018, Figure 81). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION 271-5 Action Alarm Voltage Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

8. Remove jumper wire from between pin 1 and 2 on instrument panel harness action alarm connector E-C3 (WP 0018, Figure 81). 9. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262). 10. Using digital multimeter (WP 0296), test for continuity between pin 1 on instrument panel harness action alarm connector E-C3 (WP 0018, Figure 81) and pin 4 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 11.

11. Using digital multimeter (WP 0296), test for continuity between pin 2 on instrument panel harness action alarm connector E-C3 (WP 0018, Figure 81) and pin 2 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 12.

12. Using digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between instrument panel harness pin 4 on dash monitor connector (WP 0260). Ensure all harness E-C7 (WP 0018, Figure 5) and all connectors are reconnected. Verother pins in dash monitor conify correct operation of machine nector E-C7 (WP 0018, Figure 5). (TM 5-2410-241-10). 2. If continuity is NOT found, replace dash monitor ECM (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 324-3 Action Lamp Voltage Above Normal

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013). 2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262).

0021-13

1. If active 324-3 code is present, proceed to step 2. 2. If no active codes are present, problem does NOT exist at this time. Resume normal operation.

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION 324-3 Action Lamp Voltage Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

4. Disconnect instrument panel harness action lamp connector EC25 (WP 0018, Figure 82) from action lamp (WP 0262). 5. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between instrument panel harness PINK WIRE on instrument panel (WP 0260). Ensure all harness harness action lamp connector Econnectors are reconnected. VerC25 (WP 0018, Figure 82) and ify correct operation of machine pin 13 on dash monitor connector (TM 5-2410-241-10). E-C7 (WP 0018, Figure 5). 2. If continuity is found, proceed to step 6. 6. Using digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between instrument panel harness pin 13 on dash monitor connector (WP 0260). Ensure all harness E-C7 (WP 0018, Figure 5) and all connectors are reconnected. Verother pins in dash monitor conify correct operation of machine nector E-C7 (WP 0018, Figure 5). (TM 5-2410-241-10). 2. If continuity is NOT found, replace dash monitor ECM (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

490-3 Hydraulic Lockout Solenoid Voltage Above Normal

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013). 2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove right platform access panel (WP 0213). 4. Disconnect RH console harness hydraulic lockout switch connector RW-C7 (WP 0018, Figure 89) from hydraulic lockout switch (WP 0018, Figure 91). 5. Ensure hydraulic lockout switch is in LOCKED (Figure 1, Item 2) position.

0021-14

1. If active 490-3 code is present, proceed to step 2. 2. If no active codes are present, problem does NOT exist at this time. Resume normal operation.

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued.

0021

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

490-3 Hydraulic Lockout Solenoid Voltage Above Normal - Continued

6. Using digital multimeter (WP 0296), test for continuity between pin 4 and 5 on hydraulic lockout switch (WP 0018, Figure 91).

1. If continuity is found, replace hydraulic lockout switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 7.

7. Ensure hydraulic lockout switch is in LOCKED (Figure 1, Item 2) position.

Figure 1. Hydraulic Lockout Switch. 8. Using digital multimeter (WP 0296), test for continuity between pin 5 and 6 on hydraulic lockout switch (WP 0018, Figure 91).

9. Change hydraulic lockout switch to UNLOCKED (Figure 2, Item 1) position.

0021-15

0021

1. If continuity is NOT found, replace hydraulic lockout switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 9.

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued.

0021

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

490-3 Hydraulic Lockout Solenoid Voltage Above Normal - Continued

10. Using digital multimeter (WP 0296), test for continuity between pin 5 and 6 on hydraulic lockout switch (WP 0018, Figure 91).

1. If continuity is found, replace hydraulic lockout switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 11.

11. Ensure hydraulic lockout switch is in UNLOCKED (Figure 2, Item 1) position. 12. Using digital multimeter (WP 0296), test for continuity between pin 4 and 5 on hydraulic lockout switch (WP 0018, Figure 91).

1. If continuity is NOT found, replace hydraulic lockout switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 13.

Figure 2. Hydraulic Lockout Switch.

0021-16

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

490-3 Hydraulic Lockout Solenoid Voltage Above Normal - Continued

13. Disconnect RH console harness connector R-C1 (WP 0018, Figure 14) from RH platform harness connector MA-C1 (WP 0018, Figure 15).

CORRECTIVE ACTION

14. Using digital multimeter (WP 0296), test for continuity between pin 4 on RH console harness hydraulic lockout switch connector RW-C7 (WP 0018, Figure 89) and pin 10 on RH console harness connector R-C1 (WP 0018, Figure 14).

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

15. Using digital multimeter (WP 0296), test for continuity between pin 6 on RH console harness hydraulic lockout switch connector RW-C7 (WP 0018, Figure 89) and pin 9 on RH console harness connector R-C1 (WP 0018, Figure 14).

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

16. Using digital multimeter (WP 1. If continuity is NOT found, pro0296), test for continuity between ceed to step 17. pin 9 on RH console harness con- 2. If continuity is found, replace nector R-C1 (WP 0018, Figure chassis harness (WP 0172). 14) and all other pins in RH conEnsure all harness connectors sole harness connector R-C1 are reconnected. Verify correct (WP 0018, Figure 14). operation of machine (TM 5-2410241-10). 17. Using digital multimeter (WP 0296), test for continuity between pin 10 on RH console harness connector R-C1 (WP 0018, Figure 14) and all other pins in RH console harness connector R-C1 (WP 0018, Figure 14). 18. Remove left platform access panel (WP 0212). 19. Disconnect powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33).

0021-17

1. If continuity is NOT found, proceed to step 18. 2. If continuity is found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

490-3 Hydraulic Lockout Solenoid Voltage Above Normal - Continued

20. Using digital multimeter (WP 0296), test for continuity between pin 10 on RH platform harness connector MA-C1 (WP 0018, Figure 15) and pin 62 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

21. Using digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 22. pin 9 on RH platform harness con- 2. If continuity is NOT found, replace nector MA-C1 (WP 0018, Figure platform harness (WP 0209). 15) and pin 63 on platform harEnsure all harness connectors ness MA-C14 (WP 0018, Figure are reconnected. Verify correct 33). operation of machine (TM 5-2410241-10). 22. Using digital multimeter (WP 0296), test for continuity between pin 62 on platform harness MAC14 (WP 0018, Figure 33) and all other pins in platform harness MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 23. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

23. Using digital multimeter (WP 0296), test for continuity between pin 63 on platform harness MAC14 (WP 0018, Figure 33) and all other pins in platform harness MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 24. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

24. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 25. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 26. Using digital multimeter (WP 0296), test for continuity between pin 46 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 62 on powertrain ECM steering harness X-C1 (WP 0018, Figure 34).

0021-18

1. If continuity is found, proceed to step 27. 2. If continuity is NOT found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

490-3 Hydraulic Lockout Solenoid Voltage Above Normal - Continued

27. Using digital multimeter (WP 0296), test for continuity between pin 47 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 63 on powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 28. 2. If continuity is NOT found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

28. Using digital multimeter (WP 0296), test for continuity between pin 46 on powertrain ECM connector X-C3 (WP 0018, Figure e 3) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, proceed to step 29. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

29. Using digital multimeter (WP 0296), test for continuity between pin 46 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 30. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

30. Using digital multimeter (WP 0296), test for continuity between pin 47 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, proceed to step 31. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

31. Using digital multimeter (WP 0296), test for continuity between pin 47 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0021-19

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

490-4 Hydraulic Lockout Solenoid Voltage Below Normal

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013).

CORRECTIVE ACTION 1. If active 490-4 code is present, proceed to step 2. 2. If no active codes are present, problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove right platform access panel (WP 0213). 4. Disconnect RH console harness hydraulic lockout switch connector RW-C7 (WP 0018, Figure 89) from hydraulic lockout switch (WP 0018, Figure 91). (WP 0208). 5. Ensure hydraulic lockout switch is in LOCKED (Figure 3, Item 2) position. 6. Using digital multimeter (WP 0296), test for continuity between pin 4 and 5 on hydraulic lockout switch (WP 0018, Figure 91)

1. If continuity is found, replace hydraulic lockout switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 7.

7. Ensure hydraulic lockout switch is in LOCKED (Figure 3, Item 2) position. 8. Using digital multimeter (WP 0296), test for continuity between pin 5 and 6 on hydraulic lockout switch (WP 0018, Figure 91).

9. Change hydraulic lockout switch to UNLOCKED (Figure 3, Item 1) position.

0021-20

1. If continuity is NOT found, replace hydraulic lockout switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 9.

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued.

0021

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

490-4 Hydraulic Lockout Solenoid Voltage Below Normal - Continued

10. Using digital multimeter (WP 0296), test for continuity between pin 5 and 6 on hydraulic lockout switch (WP 0018, Figure 91).

1. If continuity is found, replace hydraulic lockout switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 11.

11. Ensure hydraulic lockout switch is in the UNLOCKED (Figure 3, Item 1) position. 12. Using digital multimeter (WP 0296), test for continuity between pin 4 and 5 on hydraulic lockout switch (WP 0018, Figure 91).

1. If continuity is NOT found, replace hydraulic lockout switch (WP 0208). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 13.

13. Remove left platform access panel (WP 0212).

Figure 3. Hydraulic Lockout Switch.

0021-21

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

490-4 Hydraulic Lockout Solenoid Voltage Below Normal - Continued

14. Disconnect RH console harness connector R-C1 (WP 0018, Figure 14) from RH platform harness connector MA-C1 (WP 0018, Figure 15).

CORRECTIVE ACTION

15. Using digital multimeter (WP 0296), test for continuity between pin 4 on RH console harness hydraulic lockout switch connector RW-C7 (WP 0018, Figure 89) and pin 10 on RH console harness connector R-C1 (WP 0018, Figure 14).

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

16. Using digital multimeter (WP 0296), test for continuity between pin 6 on RH console harness hydraulic lockout switch connector RW-C7 (WP 0018, Figure 89) and pin 9 on RH console harness connector R-C1 (WP 0018, Figure 14).

1. If continuity is found, proceed to step 17. 2. If continuity is NOT found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

17. Using digital multimeter (WP 1. If continuity is NOT found, pro0296), test for continuity between ceed to step 18. pin 9 on RH console harness con- 2. If continuity is found, replace nector R-C1 (WP 0018, Figure chassis harness (WP 0172). 14) and all other pins in RH conEnsure all harness connectors sole harness connector R-C1 are reconnected. Verify correct (WP 0018, Figure 14). operation of machine (TM 5-2410241-10). 18. Using digital multimeter (WP 0296), test for continuity between pin 10 on RH console harness connector R-C1 (WP 0018, Figure 14) and all other pins in RH console harness connector R-C1 (WP 0018, Figure 14). 19. Disconnect powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33).

0021-22

1. If continuity is NOT found, proceed to step 19. 2. If continuity is found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

490-4 Hydraulic Lockout Solenoid Voltage Below Normal - Continued

20. Using digital multimeter (WP 0296), test for continuity between pin 10 on RH platform harness connector MA-C1 (WP 0018, Figure 15) and pin 62 on platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace platform harness (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

21. Using digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 22. pin 9 on RH platform harness con- 2. If continuity is NOT found, replace nector MA-C1 (WP 0018, Figure platform harness (WP 0209). 15) and pin 63 on platform harEnsure all harness connectors ness connector MA-C14 (WP are reconnected. Verify correct 0018, Figure 33). operation of machine (TM 5-2410241-10). 22. Using digital multimeter (WP 0296), test for continuity between pin 62 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 23. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

23. Using digital multimeter (WP 0296), test for continuity between pin 63 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 24. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

24. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 25. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 26. Using digital multimeter (WP 0296), test for continuity between pin 46 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 62 on powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34).

0021-23

1. If continuity is found, proceed to step 27. 2. If continuity is NOT found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

490-4 Hydraulic Lockout Solenoid Voltage Below Normal - Continued

27. Using digital multimeter (WP 0296), test for continuity between pin 47 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 63 on powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 28. 2. If continuity is NOT found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

28. Using digital multimeter (WP 0296), test for continuity between pin 46 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, proceed to step 29. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

29. Using digital multimeter (WP 0296), test for continuity between pin 46 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 30. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

30. Using digital multimeter (WP 0296), test for continuity between pin 47 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, proceed to step 31. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

31. Using digital multimeter (WP 0296), test for continuity between pin 47 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0021-24

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

600-4 Hydraulic Oil Temperature Sensor Voltage Below Normal

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 600-4 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove right side hydraulic tank access plate (WP 0186). 4. Disconnect chassis harness hydraulic oil temperature sensor connector L-C2 (WP 0018, Figure 83) from hydraulic oil temperature sensor (WP 0146). 5. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 6. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 600-4 code is NOT present, replace hydraulic oil temperature sensor (WP 0146). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 600-4 code is present, proceed to step 7.

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Disconnect chassis harness connector L-C1 (WP 0018, Figure 84) from platform harness connector MA-C17 (WP 0018, Figure 85). 9. Using digital multimeter (WP 0296), test for continuity between pin 6 on chassis harness connector L-C1 (WP 0018, Figure 84) and pin 1 on chassis harness oil temperature sensor connector LC2 (WP 0018, Figure 83).

0021-25

1. If continuity is NOT found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, proceed to step 10.

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

600-4 Hydraulic Oil Temperature Sensor Voltage Below Normal - Continued

10. Using digital multimeter (WP 0296), test for continuity between pin 6 on chassis harness connector L-C1 (WP 0018, Figure 84) and all other pins in chassis harness connector L-C1 (WP 0018, Figure 84).

1. If continuity is found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, proceed to step 11.

11. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262). 12. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between platform harness (WP 0209) and pin 6 on platform harness connecinstrument panel harness (WP tor MA-C17 (WP 0018, Figure 85) 0260). Ensure all harness conand pin 10 on dash monitor connectors are reconnected. Verify nector E-C7 (WP 0018, Figure 5). correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 13. 13. Using digital multimeter (WP 1. If continuity is found, replace plat0296), test for continuity between form harness (WP 0209) and pin 10 on dash monitor connector instrument panel harness (WP E-C7 (WP 0018, Figure 5) and all 0260). Ensure all harness conother pins in dash monitor connectors are reconnected. Verify nector E-C7 (WP 0018, Figure 5). correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace dash monitor ECM (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 600-8 Hydraulic Oil Temperature Sensor Voltage Abnormal Signal

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013). 2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove right side hydraulic tank access plate (WP 0186).

0021-26

1. If active 600-8 code is present, proceed to step 2. 2. If no active codes are present, the problem does NOT exist at this time. Resume normal operation.

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

600-8 Hydraulic Oil Temperature Sensor Voltage Abnormal Signal - Continued

4. Disconnect chassis harness hydraulic oil temperature sensor connector L-C2 (WP 0018, Figure 83) from hydraulic oil temperature sensor (WP 0146).

CORRECTIVE ACTION

5. Turn battery disconnect switch and ignition switch to ON position TM 5-2410-241-10. 6. Using a digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on chassis harness oil temperature sensor connector L-C2 (WP 0018, Figure 83).

1. If voltage is 5.5 -6.5 Volts, replace hydraulic oil temperature sensor (WP 0146). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If voltage is NOT 5.5 -6.5 Volts, proceed to step 7.

7. Turn ignition switch and battery disconnect switch to OFF position TM 5-2410-241-10. 8. Disconnect chassis harness connector L-C1 (WP 0018, Figure 84) from platform harness connector MA-C17 (WP 0018, Figure 85). 9. Using digital multimeter (WP 0296), test for continuity between pin 6 on chassis harness connector L-C1 (WP 0018, Figure 84) and pin 1 on chassis harness oil temperature sensor connector LC2 (WP 0018, Figure 83).

1. If continuity is NOT found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, proceed to step 10.

10. Using digital multimeter (WP 0296), test for continuity between pin 6 on chassis harness connector L-C1 (WP 0018, Figure 84) and all other pins in chassis harness connector L-C1 (WP 0018, Figure 84).

1. If continuity is found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, proceed to step 11.

11. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262).

0021-27

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION 600-8 Hydraulic Oil Temperature Sensor Voltage Abnormal Signal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

12. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between platform harness (WP 0209) and pin 6 on platform harness connecinstrument panel harness (WP tor MA-C17 (WP 0018, Figure 85) 0260). Ensure all harness conand pin 10 on dash monitor connectors are reconnected. Verify nector E-C7 (WP 0018, Figure 5). correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 13. 13. Using digital multimeter (WP 1. If continuity is found, replace plat0296), test for continuity between form harness (WP 0209) and pin 10 on dash monitor connector instrument panel harness (WP E-C7 (WP 0018, Figure 5) and all 0260). Ensure all harness conother pins in dash monitor connectors are reconnected. Verify nector E-C7 (WP 0018, Figure 5). correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace dash monitor ECM (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

819-2 Display Data Link Abnormal Update

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013). 2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262). 4. Disconnect instrument panel harness gauge cluster connector EC9 (WP 0018, Figure 86) from gauge cluster (WP 0262). 5. Disconnect instrument panel harness lamp gear module connector E-C10 (WP 0018, Figure 87) from lamp gear module (WP 0262).

0021-28

1. If active 819-2 code is present, proceed to step 2. 2. If no active codes are present, problem does NOT exist at this time. Resume normal operation.

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

819-2 Display Data Link Abnormal Update - Continued

6. Using digital multimeter (WP 0296), test for continuity between pin 1 on instrument panel harness gauge cluster connector E-C9 (WP 0018, Figure 86) and pin 34 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found proceed to step 7.

7. Using digital multimeter (WP 0296), test for continuity between pin 2 on instrument panel harness gauge cluster connector E-C9 (WP 0018, Figure 86) and pin 2 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 8.

8. Using digital multimeter (WP 0296), test for continuity between pin 3 on instrument panel harness gauge cluster connector E-C9 (WP 0018, Figure 86) and pin 25 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 9.

9. Using digital multimeter (WP 0296), test for continuity between pin 4 on instrument panel harness gauge cluster connector E-C9 (WP 0018, Figure 86) and pin 35 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 10.

10. Using digital multimeter (WP 0296), test for continuity between pin 5 on instrument panel harness gauge cluster connector E-C9 (WP 0018, Figure 86) and pin 15 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 11.

11. Using digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between instrument panel harness (WP pin 15 on dash monitor connector 0260). Ensure all harness conE-C7 (WP 0018, Figure 5) to all nectors are reconnected. Verify other pins in dash monitor concorrect operation of machine (TM nector E-C7 (WP 0018, Figure 5). 5-2410-241-10). 2. If continuity is NOT found, proceed to step 12.

0021-29

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION 819-2 Display Data Link Abnormal Update - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

12. Using digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between instrument panel harness (WP pin 35 on dash monitor connector 0260). Ensure all harness conE-C7 (WP 0018, Figure 5) and all nectors are reconnected. Verify other pins in dash monitor concorrect operation of machine (TM nector E-C7 (WP 0018, Figure 5). 5-2410-241-10). 2. If continuity is NOT found, proceed to step 13. 13. Using digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between instrument panel harness (WP pin 25 on dash monitor connector 0260). Ensure all harness conE-C7 (WP 0018, Figure 5) and all nectors are reconnected. Verify other pins in dash monitor concorrect operation of machine (TM nector E-C7 (WP 0018, Figure 5). 5-2410-241-10). 2. If continuity is NOT found, proceed to step 14. 14. Using digital multimeter (WP 0296), test for continuity between pin 1 on instrument panel harness lamp gear module connector EC10 (WP 0018, Figure 87) and pin 34 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 15.

15. Using digital multimeter (WP 0296), test for continuity between pin 2 on instrument panel harness lamp gear module connector EC10 (WP 0018, Figure 87) and pin 2 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 16.

16. Using digital multimeter (WP 0296), test for continuity between pin 3 on instrument panel harness lamp gear module connector EC10 (WP 0018, Figure 87) and pin 25 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace instrument panel harness (WP 0259). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 17.

17. Using digital multimeter (WP 0296), test for continuity between pin 4 on instrument panel harness lamp gear module connector EC10 (WP 0018, Figure 87) and pin 35 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace instrument panel harness (WP 0259). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 18.

0021-30

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

819-2 Display Data Link Abnormal Update - Continued

18. Using digital multimeter (WP 0296), test for continuity between pin 5 on instrument panel harness lamp gear module connector EC10 (WP 0018, Figure 87) and pin 15 on dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 19.

19. Connect dash monitor connector E-C7 (WP 0018, Figure 5) on instrument panel (WP 0262). 20. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

821-3 Display Power Supply Voltage Above Normal

21. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on instrument panel harness gauge cluster connector E-C9 (WP 0018, Figure 86).

1. If 8.5 - 9.5 Volts is found, proceed to step 22. 2. If 8.5 - 9.5 Volts is NOT found, replace dash monitor ECM (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

22. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on instrument panel harness lamp gear module connector E-C10 (WP 0018, Figure 87).

1. If 8.5 - 9.5 Volts is found, replace lamp gear module and gauge cluster (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 8.5 - 9.5 Volts is NOT found, replace dash monitor ECM (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 821-3 code is present, proceed to step 2. 2. If no active codes are present, problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262).

0021-31

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

821-3 Display Power Supply Voltage Above Normal Continued

4. Disconnect instrument panel harness gauge cluster connector EC9 (WP 0018, Figure 86) from gauge cluster (WP 0262).

CORRECTIVE ACTION

5. Disconnect instrument panel harness lamp gear module connector E-C10 (WP 0018, Figure 87) from lamp gear module (WP 0262). 6. Using digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between instrument panel harness (WP pin 34 on dash monitor connector 0260). Ensure all harness conE-C7 (WP 0018, Figure 5) and all nectors are reconnected. Verify other pins in dash monitor concorrect operation of machine (TM nector E-C7 (WP 0018, Figure 5). 5-2410-241-10). 2. If continuity is NOT found, proceed to step 7. 7. Connect dash monitor connector E-C7 (WP 0018, Figure 5) on instrument panel (WP 0262). 8. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

821-4 Display Power Supply Voltage Below Normal

9. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on instrument panel harness gauge cluster connector E-C9 (WP 0018, Figure 86).

1. If 8.5 - 9.5 Volts is found, proceed to step 10. 2. If 8.5 - 9.5 Volts is NOT found, replace dash monitor ECM (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

10. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on instrument panel harness lamp gear module connector E-C10 (WP 0018, Figure 87).

1. If 8.5 - 9.5 Volts is found, replace lamp gear module and gauge cluster (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 8.5 - 9.5 Volts is NOT found, replace dash monitor ECM (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 821-4 code is present, proceed to step 2. 2. If no active codes are present, problem does NOT exist at this time. Resume normal operation.

0021-32

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

821-4 Display Power Supply Voltage Below Normal Continued

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

CORRECTIVE ACTION

3. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262). 4. Disconnect instrument panel harness gauge cluster connector EC9 (WP 0018, Figure 86) from gauge cluster (WP 0262). 5. Disconnect instrument panel harness lamp gear module connector E-C10 (WP 0018, Figure 87) from lamp gear module (WP 0262). 6. Using digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between instrument panel harness (WP pin 34 on dash monitor connector 0260). Ensure all harness conE-C7 (WP 0018, Figure 5) and all nectors are reconnected. Verify other pins in dash monitor concorrect operation of machine (TM nector E-C7 (WP 0018, Figure 5). 5-2410-241-10). 2. If continuity is NOT found, proceed to step 7. 7. Connect dash monitor connector E-C7 (WP 0018, Figure 5) on instrument panel (WP 0262). 8. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 9. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on instrument panel harness gauge cluster connector E-C9 (WP 0018, Figure 86).

0021-33

1. If 8.5 - 9.5 Volts is found, proceed to step 10. 2. If 8.5 - 9.5 Volts is NOT found, replace dash monitor ECM (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

821-4 Display Power Supply Voltage Below Normal Continued

10. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on instrument panel harness lamp gear module connector E-C10 (WP 0018, Figure 87).

1. If 8.5 - 9.5 Volts is found, replace lamp gear module and gauge cluster (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 8.5 - 9.5 Volts is NOT found, replace dash monitor ECM (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

826-4 Powertrain Oil Temperature Sensor Voltage Below Normal

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 826-4 code is present, proceed to step 2. 2. If no active codes are present, problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove front floor plate (WP 0239). 4. Disconnect engine harness torque converter outlet temperature sensor connector V-C9 (WP 0018, Figure 88) from torque converter outlet temperature sensor (WP 0124). 5. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 6. Check for Diagnostic Codes or Event Codes (WP 0013).

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0021-34

1. If active 826-4 code is NOT present, replace torque converter outlet temperature sensor (WP 0124). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 826-4 code is present, proceed to step 7.

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

826-4 Powertrain Oil Temperature Sensor Voltage Below Normal - Continued

8. Disconnect platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11) from engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) (WP 0055). 9. Using digital multimeter (WP 0296), test for continuity between pin 1 on engine harness torque converter outlet temperature sensor connector V-C9 (WP 0018, Figure 88) and pin 32 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12).

CORRECTIVE ACTION

1. If continuity is NOT found, replace engine main harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, proceed to step 10.

10. Using digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity on pin 32 engine main wiring harness (WP on engine harness (engine to plat0055). Ensure all harness conform) connector V-C1 (WP 0018, nectors are reconnected. Verify Figure 12) and all other pins in correct operation of machine (TM engine harness (engine to plat5-2410-241-10). form) connector V-C1 (WP 0018, 2. If continuity is NOT found, proFigure 12). ceed to step 11. 11. Disconnect dash monitor connector E-C7 (WP 0018, Figure 5) from instrument panel (WP 0262). 12. Using digital multimeter (WP 0296), test for continuity between pin 32 on platform harness (platform to engine) connector MAC22 (WP 0018, Figure 11) and pin 28 on dash monitor connector EC7 (WP 0018, Figure 5).

1. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 13.

13. Using digital multimeter (WP 0296), test for continuity between pin 28 on dash monitor connector E-C7 (WP 0018, Figure 5) and all other pins in dash monitor connector E-C7 (WP 0018, Figure 5).

1. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace dash monitor ECM (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0021-35

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

882-3 Hydraulic Lockout Solenoid Voltage Above Normal

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013).

CORRECTIVE ACTION 1. If active 882-3 code is present, proceed to step 2. 2. If no active codes are present, problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Remove right side hydraulic tank access panel (WP 0186). 4. Disconnect chassis harness implement lockout solenoid connector L-C4 (WP 0018, Figure 90) from implement lockout solenoid (WP 0216). 5. Disconnect platform harness connector MA-C17 (WP 0018, Figure 85) from chassis harness connector L-C1 (WP 0018, Figure 84) (WP 0055). 6. Using digital multimeter (WP 0296), test for continuity between pin 1 on chassis harness implement lockout solenoid connector L-C4 (WP 0018, Figure 90) and pin 1 on chassis harness connector L-C1 (WP 0018, Figure 84).

1. If continuity is NOT found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, proceed to step 7.

7. Using digital multimeter (WP 0296), test for continuity between pin 1 on chassis harness implement lockout solenoid connector L-C4 (WP 0018, Figure 90) and all other pins in chassis harness implement lockout solenoid connector L-C4 (WP 0018, Figure 90).

1. If continuity is found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, proceed to step 8.

8. Remove left platform access panel (WP 0212). 9. Disconnect powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33).

0021-36

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION 882-3 Hydraulic Lockout Solenoid Voltage Above Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Remove right platform access panel (WP 0213). 11. Disconnect RH console harness connector R-C1 (WP 0018, Figure 14) from RH platform harness connector MA-C1 (WP 0018, Figure 15). 12. Using digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 13. pin 1 on platform harness connec- 2. If continuity is NOT found, replace tor MA-C17 (WP 0018, Figure 85) platform harness (WP 0209). and pin 51 on platform harness Ensure all harness connectors connector MA-C14 (WP 0018, are reconnected. Verify correct Figure 33). operation of machine (TM 5-2410241-10). 13. Using digital multimeter (WP 0296), test for continuity between pin 51 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 14. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

14. Using digital multimeter (WP 0296), test for continuity between pin 51 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin 11 on RH platform harness connector MA-C1 (WP 0018, Figure 15).

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

15. Using digital multimeter (WP 0296), test for continuity between pin 64 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin 8 on RH platform harness connector MA-C1 (WP 0018, Figure 15).

1. If continuity is found, proceed to step 16. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0021-37

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION 882-3 Hydraulic Lockout Solenoid Voltage Above Normal - Continued

TEST OR INSPECTION 16. Using digital multimeter (WP 0296), test for continuity between pin 64 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

CORRECTIVE ACTION 1. If continuity is NOT found, proceed to step 17. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

17. Disconnect RH console harness hydraulic lockout switch connector RW-C7 (WP 0018, Figure 89) from hydraulic lockout switch (WP 0208). 18. Using digital multimeter (WP 0296), test for continuity between pin 1 on RH console harness hydraulic lockout switch connector RW-C7 (WP 0018, Figure 89) and pin 11 on RH console harness connector R-C1 (WP 0018, Figure 14).

1. If continuity is found, proceed to step 19. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

19. Using digital multimeter (WP 0296), test for continuity between pin 2 on RH console harness hydraulic lockout switch connector RW-C7 (WP 0018, Figure 89) and pin 8 on RH console harness connector R-C1 (WP 0018, Figure 3).

1. If continuity is found, proceed to step 20. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

20. Using digital multimeter (WP 1. If continuity is NOT found, pro0296), test for continuity between ceed to step 21. pin 8 on RH console harness con- 2. If continuity is found, replace platnector R-C1 (WP 0018, Figure form harness (WP 0209). Ensure 14) and all other pins in RH conall harness connectors are reconsole harness connector R-C1 nected. Verify correct operation of (WP 0018, Figure 14). machine (TM 5-2410-241-10). 21. Using digital multimeter (WP 0296), test for continuity between pin 11 on RH console harness connector R-C1 (WP 0018, Figure 14) and all other pins in RH console harness connector R-C1 (WP 0018, Figure 14). 22. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM.

0021-38

1. If continuity is NOT found, proceed to step 22. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

882-3 Hydraulic Lockout Solenoid Voltage Above Normal - Continued

23. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM.

CORRECTIVE ACTION

24. Using digital multimeter (WP 0296), test for continuity between pin 24 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and pin 51 on powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 25. 2. If continuity is NOT found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

25. Using digital multimeter (WP 0296), test for continuity between pin 24 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, proceed to step 26. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

26. Using digital multimeter (WP 0296), test for continuity between pin 24 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 27. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

27. Using digital multimeter (WP 0296), test for continuity between pin 2 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 64 on powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 28. 2. If continuity is NOT found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

28. Using digital multimeter (WP 0296), test for continuity between pin 2 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 29. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0021-39

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

882-3 Hydraulic Lockout Solenoid Voltage Above Normal - Continued

29. Using digital multimeter (WP 0296), test for continuity between pin 2 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

882-5 Hydraulic Lockout Solenoid Current Below Normal

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 882-5 code is present, proceed to step 2. 2. If no active codes are present, problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Open door (TM 5-2410-241-10). 4. Disconnect chassis harness implement lockout solenoid connector L-C4 (WP 0018, Figure 90) from implement lockout solenoid (WP 0216). 5. Install jumper wire between pin 1 and 2 on chassis harness implement lockout solenoid connector L-C4 (WP 0018, Figure 90). 6. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 7. Check for Diagnostic Codes or Event Codes (WP 0013).

8. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0021-40

1. If active 882-6 code is present, replace implement lockout solenoid (WP 0216). Remove jumper wire between pin 1 and 2 on connector L-C4 (WP 0018, Figure 90). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 2. If active 882-5 code is present, proceed to step 8.

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

882-5 Hydraulic Lockout Solenoid Current Below Normal - Continued

9. Remove jumper wire from chassis harness implement lockout solenoid connector L-C4 (WP 0018, Figure 90) between pin 1 and 2.

CORRECTIVE ACTION

10. Remove right hydraulic tank access panel (WP 0186). 11. Disconnect platform harness connector MA-C17 (WP 0018, Figure 85) from chassis harness connector L-C1 (WP 0018, Figure 84) (WP 0177). 12. Using digital multimeter (WP 0296) test for continuity between pin 1 on chassis harness implement lockout solenoid connector L-C4 (WP 0018, Figure 90) and pin 1 on chassis harness connector L-C1 (WP 0018, Figure 84).

1. If continuity is NOT found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, proceed to step 13.

13. Using digital multimeter (WP 0296) test for continuity between pin 1 on chassis harness implement lockout solenoid connector L-C4 (WP 0018, Figure 90) and pin 2 on chassis harness implement lockout solenoid connector L-C4 (WP 0018, Figure 90).

1. If continuity is found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, proceed to step 14.

14. Remove left platform access panel (WP 0212). 15. Disconnect steering harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 16. Remove upper right platform access panel (WP 0184). 17. Disconnect RH console harness connector RW-C1 (WP 0018, Figure 14) from RH platform harness connector MA-C1 (WP 0018, Figure 15).

0021-41

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION 882-5 Hydraulic Lockout Solenoid Current Below Normal - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

18. Using digital multimeter (WP 1. If continuity is found, proceed to 0296) test for continuity between step 19. pin 1 on platform harness connec- 2. If continuity is NOT found, replace tor MA-C17 (WP 0018, Figure 85) platform harness (WP 0209). and pin 51 on platform harness Ensure all harness connectors MA-C14 (WP 0018, Figure 33). are reconnected. Verify correct operation of machine (TM 5-2410241-10). 19. Using digital multimeter (WP 0296) test for continuity between pin 51 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 20. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

20. Using digital multimeter (WP 0296) test for continuity between pin 51 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin 11 on RH platform harness connector MA-C1 (WP 0018, Figure 15).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

21. Using digital multimeter (WP 1. If continuity is found, proceed to 0296) test for continuity between step 22. pin 64 on platform harness con2. If continuity is NOT found, replace nector MA-C14 (WP 0018, Figure platform harness (WP 0209). 33) and pin 8 on RH platform harEnsure all harness connectors ness connector MA-C1 (WP are reconnected. Verify correct 0018, Figure 15). operation of machine (TM 5-2410241-10). 22. Using digital multimeter (WP 0296) test for continuity between pin 64 on platform harness connector MA-C14(WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33). 23. Disconnect RH console harness hydraulic lockout switch connector RW-C7 (WP 0018, Figure 89) from hydraulic lockout switch (WP 0208).

0021-42

1. If continuity is NOT found, proceed to step 23. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

882-5 Hydraulic Lockout Solenoid Current Below Normal - Continued

24. Using digital multimeter (WP 0296) test for continuity between pin 1 on RH console harness hydraulic lockout switch connector RW-C7(WP 0018, Figure 89) and pin 11 on RH console harness connector RW-C1 (WP 0018, Figure 14).

1. If continuity is found, proceed to step 25. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

25. Using digital multimeter (WP 1. If continuity is found, proceed to 0296) test for continuity between step 26. pin 2 on RH console harness 2. If continuity is NOT found, replace hydraulic lockout switch connecplatform harness (WP 0209). tor RW-C7 (WP 0018, Figure 89) Ensure all harness connectors and pin 8 on RH console harness are reconnected. Verify correct connector RW-C1 (WP 0018, Figoperation of machine (TM 5-2410ure 14). 241-10). 26. Using digital multimeter (WP 1. If continuity is NOT found, pro0296) test for continuity between ceed to step 27. pin 8 on RH console harness con- 2. If continuity is found, replace platnector RW-C1 (WP 0018, Figure form harness (WP 0209). Ensure 14) and all other pins in RH conall harness connectors are reconsole harness connector RW-C1 nected. Verify correct operation of (WP 0018, Figure 14). machine (TM 5-2410-241-10). 27. Using digital multimeter (WP 1. If continuity is NOT found, pro0296) test for continuity between ceed to step 28. pin 11 on RH console harness 2. If continuity is found, replace platconnector RW-C1 (WP 0018, Figform harness (WP 0209). Ensure ure 14) and all other pins in RH all harness connectors are reconconsole harness connector RWnected. Verify correct operation of C1 (WP 0018, Figure 14). machine (TM 5-2410-241-10). 28. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 29. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 30. Using digital multimeter (WP 0296) test for continuity between pin 24 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and pin 51 on powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34).

0021-43

1. If continuity is found, proceed to step 31. 2. If continuity is NOT found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

882-5 Hydraulic Lockout Solenoid Current Below Normal - Continued

31. Using digital multimeter (WP 0296) test for continuity between pin 24 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, proceed to step 32. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

32. Using digital multimeter (WP 0296) test for continuity between pin 24 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 33. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

33. Using digital multimeter (WP 0296) test for continuity between pin 2 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 64 on powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 34. 2. If continuity is NOT found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

34. Using digital multimeter (WP 0296) test for continuity between pin 2 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 35. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

35. Using digital multimeter (WP 0296) test for continuity between pin 2 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0021-44

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

882-6 Hydraulic Lockout Solenoid Current Below Normal

1. Connect MSD (WP 0016). Select CAT Monitoring System D7R ECM and check for Diagnostic Codes or Event Codes (WP 0013).

CORRECTIVE ACTION 1. If active 882-6 code is present, proceed to step 2. 2. If no active codes are present, problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Open door (TM 5-2410-241-10). 4. Disconnect chassis harness implement lockout solenoid connector L-C4 (WP 0018, Figure 90) from implement lockout solenoid (WP 0216). 5. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 6. Check for Diagnostic Codes or Event Codes (WP 0013).

1. If active 882-5 code is present, replace implement lockout solenoid (WP 0216). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If active 882-6 code is NOT present, proceed to step 7.

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Remove right hydraulic tank access panel (WP 0186). 9. Disconnect platform harness connector MA-C17 (WP 0018, Figure 85) from chassis harness connector L-C1 (WP 0018, Figure 84) (WP 0055). 10. Using digital multimeter (WP 0296), test for continuity between pin 1 on chassis harness implement lockout solenoid connector L-C4 (WP 0018, Figure 90) and pin 1 on chassis harness connector L-C1 (WP 0018, Figure 84).

0021-45

1. If continuity is NOT found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, proceed to step 11.

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

882-6 Hydraulic Lockout Solenoid Current Below Normal - Continued

11. Using digital multimeter (WP 0296), test for continuity between pin 1 on chassis harness implement lockout solenoid connector L-C4 (WP 0018, Figure 90) and all other pins in chassis harness implement lockout solenoid connector L-C4 (WP 0018, Figure 90).

1. If continuity is found, replace chassis harness (WP 0172). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, proceed to step 12.

12. Remove left platform access panel (WP 0212). 13. Disconnect steering harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 14. Remove upper right access panel (WPN 0184). 15. Disconnect RH console harness connector R-C1 (WP 0018, Figure 14) from RH platform harness connector MA-C1 (WP 0018, Figure 15). 16. Using digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 17. pin 1 on platform harness connec- 2. If continuity is NOT found, replace tor MA-C17 (WP 0018, Figure 85) platform harness (WP 0209). and pin 51 on platform harness Ensure all harness connectors connector MA-C14 (WP 0018, are reconnected. Verify correct Figure 33). operation of machine (TM 5-2410241-10). 17. Using digital multimeter (WP 1. If continuity is NOT found, pro0296), test for continuity between ceed to step 18. pin 51 on platform harness con2. If continuity is found, replace platnector MA-C14 (WP 0018, form harness (WP 0209). Ensure Figure 33) to all other pins in platall harness connectors are reconform harness connector MA-C14 nected. Verify correct operation of (WP 0018, Figure 33). machine (TM 5-2410-241-10). 18. Using digital multimeter (WP 0296), test for continuity between pin 51 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin 11 on RH platform harness connector MA-C1 (WP 0018, Figure 15).

0021-46

1. If continuity is found, proceed to step 19. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

882-6 Hydraulic Lockout Solenoid Current Below Normal - Continued

19. Using digital multimeter (WP 0296), test for continuity between pin 64 on platform harness connector MA-C14 (WP 0018, Figure 33) and pin 8 on RH platform harness connector MA-C1 (WP 0018, Figure 15).

1. If continuity is found, proceed to step 20. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

20. Using digital multimeter (WP 0296), test for continuity between pin 64 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MAC14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 21. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

21. Disconnect RH console harness hydraulic lockout switch connector RW-C7 (WP 0018, Figure 89) from hydraulic lockout switch (WP 0208. 22. Using digital multimeter (WP 0296), test for continuity between pin 1 on RH console harness hydraulic lockout switch connector RW-C7 (WP 0018, Figure 89) and pin 11 on RH console harness connector R-C1 (WP 0018, Figure 14).

1. If continuity is found, proceed to step 23. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

23. Using digital multimeter (WP 0296), test for continuity between pin 2 on RH console harness hydraulic lockout switch connector RW-C7(WP 0018, Figure 89) and pin 8 on RH console harness connector R-C1 (WP 0018, Figure 14).

1. If continuity is found, proceed to step 24. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

24. Using digital multimeter (WP 1. If continuity is NOT found, pro0296), test for continuity between ceed to step 25. pin 8 on RH console harness con- 2. If continuity is found, replace platnector R-C1 (WP 0018, Figure form harness (WP 0209). Ensure 14) and all other pins in RH conall harness connectors are reconsole harness connector R-C1 nected. Verify correct operation of (WP 0018, Figure 14). machine (TM 5-2410-241-10).

0021-47

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

882-6 Hydraulic Lockout Solenoid Current Below Normal - Continued

25. Using digital multimeter (WP 0296), test for continuity between pin 11 on RH console harness connector R-C1 (WP 0018, Figure 14) and all other pins in RH console harness connector R-C1 (WP 0018, Figure 14).

1. If continuity is NOT found, proceed to step 26. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

26. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM. 27. Disconnect powertrain ECM connector X-C3 (WP 0018, Figure 3) from powertrain ECM. 28. Using digital multimeter (WP 0296), test for continuity between pin 24 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and pin 51 on powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 29. 2. If continuity is NOT found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

29. Using digital multimeter (WP 0296), test for continuity between pin 24 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, proceed to step 30. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

30. Using digital multimeter (WP 0296), test for continuity between pin 24 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 31. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

31. Using digital multimeter (WP 0296), test for continuity between pin 2 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and pin 64 on powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 32. 2. If continuity is NOT found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0021-48

0021

TM 5-2410-241-23-1

0021

Table 2. Chassis Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

882-6 Hydraulic Lockout Solenoid Current Below Normal - Continued

32. Using digital multimeter (WP 0296), test for continuity between pin 2 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C3 (WP 0018, Figure 3).

1. If continuity is NOT found, proceed to step 33. 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

33. Using digital multimeter (WP 0296), test for continuity between pin 2 on powertrain ECM connector X-C3 (WP 0018, Figure 3) and all other pins in powertrain ECM connector X-C2 (WP 0018, Figure 4).

1. If continuity is NOT found, replace powertrain ECM (WP 0175). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

END OF TASK END OF WORK PACKAGE

0021-49/(50 blank)

0021

150 TM 5-2410-241-23-1

0022

FIELD MAINTENANCE 0 0 2 2

-

CAB TROUBLESHOOTING PROCEDURES

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Tool Kit, Service, Refrigeration, Ordnance (WP 0302, Item 66) Adapter Kit Test (WP 0302, Item 5) Software Kit (Mil ET) (WP 0302, Item 55) Test Set, Electronic (MSD) (WP 0302, Item 62) Needle Tip (Tip G), (Multimeter) (WP 0302, Item 39) Screwdriver Attachment, Torx, 3/8” Drive, T-30 (S0288) (WP 0302, Item 68) Materials/Parts

Two References WP 0013 WP 0016 WP 0030 WP 0018 WP 0027 WP 0030 WP 0036 WP 0055 WP 0060 WP 0096 WP 0097 WP 0105 WP 0154

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Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Personnel Required

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0

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0

References - Continued WP 0155 WP 0167 WP 0170 WP 0176 WP 0178 WP 0179 WP 0182 WP 0208 WP 0209 WP 0210 WP 0219 WP 0222 WP 0223 WP 0224 WP 0229 WP 0232 WP 0234 WP 0240 WP 0241 WP 0242 WP 0249 WP 0250 WP 0252 WP 0253 WP 0254 WP 0260 WP 0261 WP 0262 WP 0263 WP 0296 Equipment Condition

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Machine parked (TM 5-2410-241-10)

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GENERAL

0022

This work package contains troubleshooting information for the D7R Dozer. Each malfunction or symptom listed is followed by the possible cause(s) and suggested remedy or remedies. This work package should be used as an aid in the isolation and correction of system problems.

NOTE Tag and identify connectors to aid installation.

0022-1

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures. MALFUNCTION Front Cylinder Mounted Flood Lamp(s) Do Not Work

TEST OR INSPECTION

0022

CORRECTIVE ACTION

1. Inspect operation of front cylinder- 1. If left lamp does NOT work, promounted flood lamps (TM 5-2410ceed to step 2. 241-10). 2. If right lamp does NOT work, proceed to step 119. 3. If both lamps do NOT work, proceed to step 36. 2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect left front cylindermounted flood lamp harness connector GA-C2 (WP 0018, Figure 92) from left front cylindermounted flood lamp. 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Turn main light switch to Headlight position (TM 5-2410-241-10). 6. Using digital multimeter (WP 0296), measure for voltage between pin 1 and pin 2 on left front cylinder-mounted flood lamp harness connector GA-C2 (WP 0018, Figure 92).

1. If 24 Volts is found, proceed to step 7. 2. If 24 Volts is NOT found, proceed to step 13.

7. Turn main light switch to OFF position (TM 5-2410-241-10). 8. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 9. Remove and disassemble left front cylinder-mounted flood lamp (WP 0210). 10. Inspect inside of left front cylinder- 1. If corrosion or damage is found, mounted flood lamp for corrosion replace left front cylinder-mounted and damage. flood lamp assembly (WP 0210). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If corrosion and damage is NOT found, proceed to step 11.

0022-2

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Front Cylinder Mounted Flood Lamp(s) Do Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

11. Using digital multimeter (WP 0296), test for continuity between pin 1 and terminal 4 on left front cylinder-mounted flood lamp (WP 0018, Figure 180).

1. If continuity is found, proceed to step 12. 2. If continuity is NOT found, replace left front cylinder-mounted flood lamp assembly (WP 0210). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

12. Using digital multimeter (WP 0296), test for continuity between pin 2 and terminal 3 on left front cylinder-mounted flood lamp (WP 0018, Figure 180).

1. If continuity is found, replace left front cylinder-mounted flood lamp bulb (WP 0210). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace left front cylinder-mounted flood lamp assembly (WP 0210). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

13. Turn main light switch to OFF position (TM 5-2410-241-10). 14. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 15. Open left front grille door (WP 0156). 16. Disconnect left front flood lamp harness connector GA-C1 (WP 0018, Figure 94) from front lighting harness connector G-C2 (WP 0018, Figure 95). 17. Using digital multimeter (WP 0296), test for continuity between pin 1 on left front flood lamp harness connector GA-C1 (WP 0018, Figure 94) and pin 1 on left front cylinder-mounted flood lamp harness connector GA-C2 (WP 0018, Figure 92).

0022-3

1. If continuity is found, proceed to step 18. 2. If continuity is NOT found, replace left front flood lamp harness (WP 0154). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Front Cylinder Mounted Flood Lamp(s) Do Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

18. Using digital multimeter (WP 0296), test for continuity between pin 2 on left front flood lamp harness connector GA-C1 (WP 0018, Figure 94) and pin 2 on left front cylinder-mounted flood lamp harness connector GA-C2 (WP 0018, Figure 92).

1. If continuity is found, replace front lighting harness (WP 0167). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, replace left front flood lamp harness (WP 0154). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

19. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 20. Disconnect right front cylindermounted flood lamp harness connector GC-C2 (WP 0018, Figure 93) from right front cylindermounted flood lamp. 21. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 22. Turn main light switch to Headlight position (TM 5-2410-241-10). 23. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on right front cylinder-mounted flood lamp harness connector GC-C2 (WP 0018, Figure 93). 24. Turn main light switch to OFF position (TM 5-2410-241-10). 25. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 26. Remove and disassemble right front cylinder-mounted flood lamp (WP 0210).

0022-4

1. If 24 Volts is found, proceed to step 24. 2. If 24 Volts is NOT found. Proceed to step 30.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Front Cylinder Mounted Flood Lamp(s) Do Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

27. Inspect inside of right front cylin1. If corrosion or damage is found, der-mounted flood lamp for corroreplace right front cylindersion and damage. mounted flood lamp assembly (WP 0210). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If corrosion and damage is NOT found, proceed to step 28. 28. Using digital multimeter (WP 0296), test for continuity between pin 1 and terminal 4 on right front cylinder-mounted flood lamp (WP 0018, Figure 180).

1. If continuity is found, proceed to step 29. 2. If continuity is NOT found, replace right front cylinder-mounted flood lamp assembly (WP 0210). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

29. Using digital multimeter (WP 0296), test for continuity between pin 2 and terminal 3 on right front cylinder-mounted flood lamp (WP 0018, Figure 180).

1. If continuity is found, replace right front cylinder-mounted flood lamp bulb (WP 0216). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace right front cylinder-mounted flood lamp assembly (WP 0216). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

30. Turn main light switch to OFF position (TM 5-2410-241-10). 31. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 32. Open right front grille door (WP 0156). 33. Disconnect right front flood lamp harness connector GC-C1 (WP 0018, Figure 96) from front lighting harness connector G-C3 (WP 0018, Figure 97).

0022-5

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Front Cylinder Mounted Flood Lamp(s) Do Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

34. Using digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 35. pin 1 on right front flood lamp har- 2. If continuity is NOT found, replace ness connector GC-C1 (WP right front flood lamp harness (WP 0018, Figure 96) and pin 1 on 0154). Ensure all harness conright front cylinder-mounted flood nectors are reconnected. Verify lamp harness connector GC-C2 correct operation of machine (TM (WP 0018, Figure 93). 5-2410-241-10). 35. Using digital multimeter (WP 1. If continuity is found, replace front 0296), test for continuity between lighting harness (WP 0167). pin 2 on right front flood lamp harEnsure all harness connectors ness connector GC-C1 (WP are reconnected. Verify correct 0018, Figure 96) and pin 2 on operation of machine (TM 5-2410right front cylinder-mounted flood 241-10). lamp harness connector GC-C2 2. If continuity is NOT found, replace (WP 0018, Figure 93). right front flood lamp harness (WP 0154). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 36. Turn main light switch to OFF position (TM 5-2410-241-10). 37. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 38. Disconnect right front cylindermounted flood lamp harness connector GC-C2 (WP 0018, Figure 93) from right front cylindermounted flood lamp. 39. Disconnect left front cylindermounted flood lamp harness connector GA-C2 (WP 0018, Figure 92) from left front cylindermounted flood lamp. 40. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 41. Turn main light switch to Headlight position (TM 5-2410-241-10). 42. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on right front cylinder-mounted flood lamp harness connector GC-C2 (WP 0018, Figure 93).

0022-6

1. If 24 Volts is found, proceed to step 43. 2. If 24 Volts is NOT found, proceed to step 54.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Front Cylinder Mounted Flood Lamp(s) Do Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

43. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on left front cylinder-mounted flood lamp harness connector GA-C2 (WP 0018, Figure 92).

1. If 24 Volts is found, proceed to step 44. 2. If 24 Volts is NOT found, proceed to step 54.

44. Turn main light switch to OFF position (TM 5-2410-241-10). 45. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 46. Remove and disassemble right front cylinder-mounted flood lamp (WP 0210). 1. If corrosion or damage is found, 47. Inspect inside of right front cylinreplace right front cylinderder-mounted flood lamp for corrosion and damage. mounted flood lamp assembly (WP 0216). Proceed to step 50. 2. If corrosion and damage is NOT found, proceed to step 48. 48. Using digital multimeter (WP 0296), test for continuity between pin 1 and terminal 4 on right front cylinder-mounted flood lamp (WP 0018, Figure 180).

1. If continuity is found, proceed to step 49. 2. If continuity is NOT found, replace right front cylinder-mounted flood lamp assembly (WP 0216). Proceed to step 50.

49. Using digital multimeter (WP 0296), test for continuity between pin 2 and terminal 3 on right front cylinder-mounted flood lamp (WP 0018, Figure 180).

1. If continuity is found, replace right front cylinder-mounted flood lamp bulb (WP 0216). Proceed to step 50. 2. If continuity is NOT found, replace right front cylinder-mounted flood lamp assembly (WP 0216). Proceed to step 50.

50. Remove and disassemble left front cylinder-mounted flood lamp (WP 0210). 51. Inspect inside of left front cylinder- 1. If corrosion or damage is found, mounted flood lamp for corrosion replace left front cylinder-mounted and damage. flood lamp assembly (WP 0216). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If corrosion and damage is NOT found, proceed to step 52.

0022-7

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Front Cylinder Mounted Flood Lamp(s) Do Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

52. Using digital multimeter (WP 0296), test for continuity between pin 1 and terminal 4 on left front cylinder-mounted flood lamp (WP 0018, Figure 180).

1. If continuity is found, proceed to step 53. 2. If continuity is NOT found, replace left front cylinder-mounted flood lamp assembly (WP 0216). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

53. Using digital multimeter (WP 0296), test for continuity between pin 2 and terminal 3 on left front cylinder-mounted flood lamp (WP 0018, Figure 180).

1. If continuity is found, replace left front cylinder-mounted flood lamp bulb (WP 0216). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace left front cylinder-mounted flood lamp assembly (WP 0216). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

54. Turn main light switch to OFF position (TM 5-2410-241-10). 55. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0022-8

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Front Cylinder Mounted Flood Lamp(s) Do Not Work - Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

56. Remove Fuse #8 (Figure 1, Item 1) from fuse panel (TM 52410-241-10).

Figure 1. Fuse #8. 57. Using a digital multimeter (WP 0296), test for continuity between blades of Fuse #8.

0022

1. If continuity is NOT found, replace Fuse #8 (TM 5-2410-241-10) and proceed to step 58. 2. If continuity is found, install Fuse #8 on fuse panel (TM 5-2410-24110). Proceed to step 66.

58. Connect right front cylindermounted flood lamp harness connector GC-C2 (WP 0018, Figure 93) to right front cylinder-mounted flood lamp. 59. Connect left front cylindermounted flood lamp harness connector GA-C2 (WP 0018, Figure 92) to left front cylinder-mounted flood lamp. 60. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 61. Turn main light switch to Headlight position (TM 5-2410-241-10). Observe front cylinder-mounted flood lamps.

0022-9

1. If front cylinder mounted flood lamps do NOT operate, proceed to step 62. 2. If front cylinder-mounted flood lamps operate, resume normal operation (TM 5-2410-241-10).

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Front Cylinder Mounted Flood Lamp(s) Do Not Work - Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

62. Turn main light switch to OFF position (TM 5-2410-241-10). 63. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 64. Remove Fuse #8 (Figure 2, Item 1) from fuse panel (TM 52410-241-10).

Figure 2. Fuse #8. 65. Using a digital multimeter (WP 0296), test for continuity between blades of Fuse #8.

66. Disconnect left front flood lamp harness connector GA-C1 (WP 0018, Figure 94) from front lighting harness connector G-C2 (WP 0018, Figure 95). 67. Disconnect right front flood lamp harness connector GC-C1 (WP 0018, Figure 96) from front lighting harness connector G-C3 (WP 0018, Figure 97). 68. Install a jumper between pin 1 and pin 2 of front lighting harness connector G-C3 (WP 0018, Figure 97).

0022-10

0022

1. If continuity is NOT found, proceed to step 78. 2. If continuity is found, install Fuse #8 on fuse panel (TM 5-2410-24110) Proceed to step 66.

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Front Cylinder Mounted Flood Lamp(s) Do Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

69. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel harness connector A-C1 (WP 0018, Figure 22). 70. Turn main light switch to Headlight position (TM 5-2410-241-10). 71. Using digital multimeter (WP 0296), test for continuity between pin 25 on platform harness connector MA-C3 (WP 0018, Figure 21) and machine ground.

1. If continuity is found, replace fuse panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 72.

72. Disconnect instrument panel harness connector E-C5 (WP 0018, Figure 100) from main light switch (WP 0262). 73. Using digital multimeter (WP 0296), test for continuity between pin 3 and pin 5 on main light switch.

1. If continuity is found, proceed to step 74. 2. If continuity is NOT found, replace main light switch (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

74. Disconnect engine harness connector V-C1 (WP 0018, Figure 12) from platform harness connector MA-C22 (WP 0018, Figure 11). 75. Using digital multimeter (WP 0296), test for continuity between pin 1 and pin 3 on engine harness connector V-C1 (WP 0018, Figure 12).

76. Disconnect engine harness connector V-C15 (WP 0018, Figure 99) from front lighting harness connector G-C1 (WP 0018, Figure 98).

0022-11

1. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 76.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Front Cylinder Mounted Flood Lamp(s) Do Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

77. Using digital multimeter (WP 0296), test for continuity between pin B and pin A on front lighting harness connector G-C1 (WP 0018, Figure 98).

1. If continuity is found, replace main engine wiring harness (WP 0056). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, replace front lighting harness (WP 0167). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

78. Disconnect right front cylindermounted flood lamp harness connector GC-C2 (WP 0018, Figure 93) from right front cylinder-mounted flood lamp. 79. Disconnect left front cylindermounted flood lamp harness connector GA-C2 (WP 0018, Figure 92) from left front cylindermounted flood lamp. 80. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel harness connector A-C1 (WP 0018, Figure 22). 81. Turn main light switch to Headlight position (TM 5-2410-241-10). 82. Using digital multimeter (WP 0296), test for continuity between pin 25 on platform harness connector MA-C3 (WP 0018, Figure 21) and machine ground.

83. Disconnect engine harness connector V-C1 (WP 0018, Figure 12) from platform harness connector MA-C22 (WP 0018, Figure 11).

0022-12

1. If continuity is NOT found, replace fuse panel harness (WP 0176). Replace Fuse #8 (TM 5-2410241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 83.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Front Cylinder Mounted Flood Lamp(s) Do Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

84. Using digital multimeter (WP 0296), test for continuity between pin 1 and pin 3 on engine harness connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, proceed to step 85. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #8 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

85. Disconnect engine harness connector V-C15 (WP 0018, Figure 99) from front lighting harness connector G-C1 (WP 0018, Figure 98). 86. Using digital multimeter (WP 0296), test for continuity between pin A and pin B on front lighting harness connector G-C1 (WP 0018, Figure 98).

1. If continuity is found, proceed to step 87. 2. If continuity is NOT found, replace main engine wiring harness (WP 0055). Replace Fuse #8 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

87. Disconnect left front flood lamp harness connector GA-C1 (WP 0018, Figure 94) from front lighting harness connector G-C2 (WP 0018, Figure 95). 88. Using digital multimeter (WP 0296), test for continuity between pin 1 and pin 2 on left front flood lamp harness connector GA-C1 (WP 0018, Figure 94).

89. Disconnect right front flood lamp harness connector GC-C1 (WP 0018, Figure 96) from front lighting harness connector G-C3 (WP 0018, Figure 97).

0022-13

1. If continuity is found, replace left front flood lamp harness (WP 0154). Replace Fuse #8 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 89.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Front Cylinder Mounted Flood Lamp(s) Do Not Work - Continued

90. Using digital multimeter (WP 0296), test for continuity between pin 1 and pin 2 on right front flood lamp harness connector GC-C1 (WP 0018, Figure 96).

1. If continuity is found, replace right front flood lamp harness (WP 0154). Replace Fuse #8 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace front lighting harness (WP 0167). Replace Fuse #8 (TM 5-2410241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

ROPS Mounted Forward Facing Flood Lamp(s) Do Not Work

1. Inspect operation of ROPSmounted forward facing flood lamps (TM 5-2410-241-10).

1. If left lamp does NOT work, proceed to step 2. 2. If right lamp does NOT work, proceed to step 18. 3. If both lamps do NOT work, proceed to step 34.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect left rear flood lamp harness connector TK-C2 (WP 0018, Figure 101) from left side ROPS mounted forward facing flood lamp. 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Turn main light switch to Floodlight position (TM 5-2410-241-10). 6. Using digital multimeter (WP 1. If 24 Volts is found, proceed to 0296), measure for voltage step 7. between pin 1 and 2 on left rear 2. If 24 Volts is NOT found. Proceed flood lamp harness connector TKto step 13. C2 (WP 0018, Figure 101). 7. Turn main light switch to OFF position (TM 5-2410-241-10). 8. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 9. Remove and disassemble left ROPS-mounted forward facing flood lamp (WP 0252).

0022-14

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

ROPS Mounted Forward 10. Inspect inside of left ROPSFacing Flood Lamp(s) mounted forward facing flood Do Not Work - Continued lamp for corrosion and damage.

CORRECTIVE ACTION 1. If corrosion or damage is found, replace left ROPS-mounted forward facing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If corrosion and damage is NOT found, proceed to step 11.

11. Using digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 12. pin 1 and terminal 4 on left ROPS- 2. If continuity is NOT found, replace mounted forward facing flood left ROPS-mounted forward faclamp (WP 0018, Figure 180). ing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 12. Using digital multimeter (WP 1. If continuity is found, replace left 0296), test for continuity between ROPS-mounted forward facing pin 2 and terminal 3 on left ROPSflood lamp bulb (WP 0252). mounted forward facing flood Ensure all harness connectors lamp (WP 0018, Figure 180). are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, replace left ROPS-mounted forward facing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 13. Turn main light switch to OFF position (TM 5-2410-241-10). 14. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 15. Disconnect left rear flood lamp harness connector TK-C3 (WP 0018, Figure 103) from fuel tank harness connector TW-C3 (WP 0018, Figure 105).

0022-15

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

ROPS Mounted Forward 16. Using digital multimeter (WP Facing Flood Lamp(s) 0296), test for continuity between Do Not Work - Continued pin 3 on left rear flood lamp harness TK-C3 (WP 0018, Figure 103) and pin 1 on left rear flood lamp harness connector TK-C2 (WP 0018, Figure 101).

CORRECTIVE ACTION 1. If continuity is found, proceed to step 17. 2. If continuity is NOT found, replace left rear flood lamp harness (WP 0154). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

17. Using digital multimeter (WP 1. If continuity is found, replace fuel 0296), test for continuity between tank harness (WP 0170). Ensure pin 4 on left rear flood lamp harall harness connectors are reconness connector TK-C3 (WP 0018, nected. Verify correct operation of Figure 103) and pin 2 on left rear machine (TM 5-2410-241-10). flood lamp harness connector TK- 2. If continuity is NOT found, replace C2 (WP 0018, Figure 101). left rear flood lamp harness (WP 0154). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 18. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 19. Disconnect right rear flood lamp harness connector TJ-C2 (WP 0018, Figure 102) from right side ROPS- mounted forward facing flood lamp. 20. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 21. Turn main light switch to Floodlight position (TM 5-2410-241-10). 22. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on right rear flood lamp harness connector TJC2 (WP 0018, Figure 102). 23. Turn main light switch to OFF position (TM 5-2410-241-10). 24. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 25. Remove and disassemble right ROPS-mounted forward facing flood lamp (WP 0210).

0022-16

1. If 24 Volts is found, proceed to step 23. 2. If 24 Volts is NOT found. Proceed to step 29.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

ROPS Mounted Forward 26. Inspect inside of right ROPSFacing Flood Lamp(s) mounted forward facing flood Do Not Work - Continued lamp for corrosion and damage.

CORRECTIVE ACTION 1. If corrosion or damage is found, replace right ROPS-mounted forward facing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If corrosion and damage is NOT found, proceed to step 27.

27. Using digital multimeter (WP 0296), test for continuity between pin 1 and terminal 4 on right ROPS-mounted forward facing flood lamp (WP 0018, Figure 180).

1. If continuity is found, proceed to step 28. 2. If continuity is NOT found, replace right ROPS-mounted forward facing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

28. Using digital multimeter (WP 0296), test for continuity between pin 2 and terminal 3 on right ROPS-mounted forward facing flood lamp (WP 0018, Figure 180).

1. If continuity is found, replace right ROPS-mounted forward facing flood lamp bulb (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, replace right ROPS-mounted forward facing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

29. Turn main light switch to OFF position (TM 5-2410-241-10). 30. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 31. Disconnect right rear flood lamp harness connector TJ-C3 (WP 0018, Figure 104) from fuel tank harness connector TW-C5 (WP 0018, Figure 106).

0022-17

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

ROPS Mounted Forward 32. Using digital multimeter (WP Facing Flood Lamp(s) 0296), test for continuity between Do Not Work - Continued pin 3 on right rear flood lamp harness connector TJ-C3 (WP 0018, Figure 104) and pin 1 on right rear flood lamp harness connector TJ-C2 (WP 0018, Figure 102).

1. If continuity is found, proceed to step 33. 2. If continuity is NOT found, replace right rear flood lamp harness (WP 0154). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

33. Using digital multimeter (WP 0296), test for continuity between pin 4 on right rear flood lamp harness connector TJ-C3 (WP 0018, Figure 104) and pin 2 on right ROPS-mounted forward facing flood lamp harness connector TJ-C2 (WP 0018, Figure 102).

1. If continuity is found, replace fuel tank harness (WP 0170). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace right rear flood lamp harness (WP 0154). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

34. Turn main light switch to OFF position (TM 5-2410-241-10). 35. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 36. Disconnect right rear flood lamp harness connector TJ-C2 (WP 0018, Figure 102) from right ROPS-mounted forward facing flood lamp. 37. Disconnect left rear flood lamp harness connector TK-C2 (WP 0018, Figure 101) from left side ROPS-mounted forward facing flood lamp. 38. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 39. Turn main light switch to Floodlight position (TM 5-2410-241-10). 40. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on right rear flood lamp harness connector TJ-C2 (WP 0018, Figure 102).

0022-18

1. If 24 Volts is found, proceed to step 41. 2. If 24 Volts is NOT found, proceed to step 52.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

ROPS Mounted Forward 41. Using digital multimeter (WP Facing Flood Lamp(s) 0296), measure for voltage Do Not Work - Continued between pin 1 and 2 on left rear flood lamp harness connector TK-C2 (WP 0018, Figure 101).

CORRECTIVE ACTION 1. If 24 Volts is found, proceed to step 42. 2. If 24 Volts is NOT found, proceed to step 52.

42. Turn main light switch to OFF position (TM 5-2410-241-10). 43. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 44. Remove and disassemble right ROPS-mounted forward facing flood lamp (WP 0210). 45. Inspect inside of right ROPSmounted forward facing flood lamp for corrosion and damage.

1. If corrosion or damage is found, replace right ROPS-mounted forward facing flood lamp assembly (WP 0252). Proceed to step 48. 2. If corrosion and damage is NOT found, proceed to step 46.

46. Using digital multimeter 1. If continuity is found, proceed to (WP 0296), test for continuity step 47. between pin 1 and terminal 4 on 2. If continuity is NOT found, replace right ROPS -mounted forward facright ROPS-mounted forward facing flood lamp (WP 0018, Figure ing flood lamp assembly (WP 180). 0252). Proceed to step 48. 47. Using digital multimeter (WP 0296), test for continuity between pin 2 and terminal 3 on right ROPS-mounted forward facing flood lamp (WP 0018, Figure 180).

1. If continuity is found, replace right ROPS-mounted forward facing flood lamp bulb (WP 0252). Proceed to step 48. 2. If continuity is NOT found, replace right ROPS-mounted forward facing flood lamp assembly (WP 0252). Proceed to step 48.

48. Remove and disassemble left ROPS-mounted forward facing flood lamp (WP 0252). 49. Inspect inside of left ROPSmounted forward facing flood lamp for corrosion and damage.

0022-19

1. If corrosion or damage is found, replace left ROPS-mounted forward facing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If corrosion and damage is NOT found, proceed to step 50.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

ROPS Mounted Forward 50. Using digital multimeter (WP 1. If continuity is found, proceed to Facing Flood Lamp(s) 0296), test for continuity between step 51. Do Not Work - Continued pin 1 and terminal 4 on left ROPS- 2. If continuity is NOT found, replace mounted forward facing flood left ROPS-mounted forward faclamp (WP 0018, Figure 180). ing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 51. Using digital multimeter (WP 0296), test for continuity between pin 2 and terminal 3 on left ROPS -mounted forward facing flood lamp (WP 0018, Figure 180).

52. Turn main light switch to OFF position (TM 5-2410-241-10). 53. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0022-20

1. If continuity is found, replace left ROPS-mounted forward facing flood lamp bulb (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, replace left ROPS-mounted forward facing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

0022

CORRECTIVE ACTION

ROPS Mounted Forward Facing Flood Lamp(s) Do Not Work - Continued 54. Remove Fuse #16 (Figure 3, Item 1) from fuse panel (TM 5-2410241-10).

Figure 3. Fuse #16. 55. Using a digital multimeter (WP 0296), test for continuity between blades of Fuse #16.

0022-21

0022

1. If continuity is NOT found, replace Fuse #16 (TM 5-2410-241-10) and proceed to step 56. 2. If continuity is found, install Fuse #16 on fuse panel (TM 5-2410241-10). Proceed to step 64.

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

ROPS Mounted Forward 56. Connect right rear flood lamp harFacing Flood Lamp(s) ness connector TJ-C2 (WP 0018, Do Not Work - Continued Figure 102) to right ROPSmounted forward facing flood lamp. 57. Connect left rear flood lamp harness connector TK-C2 (WP 0018, Figure 101) to left side ROPSmounted forward facing flood lamp. 58. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 59. Turn main light switch to Flood1. If ROPS-mounted forward facing light position (TM 5-2410-241-10). flood lamps do NOT operate, proceed to step 60. 2. If ROPS-mounted forward facing flood lamps operate, resume normal operation (TM 5-2410-24110). 60. Turn main light switch to OFF position (TM 5-2410-241-10). 61. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0022-22

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

0022

CORRECTIVE ACTION

ROPS Mounted Forward 62. Remove Fuse #16 (Figure 4, Facing Flood Lamp(s) Item 1) from fuse panel (TM 5Do Not Work - Continued 2410-241-10).

Figure 4. Fuse #16. 63. Using a digital multimeter (WP 0296), test for continuity between blades of Fuse #16.

64. Disconnect left rear flood lamp harness connector TK-C3 (WP 0018, Figure 103) from fuel tank harness connector TW-C3 (WP 0018, Figure 105). 65. Disconnect right rear flood lamp harness connector TJ-C3 (WP 0018, Figure 104) from fuel tank harness connector TW-C5 (WP 0018, Figure 106). 66. Install jumper wire between pin 3 and pin 4 on fuel tank harness connector TW-C5 (WP 0018, Figure 106).

0022-23

0022

1. If continuity is NOT found, proceed to step 74. 2. If continuity is found, install Fuse #16 on fuse panel (TM 5-2410241-10). Proceed to step 64.

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

ROPS Mounted Forward 67. Disconnect platform harness conFacing Flood Lamp(s) nector MA-C3 (WP 0018, Figure Do Not Work - Continued 21) from fuse panel harness connector A-C1 (WP 0018, Figure 22). 68. Turn main light switch to Floodlight position (TM 5-2410-241-10). 69. Using digital multimeter (WP 0296), test for continuity between pin 30 on platform harness connector MA-C3 (WP 0018, Figure 21) and machine ground.

1. If continuity is found, replace fuse panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 70.

70. Disconnect instrument panel harness connector E-C5 (WP 0018, Figure 100) from main light switch (WP 0262). 71. Using digital multimeter (WP 0296), test for continuity between pin 1 and pin 8 on main light switch.

1. If continuity is found, proceed to step 72. 2. If continuity is NOT found, replace main light switch (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

72. Disconnect fuel tank harness connector TW-C7 (WP 0018, Figure 80) from platform harness connector MA-C23 (WP 0018, Figure 79). 73. Using digital multimeter (WP 0296), test for continuity between pin 6 and pin 5 on fuel tank harness connector TW-C7 (WP 0018, Figure 80).

0022-24

1. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace fuel tank harness (WP 0170). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

ROPS Mounted Forward 74. Disconnect right rear flood lamp Facing Flood Lamp(s) harness connector TJ-C2 (WP Do Not Work - Continued 0018, Figure 102) from right ROPS-mounted forward facing flood lamp. 75. Disconnect left rear flood lamp harness connector TK-C2 (WP 0018, Figure 101) from left side ROPS-mounted forward facing flood lamp. 76. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel harness connector A-C1 (WP 0018, Figure 22). 77. Turn main light switch to Floodlight position (TM 5-2410-241-10). 78. Using digital multimeter (WP 0296), test for continuity between pin 30 on platform harness connector MA-C3 (WP 0018, Figure 21) and machine ground.

1. If continuity is NOT found, replace fuse panel harness (WP 0176). Replace Fuse #16 (TM 5-2410241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 79.

79. Disconnect fuel tank harness connector TW-C7 (WP 0018, Figure 80) from platform harness connector MA-C23 (WP 0018, Figure 79). 80. Using digital multimeter (WP 0296), test for continuity between pin 6 and pin 5 on fuel tank harness connector TW-C7 (WP 0018, Figure 80).

81. Disconnect left rear flood lamp harness connector TK-C3 (WP 0018, Figure 103) from fuel tank harness connector TW-C3 (WP 0018, Figure 105).

0022-25

1. If continuity is found, proceed to step 81. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #16 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

ROPS Mounted Forward 82. Using digital multimeter (WP Facing Flood Lamp(s) 0296), test for continuity between Do Not Work - Continued pin 3 and pin 4 on left rear flood lamp harness connector TK-C3 (WP 0018, Figure 103).

CORRECTIVE ACTION 1. If continuity is found, replace left rear flood lamp harness (WP 0154). Replace Fuse #16 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 83.

83. Disconnect right rear flood lamp harness connector TJ-C3 (WP 0018, Figure 104) from fuel tank harness connector TW-C5 (WP 0018, Figure 106). 84. Using digital multimeter (WP 0296), test for continuity between pin 3 and pin 4 on right rear flood lamp harness connector TJ-C3 (WP 0018, Figure 104).

0022-26

1. If continuity is found, replace right rear flood lamp harness (WP 0154). Replace Fuse #16 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace fuel tank harness (WP 0170). Replace Fuse #16 (TM 5-2410241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION ROPS Mounted Rearward Facing Flood Lamp(s) Do Not Work

TEST OR INSPECTION

CORRECTIVE ACTION

1. Inspect operation of rearward fac- 1. If left lamp does NOT work, proing flood lamps (TM 5-2410-241ceed to step 2. 10). 2. If right lamp does NOT work, proceed to step 21. 3. If both lamps do NOT work, proceed to step 40. 2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect left rear flood lamp harness connector TK-C1 (WP 0018, Figure 107) from left rearward facing flood lamp. 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Turn main light switch to floodlight position (TM 5-2410-241-10). 6. Turn rear facing floodlight switch to ON position (TM 5-2410-241-10). 7. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on left rear flood lamp harness connector TK-C1 (WP 0018, Figure 107).

1. If 24 Volts is found, proceed to step 8. 2. If 24 Volts is NOT found. Proceed to step 15.

8. Turn rear facing floodlight switch to OFF position (TM 5-2410-24110). 9. Turn main light switch to OFF position (TM 5-2410-241-10). 10. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 11. Remove and disassemble left rearward facing flood lamp (WP 0210). 12. Inspect inside of left rearward fac- 1. If corrosion or damage is found, ing flood lamp for corrosion and replace left rearward facing flood damage. lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If corrosion and damage is NOT found, proceed to step 13.

0022-27

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

ROPS Mounted Rearward Facing Floodlamp(s) Do Not Work - Continued

13. Using digital multimeter (WP 0296), test for continuity between pin 1 and terminal 4 on left rearward facing flood lamp (WP 0018, Figure 180).

1. If continuity is found, proceed to step 14. 2. If continuity is NOT found, replace left rearward facing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

14. Using digital multimeter (WP 0296), test for continuity between pin 2 and terminal 3 on left rearward facing flood lamp (WP 0018, Figure 180).

1. If continuity is found, replace left rearward facing flood lamp bulb (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace left rearward facing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

15. Turn rear facing floodlight switch to OFF position (TM 5-2410-24110). 16. Turn main light switch to OFF position (TM 5-2410-241-10). 17. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 18. Disconnect left rear flood lamp harness connector TK-C3 (WP 0018, Figure 103) from fuel tank harness TW-C3 (WP 0018, Figure 105). 19. Using digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 20. pin 1 on left rear flood lamp har2. If continuity is NOT found, replace ness connector TK-C3 (WP 0018, left rear flood lamp harness (WP Figure 103) and pin 1 on left rear 0154). Ensure all harness conflood lamp harness connector TKnectors are reconnected. Verify C1 (WP 0018, Figure 107). correct operation of machine (TM 5-2410-241-10).

0022-28

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION ROPS Mounted Rearward Facing Floodlamp(s) Do Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

20. Using digital multimeter (WP 1. If continuity is found, replace fuel 0296), test for continuity between tank harness (WP 0170). Ensure pin 2 on left rear flood lamp harall harness connectors are reconness connector TK-C3 (WP 0018, nected. Verify correct operation of Figure 103) and pin 2 on left rear machine (TM 5-2410-241-10). flood lamp harness connector TK- 2. If continuity is NOT found, replace C1 (WP 0018, Figure 107). left rear flood lamp harness (WP 0154). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 21. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 22. Disconnect right rear flood lamp harness connector TJ-C1 (WP 0018, Figure 108) from right rear flood lamp. 23. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 24. Turn main light switch to Floodlight position (TM 5-2410-241-10). 25. Turn rear facing floodlight switch to ON position. 26. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on right rear flood lamp harness connector TJC1 (WP 0018, Figure 108). 27. Turn rear facing floodlight switch to OFF position (TM 5-2410-24110). 28. Turn main light switch to OFF position (TM 5-2410-241-10). 29. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 30. Remove and disassemble right rearward facing flood lamp (WP 0210).

0022-29

1. If 24 Volts is found, proceed to step 27. 2. If 24 Volts is NOT found, proceed to step 34.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION ROPS Mounted Rearward Facing Floodlamp(s) Do Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

31. Inspect inside of right rearward facing flood lamp for corrosion and damage.

1. If corrosion or damage is found, replace right rearward facing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If corrosion and damage is NOT found, proceed to step 32.

32. Using digital multimeter (WP 0296), test for continuity between pin 1 and terminal 4 on right rearward facing flood lamp (WP 0018, Figure 180).

1. If continuity is found, proceed to step 33. 2. If continuity is NOT found, replace right rearward facing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

33. Using digital multimeter (WP 0296), test for continuity between pin 2 and terminal 3 on right rearward facing flood lamp (WP 0018, Figure 180).

1. If continuity is found, replace right rearward facing flood lamp bulb (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace right rearward facing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

34. Turn rear facing floodlight switch to OFF position (TM 5-2410-24110). 35. Turn main light switch to OFF position (TM 5-2410-241-10). 36. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 37. Disconnect right rear flood lamp harness connector TJ-C3 (WP 0018, Figure 104) from fuel tank harness connector TW-C5 (WP 0018, Figure 106).

0022-30

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

ROPS Mounted Rearward Facing Floodlamp(s) Do Not Work - Continued

38. Using digital multimeter (WP 0296), test for continuity between pin 1 on right rear flood lamp harness connector TJ-C3 (WP 0018, Figure 104) and pin 1 on right rear flood lamp harness connector TJC1 (WP 0018, Figure 108).

1. If continuity is found, proceed to step 39. 2. If continuity is NOT found, replace right rear flood lamp harness (WP 0154). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

39. Using digital multimeter (WP 0296), test for continuity between pin 2 on right rear flood lamp harness connector TJ-C3 (WP 0018, Figure 104) and pin 2 on right rear flood lamp harness connector TJC1 (WP 0018, Figure 108).

1. If continuity is found, replace fuel tank harness (WP 0170). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace right rear flood lamp harness (WP 0154). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

40. Turn rear facing floodlight switch to OFF position (TM 5-2410-24110). 41. Turn main light switch to OFF position (TM 5-2410-241-10). 42. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 43. Disconnect right rear flood lamp harness connector TJ-C1 (WP 0018, Figure 108) from right rearward facing flood lamp. 44. Disconnect left rear flood lamp harness connector TK-C1 (WP 0018, Figure 107) from left rearward facing flood lamp. 45. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 46. Turn main light switch to floodlight position (TM 5-2410-241-10). 47. Turn rear facing floodlight switch to ON position (TM 5-2410-241-10).

0022-31

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

ROPS Mounted Rearward Facing Floodlamp(s) Do Not Work - Continued

48. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on right rear flood lamp harness connector TJ-C1 (WP 0018, Figure 108).

1. If 24 Volts is found, proceed to step 49. 2. If 24 Volts is NOT found, proceed to step 61.

49. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on left rear flood lamp harness connector TK-C1 (WP 0018, Figure 107).

1. If 24 Volts is found, proceed to step 50. 2. If 24 Volts is NOT found, proceed to step 61.

50. Turn rear facing floodlight switch to OFF position (TM 5-2410-24110). 51. Turn main light switch to OFF position (TM 5-2410-241-10). 52. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 53. Remove and disassemble right rearward facing flood lamp (WP 0210). 54. Inspect inside of right rearward facing flood lamp for corrosion and damage.

1. If corrosion or damage is found, replace right rearward facing flood lamp assembly (WP 0252). Proceed to step 57. 2. If corrosion and damage is NOT found, proceed to step 55.

55. Using digital multimeter (WP 0296), test for continuity between pin 1 and terminal 4 on right rearward facing flood lamp (WP 0018, Figure 180).

1. If continuity is found, proceed to step 56. 2. If continuity is NOT found, replace right rearward facing flood lamp assembly (WP 0252). Proceed to step 57.

56. Using digital multimeter (WP 0296), test for continuity between pin 2 and terminal 3 on right rearward facing flood lamp (WP 0018, Figure 180).

1. If continuity is found, replace right rearward facing flood lamp bulb (WP 0252). Proceed to step 57.

57. Remove and disassemble left rearward facing flood lamp (WP 0210).

0022-32

2. If continuity is NOT found, replace right rearward facing flood lamp assembly (WP 0252). Proceed to step 57.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION ROPS Mounted Rearward Facing Floodlamp(s) Do Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

58. Inspect inside of left rearward fac- 1. If corrosion or damage is found, ing flood lamp for corrosion and replace left rearward facing flood damage. lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If corrosion and damage is NOT found, proceed to step 59. 59. Using digital multimeter (WP 0296), test for continuity between pin 1 and terminal 4 on left rearward facing flood lamp (WP 0018, Figure 180).

1. If continuity is found, proceed to step 60. 2. If continuity is NOT found, replace left rearward facing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

60. Using digital multimeter (WP 0296), test for continuity between pin 2 and terminal 3 on left rearward facing flood lamp (WP 0018, Figure 180).

1. If continuity is found, replace left rearward facing flood lamp bulb (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace left rearward facing flood lamp assembly (WP 0252). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

61. Turn rear facing floodlight switch to OFF position (TM 5-2410-24110). 62. Turn main light switch to OFF position (TM 5-2410-241-10). 63. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0022-33

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION ROPS Mounted Rearward Facing Floodlamp(s) Do Not Work - Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

64. Remove Fuse # 9 (Figure 5, Item 1) from fuse panel (TM 52410-241-10).

Figure 5. Fuse #9. 65. Using a digital multimeter (WP 0296), test for continuity between blades of Fuse #9.

66. Connect right rear flood lamp harness connector TJ-C1 (WP 0018, Figure 108) to Right rearward facing flood lamp. 67. Connect left rear flood lamp harness connector TK-C1 (WP 0018, Figure 107) to left rearward facing flood lamp. 68. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 69. Turn main light switch to floodlight position (TM 5-2410-241-10). 70. Turn rear facing floodlight switch to ON position (TM 5-2410-241-10).

0022-34

0022

1. If continuity is NOT found, replace Fuse #9 (TM 5-2410-241-10) and proceed to step 66. 2. If continuity is found, install Fuse #9 on fuse panel (TM 5-2410-24110). Proceed to step 77.

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued.

0022

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

ROPS Mounted Rearward Facing Floodlamp(s) Do Not Work - Continued

71. Verify operation of rearward facing flood lamps (TM 5-2410-24110).

1. If rearward facing flood lamps do NOT operate, proceed to step 72. 2. If rearward facing flood lamps operate, resume normal operation (TM 5-2410-241-10).

72. Turn rear facing floodlight switch to OFF position (TM 5-2410-24110). 73. Turn main light switch to OFF position (TM 5-2410-241-10). 74. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 75. Remove Fuse # 9 (Figure 6, Item 1) from fuse panel (TM 52410-241-10).

Figure 6. Fuse #9. 76. Using a digital multimeter (WP 0296), test for continuity between blades of Fuse #9.

77. Disconnect left rear flood lamp harness connector TK-C3 (WP 0018, Figure 103) from fuel tank harness connector TW-C3 (WP 0018, Figure 105).

0022-35

0022

1. If continuity is NOT found, proceed to step 92. 2. If continuity is found, install Fuse #9 on fuse panel (TM 5-2410-24110). Proceed to step 77.

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION ROPS Mounted Rearward Facing Floodlamp(s) Do Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

78. Disconnect right rear flood lamp harness connector TJ-C3 (WP 0018, Figure 104) from fuel tank harness connector TW-C5 (WP 0018, Figure 106). 79. Install a jumper wire between pin 1 and pin 2 on fuel tank harness connector TW-C5 (WP 0018, Figure 106). 80. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel harness connector A-C1 (WP 0018, Figure 22). 81. Turn main light switch to floodlight position (TM 5-2410-241-10). 82. Turn rear facing floodlight switch to ON position (TM 5-2410-24110). 83. Using digital multimeter (WP 0296), test for continuity between pin 27 on platform harness connector MA-C3 (WP 0018, Figure 21) and machine ground.

1. If continuity is found, replace fuse panel harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 84.

84. Disconnect instrument panel harness connector E-C5 (WP 0018, Figure 100) from main light switch (WP 0018, Figure 100). 85. Using digital multimeter (WP 0296), test for continuity between pin 2 and pin 6 on main light switch.

86. Disconnect instrument panel harness connector E-C22 (WP 0018, Figure 109) from rear facing floodlight switch (WP 0018, Figure 109).

0022-36

1. If continuity is found, proceed to step 86. 2. If continuity is NOT found, replace main light switch (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

ROPS Mounted Rearward Facing Floodlamp(s) Do Not Work - Continued

87. Using digital multimeter (WP 0296), test for continuity between pin 5 and pin 6 on rear facing floodlight switch.

1. If continuity is found, proceed to step 88. 2. If continuity is NOT found, replace rear facing floodlight switch (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

88. Disconnect instrument panel harness connector E-C22 (WP 0018, Figure 109) from rear facing floodlight switch (WP 0262). 89. Using digital multimeter (WP 0296), test for continuity between pin 6 and pin 5 on rear facing floodlight switch.

1. If continuity is found, proceed to step 90. 2. If continuity is NOT found, replace rear facing floodlight switch (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

90. Disconnect fuel tank harness connector TW-C7 (WP 0018, Figure 80) from platform harness connector MA-C23 (WP 0018, Figure 79). 91. Using digital multimeter (WP 0296), test for continuity between pin 1 and pin 2 on fuel tank harness connector TW-C7 (WP 0018, Figure 80).

92. Disconnect right rear flood lamp harness connector TJ-C1 (WP 0018, Figure 108) from right rearward facing flood lamp. 93. Disconnect left rear flood lamp harness connector TK-C1 (WP 0018, Figure 107) from left rearward facing flood lamp.

0022-37

1. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace fuel tank harness (WP 0170). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

ROPS Mounted Rearward Facing Floodlamp(s) Do Not Work - Continued

94. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel harness connector A-C1 (WP 0018, Figure 22). 95. Using digital multimeter (WP 0296), test for continuity between pin 27 on platform harness connector MA-C3 (WP 0018, Figure 21) and machine ground.

CORRECTIVE ACTION

1. If continuity is found, replace fuse panel harness (WP 0176). Replace Fuse #9 (TM 5-2410241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 96.

96. Disconnect fuel tank harness connector TW-C7 (WP 0018, Figure 80) from platform harness connector MA-C23 (WP 0018, Figure 79). 97. Using digital multimeter (WP 0296), test for continuity between pin 1 and pin 2 on fuel tank harness connector TW-C7 (WP 0018, Figure 80).

1. If continuity is found, proceed to step 98. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Replace Fuse #9 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

98. Disconnect left rear flood lamp harness connector TK-C3 (WP 0018, Figure 103) from fuel tank harness connector TW-C3 (WP 0018, Figure 105). 99. Using digital multimeter (WP 0296), test for continuity between pin 1 and pin 2 on left rear flood lamp harness connector TK-C3 (WP 0018, Figure 103).

0022-38

1. If continuity is found, replace left rear flood lamp harness (WP 0154). Replace Fuse #9 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, proceed to step 100.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION ROPS Mounted Rearward Facing Floodlamp(s) Do Not Work - Continued

Engine Flood Lamp Does Not Work

TEST OR INSPECTION

CORRECTIVE ACTION

100.Disconnect right rear flood lamp harness connector TJ-C3 (WP 0018, Figure 104) from fuel tank harness connector TW-C5 (WP 0018, Figure 106). 101.Using digital multimeter (WP 0296), test for continuity between pin 1 and pin 2 on right rear flood lamp harness connector TJ-C3 (WP 0018, Figure 104).

1. If continuity is found, replace right rear flood lamp harness (WP 0154). Replace Fuse #9 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace fuel tank harness (WP 0170). Replace Fuse #9 (TM 5-2410241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Inspect operation of engine flood lamp (TM 5-2410-241-10).

1. If flood lamp does NOT work, proceed to step 2. 2. If problem is found, resume normal operation (TM 5-2410-24110).

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect engine harness connector V-C16 (WP 0018, Figure 110) from engine flood lamp. 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Turn engine compartment lamp switch to ON position (TM 5-2410241-10). 6. Using digital multimeter (WP 0296), measure for voltage between pin 1 and 2 on engine harness connector V-C16 (WP 0018, Figure 110). 7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Remove and disassemble engine Flood Lamp (WP 0253).

0022-39

1. If 24 Volts is found, proceed to step 7. 2. If 24 Volts is NOT found, proceed to step 12.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Engine Flood Lamp Does Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

9. Inspect inside of engine flood lamp for corrosion and damage.

1. If corrosion or damage is found, replace engine flood lamp assembly (WP 0253). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If corrosion and damage is NOT found, proceed to step 10.

10. Using digital multimeter (WP 0296), test for continuity between pin 1 and terminal 4 on engine flood lamp (WP 0018, Figure 181).

1. If continuity is found, proceed to step 11. 2. If continuity is NOT found, replace engine flood lamp assembly (WP 0253). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

11. Using digital multimeter (WP 0296), test for continuity between pin 2 and terminal 3 on engine flood lamp (WP 0018, Figure 181).

1. If continuity is found, replace engine flood lamp bulb (WP 0253). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace engine flood lamp assembly (WP 0253). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

12. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0022-40

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Engine Flood Lamp Does Not Work - Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

13. Remove Fuse # 16 (Figure 7, Item 1) from fuse panel (TM 52410-241-10)

Figure 7. Fuse #16. 14. Using a digital multimeter (WP 0296), test for continuity between blades of Fuse #16.

0022

1. If continuity is NOT found, replace Fuse #16 (TM 5-2410-241-10) and proceed to step 15. 2. If continuity is found, install Fuse #16 on fuse panel (TM 5-2410241-10). Proceed to step 21.

15. Connect engine harness connector V-C16 (WP 0018, Figure 110) to engine flood lamp. 16. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 17. Turn on engine flood lamp switch and verify operation of engine flood lamp (TM 5-2410-241-10).

18. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0022-41

1. If engine flood lamp does NOT operate, proceed to step 18. 2. If engine flood lamp operates, resume normal operation (TM 52410-241-10).

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Engine Flood Lamp Does Not Work - Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

19. Remove Fuse #16 (Figure 8, Item 1) from fuse panel (TM 52410-241-10).

Figure 8. Fuse #16. 20. Using a digital multimeter (WP 0296), test for continuity between blades of Fuse #16.

21. Disconnect engine harness connector V-C16 (WP 0018, Figure 110) from engine flood lamp. 22. Install a jumper between pin 1 and pin 2 on engine harness connector V-C16 (WP 0018, Figure 110). 23. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22). 24. Turn engine compartment lamp switch to ON position (TM 5-2410241-10).

0022-42

0022

1. If continuity is NOT found, proceed to step 30. 2. If continuity is found, install Fuse #16 on fuse panel (TM 5-2410241-10). Proceed to step 21.

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Engine Flood Lamp Does Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

25. Using digital multimeter (WP 0296), test for continuity between pin 30 on platform harness connector MA-C3 (WP 0018, Figure 21) and machine ground.

1. If continuity is NOT found, proceed to step 26. 2. If continuity is found, replace fuse panel wiring harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

26. Disconnect engine harness connector V-C1 (WP 0018, Figure 12) from platform harness connector MA-C22 (WP 0018, Figure 11). 27. Using digital multimeter (WP 0296), test for continuity between pin 3 and pin 8 on engine harness connector V-C1 (WP 0018, Figure 12).

1. If continuity is NOT found, proceed to step 28. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

28. Disconnect engine harness connector V-C17 (WP 0018, Figure 111) from engine flood lamp switch. 29. Using digital multimeter (WP 0296), test for continuity between pin B and pin A on engine harness connector V-C17 (WP 0018, Figure 111).

30. Disconnect engine harness connector V-C16 (WP 0018, Figure 110) from engine flood lamp. 31. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22).

0022-43

1. If continuity is NOT found, replace engine flood lamp switch (WP 0253). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, replace engine harness (WP 0105). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Engine Flood Lamp Does Not Work - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

32. Turn engine compartment lamp switch to ON position (TM 5-2410241-10). 33. Using digital multimeter (WP 0296), test for continuity between pin 30 ion fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) to machine ground.

1. If continuity is NOT found, proceed to step 34. 2. If continuity is found, replace fuse panel wiring harness (WP 0176). Replace Fuse #16 (TM 5-2410241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

34. Disconnect engine harness connector V-C1 (WP 0018 Figure 12) from platform harness connector MA-C22 (WP 0018, Figure 11).

All Windshield Wipers and Washers Do NOT Operate.

35. Using digital multimeter (WP 0296), test for continuity between pin 3 and pin 8 on engine harness connector V-C1 (WP 0018, Figure 12).

1. If continuity is found, replace main engine harness (WP 0055). Replace Fuse #16 (TM 5-2410241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace platform harness (WP 0209). Replace Fuse #16 (TM 5-2410241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Inspect operation of all windshield wipers and washers (TM 5-2410241-10).

1. If all windshield wipers and washers do NOT operate, proceed to step 2. 2. If one windshield wiper or washer does NOT operate, proceed to Troubleshooting Index for correct symptom (WP 0013).

NOTE Ensure all wiper switches are turned to the OFF position. 2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0022-44

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

3. Remove Fuse #1 (Figure 9, Item 1) from fuse panel (TM 52410-241-10).

Figure 9. Fuse #1. 4. Using digital multimeter (WP 0296), test for continuity between blades of Fuse #1.

0022

1. If continuity is found, proceed to step 19. 2. If continuity is NOT found, replace Fuse #1(TM 5-2410-241-10). Proceed to step 5.

5. Disconnect engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) from platform harness (platform to engine) connector MA-C22 (WP 0018, Figure 11). 6. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Remove Fuse #1 (Figure 9, Item 1) from fuse panel (TM 52410-241-10). 9. Using digital multimeter (WP 0296), test for continuity between blades of Fuse #1.

0022-45

1. If continuity is found, install Fuse #1 on fuse panel (TM 5-2410-24110). Proceed to step 10. 2. If continuity is NOT found, proceed to step 31.

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

10. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 11. Turn front wiper switch to the LOW, HIGH, and OFF position (TM 5-2410-241-10).

1. If wiper is working, proceed to step 12. 2. If wiper is NOT working, proceed to step 58.

12. Activate front windshield washer (TM 5-2410-241-10).

1. If washer is working, proceed to step 13. 2. If washer is NOT working, proceed to step 125.

13. Turn left door wiper switch to the LOW, HIGH, and OFF position (TM 5-2410-241-10).

1. If wiper is working, proceed to step 14. 2. If wiper is NOT working, proceed to step 76.

14. Activate left door washer (TM 52410-241-10).

1. If washer is working, proceed to step 15. 2. If washer is NOT working, proceed to step 138.

15. Turn right door wiper switch to the LOW, HIGH, and OFF position (TM 5-2410-241-10).

1. If wiper is working, proceed to step 16. 2. If wiper is NOT working, proceed to step 93.

16. Activate right door washer (TM 52410-241-10).

1. If washer is working, proceed to step 17. 2. If washer is NOT working, proceed to step 151.

17. Turn rear wiper switch to the Low, HIGH, and OFF position (TM 52410-241-10).

1. If wiper is working, proceed to step 18. 2. If wiper is NOT working, proceed to step 110.

18. Activate rear washer (TM 5-2410- 1. If washer is working, ether aid 241-10). may be cause of open fuse. Proceed to Ether Aid Does NOT Work in this work package to diagnose ether system. 2. If washer is NOT working, proceed to step 164. 19. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22).

0022-46

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

20. Using digital multimeter (WP 0296), test for continuity between pin 1 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and left cavity of fuse number 1 (WP 0018, Item 2).

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace fuse panel wiring harness (WP 0176). Install Fuse #1 on fuse panel (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

21. Disconnect instrument panel harness connector E-C16 (WP 0018, Figure 112) from cab harness connector H-C2 (WP 0018, Figure 113). 22. Using digital multimeter (WP 0296), test for continuity between pin 4 on instrument panel harness connector E-C16 (WP 0018, Figure 112) and pin 1 on platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is found, proceed to step 23. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Install Fuse #1 on fuse panel (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

23. Remove rear wiper motor trim panel (WP 0229). 24. Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness H-C6 (WP 0018, Figure 114). 25. Using digital multimeter (WP 0296), test for continuity between pin 4 on cab harness connector H-C2 (WP 0018, Figure 113) and pin 2 on cab harness connector H-C6 (WP 0018, Figure 114).

26. Lower windshield wiper control plate and switches from headliner (WP 0234).

0022-47

1. If continuity is found, proceed to step 26. 2. If continuity is NOT found, replace cab harness (WP 0254). Install Fuse #1 on fuse panel (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

27. Disconnect 108 BLUE rear wiper power supply connector (WP 0018, Figure121) from rear wiper switch. 28. Using digital multimeter (WP 0296), test for continuity between pin 2 on headliner harness connector HA-C2 (WP 0018, Figure 115) and 108 BLUE on rear wiper power supply connector (WP 0018, Figure 121).

1. If continuity is found, proceed to step 29. 2. If continuity is NOT found, replace headliner harness (WP 0232). Install Fuse #1 on fuse panel (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

29. Remove headliner from cab (WP 0229). 30. Inspect ground point of cab harness (WP 0018, Figure 194) for dirt, corrosion, and damage.

31. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22).

0022-48

1. Ground Point or Ring Terminal Dirty or Corroded - Clean as necessary. Install cab harness terminals on ground point with mounting hardware and tighten securely. Install Fuse #1 on fuse panel (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. Ring Terminal Defective - Replace cab harness (WP 0254). Install Fuse #1 on fuse panel (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 3. No Problem Found - Replace cab harness (WP 0254). Install Fuse #1 on fuse panel (TM 5-2410-24110). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

32. Using digital multimeter (WP 0296), test for continuity between pin 1 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and ground.

1. If continuity NOT is found, proceed to step 33. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and fuse panel wiring harness (WP 0176).Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10).

33. Disconnect instrument panel harness connector E-C16 (WP 0018, Figure 112) from cab harness connector H-C2 (WP 0018, Figure 113). 34. Using digital multimeter (WP 1. If continuity is NOT found, pro0296), test for continuity between ceed to step 35. pin 1 on platform harness connec- 2. If continuity is found, replace Fuse tor MA-C3 (WP 0018, Figure 21) #1 (TM 5-2410-241-10), platform and all other pins in platform harharness (WP 0209), and instruness connector MA-C3 (WP ment panel harness (WP 0260). 0018, Figure 21). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 35. Using digital multimeter (WP 1. If continuity is NOT found, pro0296), test for continuity between ceed to step 36. pin 1 on platform harness connec- 2. If continuity is found, replace Fuse tor MA-C3 (WP 0018, Figure 21) #1 (TM 5-2410-241-10), platform and ground. harness (WP 0209), and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 36. Remove front wiper motor trim panel (WP 0229). 37. Remove rear wiper motor trim panel (WP 0229). 38. Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114) 39. Disconnect cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) from front wiper motor (WP 0222).

0022-49

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

40. Disconnect cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) from left door wiper motor (WP 0250). 41. Disconnect cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) from right door wiper motor (WP 0250). 42. Using digital multimeter (WP 0296), test for continuity between pin 2 on cab harness connector H-C6 (WP 0018, Figure 114) and all other pins in cab harness connector H-C6 (WP 0018, Figure 114).

1. If continuity is NOT found, proceed to step 43. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

43. Using digital multimeter (WP 0296), test for continuity between pin 2 on cab harness connector H-C6 (WP 0018, Figure 114) and ground.

1. If continuity is NOT found, proceed to step 44. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

44. Lower windshield wiper control plate and switches from headliner (WP 0234). 45. Disconnect 108 BLUE front wiper power supply connector (WP 0018, Figure 122) from front wiper switch. 46. Disconnect 108 BLUE left wiper power supply connector (WP 0018, Figure 148) from left door wiper switch. 47. Disconnect 108 Blue right wiper power supply connector (WP 0018, Figure 147) from right door wiper switch. 48. Disconnect 108 BLUE rear wiper power supply connector (WP 0018, Figure121) from rear wiper switch.

0022-50

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

49. Disconnect headliner harness rear wiper motor connector HAC4 (WP 0018, Figure 126) from rear wiper motor (WP 0223). 50. Using digital multimeter (WP 0296), test for continuity between terminal B on front wiper switch (WP 0018, Figure 180) and ground.

1. If continuity is NOT found, proceed to step 51. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and front wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

51. Using digital multimeter (WP 0296), test for continuity between terminal B on left door wiper switch (WP 0018, Figure 181) and ground.

1. If continuity is NOT found, proceed to step 52. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and left door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

52. Using digital multimeter (WP 0296), test for continuity between terminal B on right door wiper switch (WP 0018, Figure 182) and ground.

1. If continuity is NOT found, proceed to step 53. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and right door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

53. Using digital multimeter (WP 0296), test for continuity between terminal B on rear wiper switch (WP 0018, Figure183) and ground.

1. If continuity is NOT found, proceed to step 54. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and rear wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

54. Using digital multimeter (WP 0296), test for continuity between pin 6 on front wiper motor pigtail connector (WP 0018, Figure 184) and ground.

1. If continuity is NOT found, proceed to step 55. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and front wiper motor (WP 0222). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022-51

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

55. Using digital multimeter (WP 1. If continuity is NOT found, pro0296), test for continuity between ceed to step 56. pin 6 on left door wiper motor pig- 2. If continuity is found, replace Fuse tail connector (WP 0018, Figure #1 (TM 5-2410-241-10) and left 185) and ground. door wiper motor (WP 0250). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 56. Using digital multimeter (WP 0296), test for continuity between pin 6 on right door wiper motor pigtail connector (WP 0018, Figure 186) and ground.

1. If continuity is NOT found, proceed to step 57. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and right door wiper motor (WP 0250). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

57. Using digital multimeter (WP 0296), test for continuity between pin 6 on rear wiper motor pigtail connector (WP 0018, Figure 187) and ground.

1. If continuity is NOT found, replace Fuse #1 (TM 5-2410-241-10) and headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and rear wiper motor (WP 0223). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

58. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 59. Swap left door wiper switch and front wiper switch (WP 0234). 60. Replace Fuse #1 (TM 5-2410241-10). 61. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0022-52

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

62. Turn left door wiper switch to the LOW, HIGH, and OFF position (TM 5-2410-241-10).

1. If left door wiper is working, proceed to step 63. 2. If left door wiper is NOT working, replace Fuse #1 (TM 5-2410-24110) and left door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

63. Activate left door washer (TM 52410-241-10).

1. If left door washer is working, proceed to step 64. 2. If left door washer is NOT working, replace Fuse #1 (TM 5-2410241-10) and left door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

64. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 65. Remove front wiper motor trim panel (WP 0229). 66. Remove rear wiper motor trim panel (WP 0229). 67. Disconnect cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) from front wiper motor (WP 0222). 68. Disconnect headliner harness connector HA-C1 (WP 0018, Figure 134) from cab harness connector H-C7 (WP 0018, Figure 133). 69. Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114).

0022-53

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

70. Using digital multimeter (WP 0296), test for continuity between the following pins on cab harness connector H-C7 (WP 0018, Figure 133) and pins on cab harness connector H-C6 (WP 0018, Figure 114):

1. If continuity is NOT found, proceed to step 71. 2. If continuity is found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

a. Between pin 1 on H-C7 (WP 0018, Figure 133) and pin 6 on H-C6 (WP 0018, Figure 114). b. Between pin 3 on H-C7 (WP 0018, Figure 133) and pin 6 on H-C6 (WP 0018, Figure 114). c.

Between pin 8 on H-C7 (WP 0018, Figure 133) and pin 6 on H-C6 (WP 0018, Figure 114).

71. Disconnect 502 ORANGE front wiper HIGH supply connector (WP 0018, Figure 137) from front wiper switch. 72. Disconnect 501 GREEN front wiper LOW supply connector (WP 0018, Figure 136) from Front wiper switch. 73. Disconnect 500 BROWN front wiper PARK supply connector (WP 0018, Figure 135) from front wiper switch. 74. Disconnect 506 PURPLE front wiper washer supply connector (WP 0018, Figure 150) from Front wiper switch.

0022-54

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

75. Using digital multimeter (WP 0296), test for continuity between the following pins on headliner harness connector HA-C1 (WP 0018, Figure 134) and pins on headliner harness connector HAC2 (WP 0018, Figure 115):

1. If continuity is NOT found, replace front wiper motor (WP 0222). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

a. Between pin 1 on HA-C1 (WP 0018, Figure 134) and pin 6 on HA-C2 (WP 0018, Figure 115). b. Between pin 3 on HA-C1 (WP 0018, Figure 134) and pin 6 on HA-C2 (WP 0018, Figure 115). c.

Between pin 8 on HA-C1 (WP 0018, Figure 134) and pin 6 on HA-C2 (WP 0018, Figure 115).

76. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 77. Swap right door wiper switch and left door wiper switch (WP 0234). 78. Replace Fuse #1 (TM 5-2410241-10). 79. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 80. Turn right door wiper switch to the LOW, HIGH, and OFF position (TM 5-2410-241-10).

1. If right door wiper is working, proceed to step 81. 2. If right door wiper is NOT working, replace Fuse #1 (TM 5-2410-24110) and right door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

81. Activate right door washer (TM 52410-241-10).

1. If right door washer is working, proceed to step 82. 2. If right door washer is NOT working, replace Fuse #1 (TM 5-2410241-10) and right door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022-55

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

82. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 83. Remove rear wiper motor trim panel (WP 0229). 84. Disconnect cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) from left door wiper motor (WP 0249). 85. Disconnect headliner harness connector HA-C1 (WP 0018, Figure 134) from cab harness connector H-C7 (WP 0018, Figure 133). 86. Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114). 87. Using digital multimeter (WP 0296), test for continuity between the following pins on cab harness connector H-C7 (WP 0018, Figure 133) and pins on cab harness connector H-C6 (WP 0018, Figure 114): a. Between pin 5 on H-C7 (WP 0018, Figure 133) and pin 6 on H-C6 (WP 0018, Figure 114). b. Between pin 6 on H-C7 (WP 0018, Figure 133) and pin 6 on H-C6 (WP 0018, Figure 114). c.

Between pin 4 on H-C7 (WP 0018, Figure 133) and pin 6 on H-C6 (WP 0018, Figure 114).

88. Disconnect 525 GRAY left door wiper HIGH supply connector (WP 0018, Figure 140) from left door wiper switch. 89. Disconnect 524 BLUE left door wiper LOW supply connector (WP 0018, Figure 139) from left door wiper switch.

0022-56

1. If continuity is NOT found, proceed to step 88. 2. If continuity is found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

90. Disconnect 523 BROWN left door wiper PARK supply connector (WP 0018, Figure 138) from left door wiper motor switch. 91. Disconnect 529 WHITE left wiper washer supply connector (WP 0018, Figure 153) from left door wiper switch. 92. Using digital multimeter (WP 0296), test for continuity between the following pins on headliner harness connector HA-C1 (WP 0018, Figure 134) and pins headliner harness connector HA-C2 (WP 0018, Figure 115): a. Between pin 5 on HA-C1 (WP 0018, Figure 134) and pin 6 on HA-C2 (WP 0018, Figure 115). b. Between pin 6 on HA-C1 (WP 0018, Figure 134) and pin 6 on HA-C2 (WP 0018, Figure 115). c.

1. If continuity is NOT found, replace left door wiper motor (WP 0250). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

Between pin 4 on HA-C1 (WP 0018, Figure 134) and pin 6 on HA-C2 (WP 0018, Figure 115).

93. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 94. Swap rear wiper switch and right door wiper switch (WP 0234). 95. Replace Fuse #1 (TM 5-2410241-10). 96. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 97. Turn rear wiper switch to the LOW, HIGH, and OFF position (TM 5-2410-241-10).

0022-57

1. If rear wiper is working, proceed to step 98. 2. If rear wiper is NOT working, replace Fuse #1 (TM 5-2410-24110) and rear wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

98. Activate rear washer (TM 5-2410- 1. If rear washer is working, proceed 241-10). to step 99. 2. If rear washer is NOT working, replace Fuse #1 (TM 5-2410-24110) and rear wiper switch (WP 0234) Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 52410-241-10). 99. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 100.Remove rear wiper motor trim panel (WP 0229). 101.Disconnect cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) from right door wiper motor (WP 260). 102.Disconnect headliner harness connector HA-C1 (WP 0018, Figure 134) from cab harness connector H-C7 (WP 0018, Figure 133). 103.Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114). 104.Using digital multimeter (WP 0296), test for continuity between the following pins on cab harness connector H-C6 (WP 0018, Figure 114): a. Between pin 8 and pin 6 on H-C6 (WP 0018, Figure 114). b. Between pin 7 and pin 6 on H-C6 (WP 0018, Figure 114). c.

Between pin 3 and pin 6 on H-C6 (WP 0018, Figure 114).

105.Disconnect 528 PINK right door wiper HIGH supply connector (WP 0018, Figure 143) from right door wiper switch.

0022-58

1. If continuity is NOT found, proceed to step 105. 2. If continuity is found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

106.Disconnect 527 GREEN right door wiper LOW supply connector (WP 0018, Figure 142) from Right Door wiper switch. 107.Disconnect 526 YELLOW right door wiper PARK supply connector (WP 0018, Figure 141) from Right Door wiper switch. 108.Disconnect 530 ORANGE right wiper washer supply connector (WP 0018, Figure 152) from right door wiper switch. 109.Using digital multimeter (WP 0296), test for continuity between the following pins on headliner harness connector HA-C2 (WP 0018, Figure 115): a. Between pin 8 and pin 6 on HA-C2 (WP 0018, Figure 115). b. Between pin 7 and pin 6 on HA-C2 (WP 0018, Figure 115). c.

1. If continuity is NOT found, replace right door wiper motor (WP 0250). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

Between pin 3 and pin 6 on HA-C2 (WP 0018, Figure 115).

110.Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 111.Swap right door wiper switch and rear wiper switch (WP 0234). 112.Replace Fuse #1 (TM 5-2410241-10). 113.Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 114.Turn right door wiper switch to the LOW, HIGH, and OFF position (TM 5-2410-241-10).

0022-59

1. If right door wiper is working, proceed to step 115. 2. If right door wiper is NOT working, replace Fuse #1 (TM 5-2410-24110) and right door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

115.Activate right door washer (TM 52410-241-10).

1. If right door washer is working, proceed to step 116. 2. If right door washer is NOT working, replace Fuse #1 (TM 5-2410241-10) and right door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

116.Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 117.Remove rear wiper motor trim panel (WP 0229). 118.Disconnect headliner harness rear wiper motor connector HAC4 (WP 0018, Figure 126) from rear wiper motor (WP 0223). 119.Disconnect 505 BLUE rear wiper HIGH supply connector (WP 0018, Figure 146) from rear wiper switch. 120.Disconnect 504 YELLOW rear wiper LOW supply connector (WP 0018, Figure 145) from rear wiper switch. 121.Disconnect 503 BROWN rear wiper PARK supply connector (WP 0018, Figure 144) from rear wiper switch. 122.Disconnect 507 WHITE rear washer supply connector (WP 0018, Figure 151) from rear wiper switch. 123.Disconnect headliner harness rear wiper motor connector HAC4 (WP 0018, Figure 126)

0022-60

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

124.Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between rear wiper motor (WP 0223). the following pins on headliner Ensure all harness connectors harness rear wiper motor connecare reconnected. Verify correct tor HA-C4 (WP 0018, Figure 126) operation of machine (TM 5-2410and ground: 241-10). a. Between pin 3 on HA-C4 (WP 2. If continuity is found, replace 0018, Figure 126) and headliner harness (WP 0232). ground. Ensure all harness connectors are reconnected. Verify correct b. Between pin 4 on HA-C4 (WP operation of machine (TM 5-24100018, Figure 126) and 241-10). ground. c.

Between pin 5 on HA-C4 (WP 0018, Figure 126) and ground.

125.Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 126.Disconnect washer pump harness connector HH-C2 (WP 0018, Figure 190) from front washer pump. 127.Replace Fuse #1 (TM 5-2410241-10). 128.Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 129.Using digital multimeter (WP 0296), measure for voltage between pin 1 and pin 2 on washer pump harness connector HH-C2 (WP 0018, Figure 190) while activating front washer (TM 5-2410-241-10). 130.Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 131.Disconnect cab harness washer bottle connector H-C8 (WP 0018, Figure 154) from washer bottle connector HH-C1 (WP 0018, Figure 155).

0022-61

1. If 24 volts is found, replace Fuse #1 (TM 5-2410-241-10) and front washer pump (WP 0224). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 24 volts is NOT found, proceed to step 130.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

132.Using digital multimeter (WP 0296), test for continuity between pin 6 on washer bottle connector HH-C1 (WP 0018, Figure 155) and ground.

1. If continuity is NOT found, proceed to step 133. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and washer pump harness (WP 0224). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

133.Remove rear wiper motor trim panel (WP 0229). 134.Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114). 135.Using digital multimeter (WP 0296), test for continuity between pin 5 and pin 6 on cab harness connector H-C6 (WP 0018, Figure 114).

1. If continuity is NOT found, proceed to step 136. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

136.Lower windshield wiper control plate and switches from headliner (WP 0234). 137.Disconnect 506 PURPLE front wiper washer supply connector (WP 0018, Figure 150) from Front wiper switch. 138.Using digital multimeter (WP 0296), test for continuity between pin 5 and pin 6 on headliner harness connector HA-C2 (WP 0018, Figure 115).

0022-62

1. If continuity is NOT found, replace Fuse #1 (TM 5-2410-241-10) and front wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

139.Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 140.Disconnect washer pump harness connector HH-C3 (WP 0018, Figure 191) from left door washer pump. 141.Replace Fuse #1 (TM 5-2410241-10). 142.Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 143.Using digital multimeter (WP 0296), measure for voltage between pin 1 and pin 2 on washer pump harness connector HH-C3 (WP 0018, Figure 191) while activating left door washer (TM 5-2410-241-10).

1. If 24 volts is found, replace Fuse #1 (TM 5-2410-241-10) and left door washer pump (WP 0224). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If 24 volts is NOT found, proceed to step 144.

144.Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 145.Disconnect cab harness washer bottle connector H-C8 (WP 0018, Figure 154) from washer bottle connector HH-C1 (WP 0018, Figure 155). 146.Using digital multimeter (WP 0296), test for continuity between pin 4 on washer bottle connector HH-C1 (WP 0018, Figure 155) and ground.

147.Remove rear wiper motor trim panel (WP 0229). 148.Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114).

0022-63

1. If continuity is NOT found, proceed to step 147. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and washer pump harness (WP 0224). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

149.Using digital multimeter (WP 0296), test for continuity between pin 9 and pin 6 on cab harness connector H-C6 (WP 0018, Figure 114).

1. If continuity is NOT found, proceed to step 150. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

150.Lower windshield wiper control plate and switches from headliner (WP 0234). 151.Disconnect 529 WHITE left wiper washer supply connector (WP 0018, Figure 153) from left door wiper switch. 152.Using digital multimeter (WP 0296), test for continuity between pin 9 and pin 6 on headliner harness connector HA-C2 (WP 0018, Figure 115).

153.Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 154.Disconnect washer pump harness connector HH-C4 (WP 0018, Figure 192) from right door washer pump. 155.Replace Fuse #1 (TM 5-2410241-10). 156.Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0022-64

1. If continuity is NOT found, replace Fuse #1 (TM 5-2410-241-10) and left door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

157.Using digital multimeter (WP 0296), measure for voltage between pin 1 and pin 2 on washer pump harness connector HH-C4 (WP 0018, Figure 192) while activating right door washer (TM 5-2410-241-10).

1. If 24 volts is found, replace Fuse #1 (TM 5-2410-241-10) and right door washer pump (WP 0224). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If 24 volts is NOT found, proceed to step 158.

158.Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 159.Disconnect cab harness washer bottle connector H-C8 (WP 0018, Figure 154) from washer bottle connector HH-C1 (WP 0018, Figure 155). 160.Using digital multimeter (WP 0296), test for continuity between pin 3 on washer bottle connector HH-C1 (WP 0018, Figure 155) and ground.

1. If continuity is NOT found, proceed to step 161. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and washer pump harness (WP 0224). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

161.Remove rear wiper motor trim panel (WP 0229). 162.Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114). 163.Using digital multimeter (WP 0296), test for continuity between pin 10 and pin 6 on cab harness connector H-C6 (WP 0018, Figure 114).

164.Lower windshield wiper control plate and switches from headliner (WP 0234).

0022-65

1. If continuity is NOT found, proceed to step 164. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

165.Disconnect 530 ORANGE right wiper washer supply connector (WP 0018, Figure 152) from right door wiper switch. 166.Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between Fuse #1 (TM 5-2410-241-10) and pin 10 and pin 6 on headliner harright door wiper switch (WP ness connector HA-C2 (WP 0018, 0234). Ensure all harness conFigure 115). nectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 167.Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 168.Disconnect washer pump harness connector HH-C5 (WP 0018, Figure 193) from rear washer pump. 169.Replace Fuse #1 (TM 5-2410241-10). 170.Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 171.Using digital multimeter (WP 0296), measure for voltage between pin 1 and pin 2 on washer pump harness connector HH-C5 (WP 0018, Figure 193) while activating rear washer (TM 5-2410-241-10). 172.Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 173.Disconnect cab harness washer bottle connector H-C8 (WP 0018, Figure 154) from washer bottle connector HH-C1 (WP 0018, Figure 155).

0022-66

1. If 24 volts is found, replace Fuse #1 (TM 5-2410-241-10) and rear washer pump (WP 0224). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 24 volts is NOT found, proceed to step 172.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION All Windshield Wipers and Washers Do NOT Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

174.Using digital multimeter (WP 0296), test for continuity between pin 1 on washer bottle connector HH-C1 (WP 0018, Figure 155) and ground.

1. If continuity is NOT found, proceed to step 175. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and washer pump harness (WP 0224). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

175.Remove rear wiper motor trim panel (WP 0229). 176.Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114). 177.Using digital multimeter (WP 0296), test for continuity between pin 11 and pin 6 on cab harness connector H-C6 (WP 0018, Figure 114).

1. If continuity is NOT found, proceed to step 178. 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

178.Lower windshield wiper control plate and switches from headliner (WP 0234). 179.Disconnect 507 WHITE rear washer supply connector (WP 0018, Figure 151) from rear wiper switch. 180.Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between Fuse #1 (TM 5-2410-241-10) and pin 11 and pin 6 on headliner harrear wiper switch (WP 0234). ness connector HA-C2 (WP 0018, Ensure all harness connectors Figure 115). are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace Fuse #1 (TM 5-2410-241-10) and headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022-67

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Front Windshield Wiper Does Not Operate Properly

1. Inspect operation of all windshield wipers (TM 5-2410-241-10).

1. If front windshield wiper does NOT operate properly, proceed to step 2. 2. If all windshield wipers do NOT operate, refer to malfunction All Windshield Wipers and Washers Do NOT Operate in this work package.

2. Turn front wiper switch to the LOW, HIGH, and then OFF position (TM 5-2410-241-10).

1. If wiper does NOT work in LOW position, proceed to step 3. 2. If wiper does NOT work in High position, proceed to step 16. 3. If wiper does NOT return to PARK position, proceed to step 29. 4. If wiper does NOT operate in any position, proceed to step 44.

3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Remove front wiper motor trim panel (WP 0229). 5. Disconnect cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) from front wiper motor (WP 0222). 6. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 7. Turn front wiper switch to the LOW position (TM 5-2410-24110). 8. Using digital multimeter (WP 0296), measure for voltage between pin 4 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) and pin 2 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123). 9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 10. Remove rear wiper motor trim panel (WP 0229).

0022-68

1. If 24 Volts is found, replace front wiper motor (WP 0222). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 24 Volts is NOT found, proceed to step 9.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

Front Windshield Wiper Does Not Operate Properly - Continued

11. Disconnect headliner harness connector HA-C1 (WP 0018, Figure 134) from cab harness connector H-C7 (WP 0018, Figure 133). 12. Using digital multimeter (WP 0296), test for continuity between pin 4 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) and pin 3 on cab harness connector H-C7 (WP 0018, Figure 133).

CORRECTIVE ACTION

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 13.

13. Lower windshield wiper control plate and switches from headliner (WP 0234). 14. Disconnect 501 GREEN front wiper LOW supply connector (WP 0018, Figure 136) from front wiper switch. 15. Using digital multimeter (WP 0296), test for continuity between 501 GREEN front wiper LOW supply connector (WP 0018, Figure 136) and pin 3 on headliner harness connector HA-C1 (WP 0018, Figure 134).

16. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 17. Remove front wiper motor trim panel (WP 0229). 18. Disconnect cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) from front wiper motor (WP 0222). 19. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 20. Turn front wiper switch to the HIGH position (TM 5-2410-24110).

0022-69

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace front wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Front Windshield Wiper Does Not Operate Properly - Continued

21. Using digital multimeter (WP 0296), measure for voltage between pin 5 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) and pin 2 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123).

1. If 24 Volts is found, replace front wiper motor (WP 0222). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 24 Volts is NOT found, proceed to step 22.

22. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 23. Remove rear wiper motor trim panel (WP 0229). 24. Disconnect headliner harness connector HA-C1 (WP 0018, Figure 134) from cab harness connector H-C7 (WP 0018, Figure 133). 25. Using digital multimeter (WP 0296), test for continuity between pin 5 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) and pin 8 on cab harness connector H-C7 (WP 0018, Figure 133).

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 26.

26. Lower windshield wiper control plate and switches from headliner (WP 0234). 27. Disconnect 502 ORANGE front wiper high supply connector (WP 0018, Figure 137) from front wiper switch. 28. Using digital multimeter (WP 0296), test for continuity between 502 ORANGE front wiper high supply connector (WP 0018, Figure 137) and pin 8 on headliner harness connector HA-C1 (WP 0018, Figure 134).

29. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0022-70

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace front wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Front Windshield Wiper Does Not Operate Properly - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

30. Remove front wiper motor trim panel (WP 0229). 31. Disconnect cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) from front wiper motor (WP 0222). 32. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 33. Using digital multimeter (WP 0296), measure for voltage between pin 6 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) and pin 2 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123).

1. If 24 Volts is found, proceed to step 34. 2. If 24 Volts is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

34. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 35. Connect jumper wire between pin 6 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) and pin 3 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123). 36. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

NOTE Ensure front wiper switch is turned to the OFF position.

0022-71

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Front Windshield Wiper Does Not Operate Properly - Continued

37. Using digital multimeter (WP 0296), measure for voltage between pin 4 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) and pin 2 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123).

1. If 24 Volts is found, turn ignition switch and battery disconnect switch to OFF position (TM 52410-241-10). Remove jumper wire between pin 6 and pin 3 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123). Replace front wiper motor (WP 0222). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 24 Volts is NOT found, turn ignition switch and battery disconnect switch to OFF position (TM 52410-241-10). Remove jumper wire between pin 6 and pin 3 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123). Proceed to step 38.

38. Remove rear wiper motor trim panel (WP 0229). 39. Disconnect headliner harness connector HA-C1 (WP 0018, Figure 134) from cab harness connector H-C7 (WP 0018, Figure 133). 40. Using digital multimeter (WP 0296), test for continuity between pin 3 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) and pin 1 on cab harness connector H-C7 (WP 0018, Figure 133). 41. Lower windshield wiper control plate and switches from headliner (WP 0234). 42. Disconnect 500 BROWN front wiper PARK supply connector (WP 0018, Figure 135) from front wiper switch.

0022-72

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 41.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Front Windshield Wiper Does Not Operate Properly - Continued

43. Using digital multimeter (WP 0296), test for continuity between 500 BROWN front wiper PARK supply connector (WP 0018, Figure 135) and pin 1 on headliner harness connector HA-C1 (WP 0018, Figure 134).

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace front wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

44. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 45. Lower windshield wiper control plate and switches from headliner (WP 0234). 46. Swap left door wiper switch and front wiper switch (WP 0234). 47. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 48. Turn left door wiper switch to the LOW, HIGH, and OFF position (TM 5-2410-241-10).

1. If left door wiper is working, proceed to step 49. 2. If left door wiper is NOT working, replace left door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

49. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 50. Remove front wiper motor trim panel (WP 0229). 51. Disconnect cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) from front wiper motor (WP 0222). 52. Using digital multimeter (WP 0296), test for continuity between pin 2 on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) and ground.

0022-73

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 53.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Front Windshield Wiper Does Not Operate Properly - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

53. Remove rear wiper motor trim panel (WP 0229). 54. Disconnect headliner harness connector HA-C1 (WP 0018, Figure 134) from cab harness connector H-C7 (WP 0018, Figure 133). 55. Using digital multimeter (WP 0296), test for continuity between the following pins on cab harness front wiper motor connector H-C1 (WP 0018, Figure 123) and pins on cab harness connector H-C7 (WP 0018, Figure 133). a. Between pin 4 on H-C1 (WP 0018, Figure 123) and pin 3 on H-C7 (WP 0018, Figure 133). b. Between pin 5 on H-C1 (WP 0018, Figure 123) and pin 8 on H-C7 (WP 0018, Figure 133). c.

Between pin 3 on H-C1 (WP 0018, Figure 123) and pin 1 on H-C7 (WP 0018, Figure 133).

56. Disconnect 502 ORANGE front wiper high supply connector (WP 0018, Figure 137) from front wiper switch. 57. Disconnect 501 GREEN front wiper LOW supply connector (WP 0018, Figure 136) from front wiper switch. 58. Disconnect 500 BROWN front wiper PARK supply connector (WP 0018, Figure 135) from front wiper switch.

0022-74

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 56.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Front Windshield Wiper Does Not Operate Properly - Continued

59. Using digital multimeter (WP 0296), test for continuity between the following front wiper supply connectors and pins on headliner harness connector HA-C1 (WP 0018, Figure 134). a. Between 501 GREEN connector (WP 0018, Figure 136) and pin 3 on HA-C1 (WP 0018, Figure 134). b. Between 502 ORANGE connector (WP 0018, Figure 137) and pin 8 on HA-C1 (WP 0018, Figure 134). c. Between 500 BROWN connector (WP 0018, Figure 135) and pin 1 on HA-C1 (WP 0018, Figure 134).

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace front wiper motor (WP 0222). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

Left Door Windshield Wiper Does Not Operate Properly

1. Inspect operation of all windshield wipers (TM 5-2410-241-10).

1. If left door windshield wiper does NOT operate properly, proceed to step 2. 2. If all windshield wipers do NOT operate, refer to malfunction All Windshield Wipers and Washers Do NOT Operate in this work package.

2. Turn left door wiper switch to the LOW, HIGH, and then OFF position (TM 5-2410-241-10).

1. If wiper does NOT work in LOW position, proceed to step 3. 2. If wiper does NOT work in High position, proceed to step 15. 3. If wiper does NOT return to PARK position, proceed to step 27. 4. If wiper does NOT operate in any position, proceed to step 41.

3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Disconnect cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) from left door wiper motor (WP 0249). 5. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 6. Turn left door wiper switch to the LOW position (TM 5-2410-24110).

0022-75

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Left Door Windshield Wiper Does Not Operate Properly - Continued

7. Using digital multimeter (WP 0296), measure for voltage between pin 4 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) and pin 2 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124).

1. If 24 Volts is found, replace left door wiper motor (WP 0250). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If 24 Volts is NOT found, proceed to step 8.

8. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 9. Remove rear wiper motor trim panel (WP 0229). 10. Disconnect headliner harness connector HA-C1 (WP 0018, Figure 134) from cab harness connector H-C7 (WP 0018, Figure 133). 11. Using digital multimeter (WP 0296), test for continuity between pin 4 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) and pin 5 on cab harness connector H-C7 (WP 0018, Figure 133).

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 12.

12. Lower windshield wiper control plate and switches from headliner (WP 0234). 13. Disconnect 524 BLUE left door wiper LOW supply connector (WP 0018, Figure 139) from left door wiper switch. 14. Using digital multimeter (WP 0296), test for continuity between 524 BLUE left door wiper LOW supply connector (WP 0018, Figure 139) and pin 5 on headliner harness connector HA-C1 (WP 0018, Figure 134).

0022-76

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace left door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

Left Door Windshield Wiper Does Not Operate Properly - Continued

15. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

CORRECTIVE ACTION

16. Disconnect cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) from left door wiper motor (WP 0249). 17. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 18. Turn left door wiper switch to the HIGH position (TM 5-2410-24110). 19. Using digital multimeter (WP 0296), measure for voltage between pin 5 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) and pin 2 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124).

1. If 24 Volts is found, replace left door wiper motor (WP 0250). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If 24 Volts is NOT found, proceed to step 20.

20. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 21. Remove rear wiper motor trim panel (WP 0229). 22. Disconnect headliner harness connector HA-C1 (WP 0018, Figure 134) from cab harness connector H-C7 (WP 0018, Figure 133). 23. Using digital multimeter (WP 0296), test for continuity between pin 5 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) and pin 4 on cab harness connector H-C7 (WP 0018, Figure 133). 24. Lower windshield wiper control plate and switches from headliner (WP 0234). 25. Disconnect 525 GRAY left door wiper HIGH supply connector (WP 0018, Figure 140) from left door wiper switch.

0022-77

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 24.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Left Door Windshield Wiper Does Not Operate Properly - Continued

26. Using digital multimeter (WP 0296), test for continuity between 525 GRAY left door wiper HIGH supply connector (WP 0018, Figure 140) and pin 4 on headliner harness connector HA-C1 (WP 0018, Figure 134).

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace left door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

27. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 28. Disconnect cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) from left door wiper motor (WP 0249). 29. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 30. Using digital multimeter (WP 0296), measure for voltage between pin 6 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) and pin 2 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124). 31. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 32. Connect jumper wire between pin 6 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) and pin 3 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124). 33. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0022-78

1. If 24 Volts is found, proceed to step 31. 2. If 24 Volts is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Left Door Windshield Wiper Does Not Operate Properly - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

NOTE Ensure left door wiper switch is turned to the OFF position. 34. Using digital multimeter (WP 0296), measure for voltage between pin 4 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) and pin 2 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124).

1. If 24 Volts is found, turn ignition switch and battery disconnect switch to OFF position (TM 52410-241-10) Remove jumper wire between pin 6 and pin 3 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124). Replace left door wiper motor (WP 0250). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 24 Volts is NOT found, turn ignition switch and battery disconnect switch to OFF position (TM 52410-241-10). Remove jumper wire between pin 6 and pin 3 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124). Proceed to step 35.

35. Remove rear wiper motor trim panel (WP 0229). 36. Disconnect headliner harness connector HA-C1 (WP 0018, Figure 134) from cab harness connector H-C7 (WP 0018, Figure 133). 37. Using digital multimeter (WP 0296), test for continuity between pin 3 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) and pin 6 on cab harness connector H-C7 (WP 0018, Figure 133). 38. Lower windshield wiper control plate and switches from headliner (WP 0234). 39. Disconnect 523 BROWN left door wiper PARK supply connector (WP 0018, Figure 138) from left door wiper motor switch.

0022-79

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 38.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Left Door Windshield Wiper Does Not Operate Properly - Continued

40. Using digital multimeter (WP 0296), test for continuity between 523 BROWN left door wiper PARK supply connector (WP 0018, Figure 138) and pin 6 on headliner harness connector HAC1 (WP 0018, Figure 134).

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace left door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

41. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 42. Lower windshield wiper control plate and switches from headliner (WP 0234). 43. Swap front wiper switch and left door wiper switch (WP 0234). 44. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 45. Turn front wiper switch to the LOW, HIGH, and OFF position (TM 5-2410-241-10).

1. If front wiper is working, proceed to step 46. 2. If front wiper is NOT working, replace front wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

46. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 47. Disconnect cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) from left door wiper motor (WP 0249). 48. Using digital multimeter (WP 0296), test for continuity between pin 2 on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) and ground.

0022-80

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 49.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Left Door Windshield Wiper Does Not Operate Properly Continued

TEST OR INSPECTION

CORRECTIVE ACTION

49. Remove rear wiper motor trim panel (WP 0229). 50. Disconnect headliner harness connector HA-C1 (WP 0018, Figure 134) from cab harness connector H-C7 (WP 0018, Figure 133). 51. Using digital multimeter (WP 0296), test for continuity between the following pins on cab harness left door wiper motor connector H-C5 (WP 0018, Figure 124) and pins on cab harness connector H-C7 (WP 0018, Figure 133). a. Between pin 4 on H-C5 (WP 0018, Figure 124) and pin 5 on H-C7 (WP 0018, Figure 133). b. Between pin 5 on H-C5 (WP 0018, Figure 124) and pin 4 on H-C7 (WP 0018, Figure 133). c.

Between pin 3 on H-C5 (WP 0018, Figure 124) and pin 6 on H-C7 (WP 0018, Figure 133).

52. Disconnect 525 GRAY left door wiper HIGH supply connector (WP 0018, Figure 140) from left door wiper switch. 53. Disconnect 524 BLUE left door wiper LOW supply connector (WP 0018, Figure 139) from left door wiper switch. 54. Disconnect 523 BROWN left door wiper PARK supply connector (WP 0018, Figure 138) from left door wiper motor switch.

0022-81

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 52.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Left Door Windshield Wiper Does Not Operate Properly - Continued

55. Using digital multimeter (WP 0296), test for continuity between the following left door wiper supply connectors and pins on headliner harness connector HA-C1 (WP 0018, Figure 134). a. Between 525 GRAY connector (WP 0018, Figure 140) and pin 4 on HA-C1 (WP 0018, Figure 134). b. Between 524 BLUE connector (WP 0018, Figure 139) and pin 5 on HA-C1 (WP 0018, Figure 134). c. Between 523 BROWN connector (WP 0018, Figure 138) and pin 6 on HA-C1 (WP 0018, Figure 134).

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace left door wiper motor (WP 0250). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

Right Door Windshield Wiper Does Not Operate Properly

1. Inspect operation of all windshield wipers (TM 5-2410-241-10).

1. If right door windshield wiper does NOT operate properly, proceed to step 2. 2. If all windshield wipers do NOT operate, refer to malfunction All Windshield Wipers and Washers Do NOT Operate in this work package.

2. Turn right door wiper switch to the LOW, HIGH, and then OFF position (TM 5-2410-241-10).

1. If wiper does NOT work in LOW position, proceed to step 3. 2. If wiper does NOT work in High position, proceed to step 15. 3. If wiper does NOT return to PARK position, proceed to step 27. 4. If wiper does NOT operate in any position, proceed to step 41.

3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Disconnect cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) from right door wiper motor (WP 0250). 5. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 6. Turn right door wiper switch to the LOW position (TM 5-2410-24110).

0022-82

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Right Door Windshield Wiper Does Not Operate Properly - Continued

7. Using digital multimeter (WP 0296), measure for voltage between pin 4 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) and pin 2 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125).

1. If 24 Volts is found, replace right door wiper motor (WP 0250). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If 24 Volts is NOT found, proceed to step 8.

8. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 9. Remove rear wiper motor trim panel (WP 0229). 10. Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114). 11. Using digital multimeter (WP 0296), test for continuity between pin 4 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) and pin 8 on cab harness connector H-C6 (WP 0018, Figure 114).

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 12.

12. Lower windshield wiper control plate and switches from headliner (WP 0234). 13. Disconnect 527 GREEN right door wiper LOW supply connector (WP 0018, Figure 142) from Right Door wiper switch. 14. Using digital multimeter (WP 0296), test for continuity between 527 GREEN right door wiper LOW supply connector (WP 0018, Figure 142) and pin 8 on headliner harness connector HA-C2 (WP 0018, Figure 115).

15. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0022-83

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace right door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

Right Door Windshield Wiper Does Not Operate Properly - Continued

16. Disconnect cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) from right door wiper motor (WP 0250).

CORRECTIVE ACTION

17. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 18. Turn right door wiper switch to the HIGH position (TM 5-2410-24110). 19. Using digital multimeter (WP 0296), measure for voltage between pin 5 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) and pin 2 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125).

1. If 24 Volts is found, replace right door wiper motor (WP 0250). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If 24 Volts is NOT found, proceed to step 20.

20. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 21. Remove rear wiper motor trim panel (WP 0229). 22. Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114). 23. Using digital multimeter (WP 0296), test for continuity between pin 5 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) and pin 3 on cab harness connector H-C6 (WP 0018, Figure 114). 24. Lower windshield wiper control plate and switches from headliner (WP 0234). 25. Disconnect 528 PINK right door wiper HIGH supply connector (WP 0018, Figure 143) from right door wiper switch.

0022-84

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 24.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Right Door Windshield Wiper Does Not Operate Properly - Continued

26. Using digital multimeter (WP 0296), test for continuity between 528 PINK right door wiper HIGH supply connector (WP 0018, Figure 143) and pin 3 on headliner harness connector HA-C2 (WP 0018, Figure 115).

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace right door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

27. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 28. Disconnect cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) from right door wiper motor (WP 0250). 29. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 30. Using digital multimeter (WP 0296), measure for voltage between pin 6 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) and pin 2 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125). 31. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 32. Connect jumper wire between pin 6 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) and pin 3 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125). 33. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0022-85

1. If 24 Volts is found, proceed to step 31. 2. If 24 Volts is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Right Door Windshield Wiper Does Not Operate Properly - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

NOTE Ensure right door wiper switch is turned to the OFF position. 34. Using digital multimeter (WP 0296), measure for voltage between pin 4 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) and pin 2 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125).

1. If 24 Volts is found, turn ignition switch and battery disconnect switch to OFF position (TM 52410-241-10). Remove jumper wire between pin 6 and pin 3 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125). Replace right door wiper motor (WP 0250). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 24 Volts is NOT found, turn ignition switch and battery disconnect switch to OFF position (TM 52410-241-10). Remove jumper wire between pin 6 and pin 3 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125). Proceed to step 35.

35. Remove rear wiper motor trim panel (WP 0229). 36. Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114). 37. Using digital multimeter (WP 0296), test for continuity between pin 3 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) and pin 7 on cab harness connector H-C6 (WP 0018, Figure 114). 38. Lower windshield wiper control plate and switches from headliner (WP 0234). 39. Disconnect 526 YELLOW right door wiper PARK supply connector (WP 0018, Figure 141) from Right Door wiper switch.

0022-86

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 38.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Right Door Windshield Wiper Does Not Operate Properly - Continued

40. Using digital multimeter (WP 0296), test for continuity between 526 YELLOW right door wiper PARK supply connector (WP 0018, Figure 141) and pin 7 on headliner harness connector HAC2 (WP 0018, Figure 115).

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace right door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

41. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 42. Lower windshield wiper control plate and switches from headliner (WP 0234). 43. Swap rear wiper switch and right door wiper switch (WP 0234). 44. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 45. Turn rear wiper switch to the LOW, HIGH, and OFF position (TM 5-2410-241-10).

1. If rear wiper is working, proceed to step 46. 2. If rear wiper is NOT working, replace rear wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

46. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 47. Disconnect cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) from right door wiper motor (WP 0250). 48. Using digital multimeter (WP 0296), test for continuity between pin 2 on cab harness right door wiper motor connector H-C4 (WP 0018, Figure 125) and ground.

0022-87

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 49.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Right Door Windshield Wiper Does Not Operate Properly - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

49. Remove rear wiper motor trim panel (WP 0229). 50. Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114). 51. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between cab harness (WP 0254). Ensure the following pins on cab harness all harness connectors are reconright door wiper motor connector nected. Verify correct operation of H-C4 (WP 0018, Figure 125) and machine (TM 5-2410-241-10). pins on cab harness connector H- 2. If continuity is found, proceed to C6 (WP 0018, Figure 114). step 52. a. Between pin 4 on H-C4 (WP 0018, Figure 125) and pin 8 on H-C6 (WP 0018, Figure 114). b. Between pin 5 on H-C4 (WP 0018, Figure 125) and pin 3 on H-C6 (WP 0018, Figure 114). c.

Between pin 3 on H-C4 (WP 0018, Figure 125) and pin 7 on H-C6 (WP 0018, Figure 114).

52. Disconnect 528 PINK right door wiper HIGH supply connector (WP 0018, Figure 143) from right door wiper switch. 53. Disconnect 527 GREEN right door wiper LOW supply connector (WP 0018, Figure 142) from Right Door wiper switch. 54. Disconnect 526 YELLOW right door wiper PARK supply connector (WP 0018, Figure 141) from Right Door wiper switch.

0022-88

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Right Door Windshield Wiper Does Not Operate Properly - Continued

55. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between headliner harness (WP 0232). the following right door wiper supEnsure all harness connectors ply connectors and pins on headare reconnected. Verify correct liner harness connector HA-C2 operation of machine (TM 5-2410(WP 0018, Figure 115). 241-10). a. Between 528 PINK connector 2. If continuity is found, replace right (WP 0018, Figure 143) and door wiper motor (WP 0250). pin 3 on HA-C2 (WP 0018, Ensure all harness connectors Figure 115). are reconnected. Verify correct b. Between 527 GREEN conoperation of machine (TM 5-2410nector (WP 0018, Figure 142) 241-10). and pin 8 on HA-C2 (WP 0018, Figure 115). c. Between 526 YELLOW connector (WP 0018, Figure 141) and pin 7 on HA-C2 (WP 0018, Figure 115).

Rear Windshield Wiper Does Not Operate Properly

1. Inspect operation of all windshield wipers (TM 5-2410-241-10).

1. If rear windshield wiper does NOT operate properly, proceed to step 2. 2. If all windshield wipers do NOT operate, refer to malfunction All Windshield Wipers and Washers Do NOT Operate in this work package.

2. Turn rear wiper switch to the LOW, HIGH, and then OFF position (TM 5-2410-241-10).

1. If wiper does NOT work in LOW position, proceed to step 3. 2. If wiper does NOT work in High position, proceed to step 13. 3. If wiper does NOT return to PARK position, proceed to step 23. 4. If wiper does NOT operate in any position, proceed to step 38.

3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Remove rear wiper motor trim panel (WP 0229). 5. Disconnect headliner harness rear wiper motor connector HAC4 (WP 0018, Figure 126) from rear wiper motor (WP 0223). 6. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0022-89

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

Rear Windshield Wiper Does Not Operate Properly Continued

7. Turn rear wiper switch to the LOW position (TM 5-2410-241-10). 8. Using digital multimeter (WP 0296), measure for voltage between pin 4 on headliner harness rear wiper motor connector HA-C4 (WP 0018, Figure 126) and pin 2 on headliner harness rear wiper motor connector HAC4 (WP 0018, Figure 126).

CORRECTIVE ACTION

1. If 24 Volts is found, replace rear wiper motor (WP 0223). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 24 Volts is NOT found, proceed to step 9.

9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 10. Lower windshield wiper control plate and switches from headliner (WP 0234). 11. Disconnect 504 YELLOW rear wiper LOW supply connector (WP 0018, Figure 145) from rear wiper switch. 12. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between headliner harness (WP 0232). 504 YELLOW rear wiper LOW Ensure all harness connectors supply connector (WP 0018, Figare reconnected. Verify correct ure 145) and pin 4 on headliner operation of machine (TM 5-2410harness rear wiper motor connec241-10). tor HA-C4 (WP 0018, Figure 126). 2. If continuity is found, replace rear wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 13. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 14. Remove rear wiper motor trim panel (WP 0229). 15. Disconnect headliner harness rear wiper motor connector HAC4 (WP 0018, Figure 126) from rear wiper motor (WP 0223). 16. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0022-90

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Rear Windshield Wiper Does Not Operate Properly Continued

TEST OR INSPECTION

CORRECTIVE ACTION

17. Turn rear wiper switch to the HIGH position (TM 5-2410-24110). 18. Using digital multimeter (WP 0296), measure for voltage between pin 5 on headliner harness rear wiper motor connector HA-C4 (WP 0018, Figure 126) and pin 2 on headliner harness rear wiper motor connector HAC4 (WP 0018, Figure 126).

1. If 24 Volts is found, replace rear wiper motor (WP 0223). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 24 Volts is NOT found, proceed to step 19.

19. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 20. Lower windshield wiper control plate and switches from headliner (WP 0234). 21. Disconnect 505 BLUE rear wiper HIGH supply connector (WP 0018, Figure 146) from rear wiper switch. 22. Using digital multimeter (WP 0296), test for continuity between 505 BLUE rear wiper HIGH supply connector (WP 0018, Figure 146) and pin 5 on headliner harness rear wiper motor connector HA-C4 (WP 0018, Figure 126).

23. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 24. Remove rear wiper motor trim panel (WP 0229). 25. Disconnect headliner harness rear wiper motor connector HAC4 (WP 0018, Figure 126) from rear wiper motor (WP 0223). 26. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0022-91

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace rear wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Rear Windshield Wiper Does Not Operate Properly Continued

TEST OR INSPECTION

CORRECTIVE ACTION

27. Using digital multimeter (WP 0296), measure for voltage between pin 6 on headliner harness rear wiper motor connector HA-C4 (WP 0018, Figure 126) and pin 2 on headliner harness rear wiper motor connector HAC4 (WP 0018, Figure 126).

1. If 24 Volts is found, proceed to step 28. 2. If 24 Volts is NOT found, proceed to step 35.

28. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 29. Connect jumper wire between pin 6 on headliner harness rear wiper motor connector HA-C4 (WP 0018, Figure 126) and pin 3 on headliner harness rear wiper motor connector HA-C4 (WP 0018, Figure 126). 30. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

NOTE Ensure rear wiper switch is turned to the OFF position. 31. Using digital multimeter (WP 0296), measure for voltage between pin 4 on headliner harness rear wiper motor connector HA-C4 (WP 0018, Figure 126) and pin 2 on headliner harness rear wiper motor connector HAC4 (WP 0018, Figure 126).

0022-92

1. If 24 Volts is found, turn ignition switch and battery disconnect switch to OFF position (TM 52410-241-10). Remove jumper wire between pin 6 and pin 3 on headliner harness rear wiper motor connector HA-C4 (WP 0018, Figure 126). Replace rear wiper motor (WP 0223). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 24 Volts is NOT found, turn ignition switch and battery disconnect switch to OFF position (TM 52410-241-10). Remove jumper wire between pin 6 and pin 3 on headliner harness rear wiper motor connector HA-C4 (WP 0018, Figure 126). Proceed to step 32.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

Rear Windshield Wiper Does Not Operate Properly Continued

32. Lower windshield wiper control plate and switches from headliner (WP 0234).

CORRECTIVE ACTION

33. Disconnect 503 BROWN rear wiper PARK supply connector (WP 0018, Figure 144) from rear wiper switch. 34. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between headliner harness (WP 0232). 503 BROWN rear wiper PARK Ensure all harness connectors supply connector (WP 0018, Figare reconnected. Verify correct ure 144) and pin 3 on headliner operation of machine (TM 5-2410harness rear wiper motor connec241-10). tor HA-C4 (WP 0018, Figure 126). 2. If continuity is found, replace rear wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 35. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 36. Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114). 37. Using digital multimeter (WP 0296), test for continuity between pin 2 on headliner harness connector HA-C2 (WP 0018, Figure 115) and pin 6 on headliner harness rear wiper motor connector HA-C4 (WP 0018, Figure 126).

38. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 39. Swap right door wiper switch and rear wiper switch (WP 0234). 40. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0022-93

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Rear Windshield Wiper Does Not Operate Properly Continued

41. Turn right door wiper switch to the LOW, HIGH, and OFF position (TM 5-2410-241-10).

1. If right door wiper is working, proceed to step 42. 2. If right door wiper is NOT working, replace right door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

42. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 43. Remove rear wiper motor trim panel (WP 0229). 44. Disconnect headliner harness rear wiper motor connector HAC4 (WP 0018, Figure 126) from rear wiper motor (WP 0223). 45. Disconnect 505 BLUE rear wiper HIGH supply connector (WP 0018, Figure 146) from rear wiper switch. 46. Disconnect 504 YELLOW rear wiper LOW supply connector (WP 0018, Figure 145) from rear wiper switch. 47. Disconnect 503 BROWN rear wiper PARK supply connector (WP 0018, Figure 144) from rear wiper switch. 48. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between headliner harness (WP 0232). the following rear wiper supply Ensure all harness connectors connectors and pins on headliner are reconnected. Verify correct harness rear wiper motor connecoperation of machine (TM 5-2410tor HA-C4 (WP 0018, Figure 126). 241-10). a. Between 505 BLUE 2. If continuity is found, replace rear connector (WP 0018, Figure wiper motor (WP 0223). Ensure 146) and pin 5 on HA-C4 (WP all harness connectors are recon0018, Figure 126). nected. Verify correct operation of b. Between 504 YELLOW conmachine (TM 5-2410-241-10). nector (WP 0018, Figure 145) and pin 4 on HA-C4 (WP 0018, Figure 126). c. Between 503 BROWN connector (WP 0018, Figure 144) and pin 3 on HA-C4 (WP 0018, Figure 126).

0022-94

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Front Windshield Washer Does Not Operate

TEST OR INSPECTION

CORRECTIVE ACTION

1. Inspect operation of all windshield washers (TM 5-2410-241-10).

1. If front windshield washer does NOT operate properly, proceed to step 2. 2. If all windshield washers do NOT operate, refer to malfunction All Windshield Wipers and Washers Do NOT Operate in this work package.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect washer pump harness connector HH-C2 (WP 0018, Figure 190) from front washer pump. 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Using digital multimeter (WP 0296), measure for voltage between pin 1 and pin 2 on washer pump harness connector HH-C2 (WP 0018, Figure 190) while activating front washer (TM 5-2410-241-10).

1. If 24 volts is found, replace front washer pump (WP 0224). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 24 volts is NOT found, proceed to step 6.

6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Disconnect cab harness washer bottle connector H-C8 (WP 0018, Figure 154) from washer bottle connector HH-C1 (WP 0018, Figure 155). 8. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between washer pump harness (WP pin 1 on washer pump harness 0224). Ensure all harness conconnector HH-C2 (WP 0018, Fignectors are reconnected. Verify ure 190) and pin 6 on washer botcorrect operation of machine (TM tle connector HH-C1 (WP 0018, 5-2410-241-10). Figure 155). 2. If continuity is found, proceed to step 9.

0022-95

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Front Windshield Washer 9. Using digital multimeter (WP 1. If continuity is NOT found, replace Does Not Operate - Con0296), test for continuity between washer pump harness (WP tinued pin 2 on washer pump harness 0224). Ensure all harness conconnector HH-C2 (WP 0018, Fignectors are reconnected. Verify ure 190) and pin 2 on washer botcorrect operation of machine (TM tle connector HH-C1 (WP 0018, 5-2410-241-10). Figure 155). 2. If continuity is found, proceed to step 10. 10. Remove rear wiper motor trim panel (WP 0229). 11. Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114). 12. Using digital multimeter (WP 0296), test for continuity between pin 6 on cab harness washer bottle connector H-C8 (WP 0018, Figure 154) and pin 5 on cab harness connector H-C6 (WP 0018, Figure 114).

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 13.

13. Lower windshield wiper control plate and switches from headliner (WP 0234). 14. Disconnect 506 PURPLE front wiper washer supply connector (WP 0018, Figure 150) from Front wiper switch. 15. Using digital multimeter (WP 0296), test for continuity between 506 PURPLE front wiper washer supply connector (WP 0018, Figure 150) and pin 5 on headliner harness connector HA-C2 (WP 0018, Figure 115).

0022-96

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace front wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Left Door Windshield Washer Does Not Operate

TEST OR INSPECTION

CORRECTIVE ACTION

1. Inspect operation of all windshield washers (TM 5-2410-241-10).

1. If left door windshield washer does NOT operate properly, proceed to step 2. 2. If all windshield washers do NOT operate, refer to malfunction All Windshield Wipers and Washers Do NOT Operate in this work package.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect washer pump harness connector HH-C3 (WP 0018, Figure 191) from left door washer pump. 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Using digital multimeter (WP 1. If 24 volts is found, replace left 0296), measure for voltage washer pump (WP 0224). Ensure between pin 1 and pin 2 on all harness connectors are reconwasher pump harness connector nected. Verify correct operation of HH-C3 (WP 0018, Figure 191) machine (TM 5-2410-241-10). while activating left washer (TM 5- 2. If 24 volts is NOT found, proceed 2410-241-10). to step 6. 6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Disconnect cab harness washer bottle connector H-C8 (WP 0018, Figure 154) from washer bottle connector HH-C1 (WP 0018, Figure 155). 8. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between washer pump harness (WP pin 1 on washer pump harness 0224). Ensure all harness conconnector HH-C3 (WP 0018, Fignectors are reconnected. Verify ure 191) and pin 4 on washer botcorrect operation of machine (TM tle connector HH-C1 (WP 0018, 5-2410-241-10). Figure 155). 2. If continuity is found, proceed to step 9.

0022-97

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Left Door Windshield Washer Does Not Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

9. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between washer pump harness (WP pin 2 on washer pump harness 0224). Ensure all harness conconnector HH-C3 (WP 0018, Fignectors are reconnected. Verify ure 191) and pin 2 on washer botcorrect operation of machine (TM tle connector HH-C1 (WP 0018, 5-2410-241-10). Figure 155). 2. If continuity is found, proceed to step 10. 10. Remove rear wiper motor trim panel (WP 0229). 11. Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114). 12. Using digital multimeter (WP 0296), test for continuity between pin 4 on cab harness washer bottle connector H-C8 (WP 0018, Figure 154) and pin 9 on cab harness connector H-C6 (WP 0018, Figure 114).

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 13.

13. Lower windshield wiper control plate and switches from headliner (WP 0234). 14. Disconnect 529 WHITE left wiper washer supply connector (WP 0018, Figure 153) from left door wiper switch. 15. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between headliner harness (WP 0232). 529 WHITE left wiper washer supEnsure all harness connectors ply connector (WP 0018, Figure are reconnected. Verify correct 153) and pin 9 on headliner haroperation of machine (TM 5-2410ness connector HA-C2 (WP 0018, 241-10). Figure 115). 2. If continuity is found, replace left door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0022-98

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Right Door Windshield Washer Does Not Operate

TEST OR INSPECTION

CORRECTIVE ACTION

1. Inspect operation of all windshield washers (TM 5-2410-241-10).

1. If right door windshield washer does NOT operate properly, proceed to step 2. 2. If all windshield washers do NOT operate, refer to malfunction All Windshield Wipers and Washers Do NOT Operate in this work package.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect washer pump harness connector HH-C4 (WP 0018, Figure 192) from right door washer pump. 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Using digital multimeter (WP 0296), measure for voltage between pin 1 and pin 2 on washer pump harness connector HH-C4 (WP 0018, Figure 192) while activating right washer (TM 5-2410-241-10).

1. If 24 volts is found, replace right washer pump (WP 0224). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 24 volts is NOT found, proceed to step 6.

6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Disconnect cab harness washer bottle connector H-C8 (WP 0018, Figure 154) from washer bottle connector HH-C1 (WP 0018, Figure 155). 8. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between washer pump harness (WP pin 1 on washer pump harness 0224). Ensure all harness conconnector HH-C4 (WP 0018, Fignectors are reconnected. Verify ure 192) and pin 3 on washer botcorrect operation of machine (TM tle connector HH-C1 (WP 0018, 5-2410-241-10). Figure 155). 2. If continuity is found, proceed to step 9.

0022-99

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Right Door Windshield Washer Does Not Operate - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

9. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between washer pump harness (WP pin 2 on washer pump harness 0224). Ensure all harness conconnector HH-C4 (WP 0018, Fignectors are reconnected. Verify ure 192) and pin 2 on washer botcorrect operation of machine (TM tle connector HH-C1 (WP 0018, 5-2410-241-10). Figure 155). 2. If continuity is found, proceed to step 10. 10. Remove rear wiper motor trim panel (WP 0229). 11. Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114). 12. Using digital multimeter (WP 0296), test for continuity between pin 3 on cab harness washer bottle connector H-C8 (WP 0018, Figure 154) and pin 10 on cab harness connector H-C6 (WP 0018, Figure 114).

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 13.

13. Lower windshield wiper control plate and switches from headliner (WP 0234). 14. Disconnect 530 ORANGE right wiper washer supply connector (WP 0018, Figure 152) from right door wiper switch. 15. Using digital multimeter (WP 0296), test for continuity between 530 ORANGE right wiper washer supply connector (WP 0018, Figure 152) and pin 10 on headliner harness connector HA-C2 (WP 0018, Figure 115).

0022-100

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace right door wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Rear Windshield Washer Does Not Operate

TEST OR INSPECTION

CORRECTIVE ACTION

1. Inspect operation of all windshield washers (TM 5-2410-241-10).

1. If rear windshield washer does NOT operate properly, proceed to step 2. 2. If all windshield washers do NOT operate, refer to malfunction All Windshield Wipers and Washers Do NOT Operate in this work package.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect washer pump harness connector HH-C5 (WP 0018, Figure 193) from rear washer pump. 4. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 5. Using digital multimeter (WP 0296), measure for voltage between pin 1 and pin 2 on washer pump harness connector HH-C5 (WP 0018, Figure 193) while activating rear washer (TM 5-2410-241-10).

1. If 24 volts is found, replace rear washer pump (WP 0224). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 24 volts is NOT found, proceed to step 6.

6. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 7. Disconnect cab harness washer bottle connector H-C8 (WP 0018, Figure 154) from washer bottle connector HH-C1 (WP 0018, Figure 155). 8. Using digital multimeter (WP 1. If continuity is NOT found, replace 0296), test for continuity between washer pump harness (WP pin 1 on washer pump harness 0224). Ensure all harness conconnector HH-C5 (WP 0018, Fignectors are reconnected. Verify ure 193) and pin 1 on washer botcorrect operation of machine (TM tle connector HH-C1 (WP 0018, 5-2410-241-10). Figure 155). 2. If continuity is found, proceed to step 9.

0022-101

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Rear Windshield Washer 9. Using digital multimeter (WP 1. If continuity is NOT found, replace Does Not Operate - Con0296), test for continuity between washer pump harness (WP tinued pin 2 on washer pump harness 0224). Ensure all harness conconnector HH-C5 (WP 0018, Fignectors are reconnected. Verify ure 193) and pin 2 on washer botcorrect operation of machine (TM tle connector HH-C1 (WP 0018, 5-2410-241-10). Figure 155). 2. If continuity is found, proceed to step 10. 10. Remove rear wiper motor trim panel (WP 0229). 11. Disconnect headliner harness connector HA-C2 (WP 0018, Figure 115) from cab harness connector H-C6 (WP 0018, Figure 114). 12. Using digital multimeter (WP 0296), test for continuity between pin 1 on cab harness washer bottle connector H-C8 (WP 0018, Figure 154) and pin 11 on cab harness connector H-C6 (WP 0018, Figure 114).

1. If continuity is NOT found, replace cab harness (WP 0254). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is found, proceed to step 13.

13. Lower windshield wiper control plate and switches from headliner (WP 0234). 14. Disconnect 507 WHITE rear washer supply connector (WP 0018, Figure 151) from rear wiper switch. 15. Using digital multimeter (WP 0296), test for continuity between 507 WHITE rear washer supply connector (WP 0018, Figure 151) and pin 11 on headliner harness connector HA-C2 (WP 0018, Figure 115).

0022-102

1. If continuity is NOT found, replace headliner harness (WP 0232). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is found, replace rear wiper switch (WP 0234). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Horn Does Not Operate

TEST OR INSPECTION

CORRECTIVE ACTION

1. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 2. Inspect operation of horn (TM 52410-241-10).

1. If horn does NOT operate properly, proceed to step 3. 2. If horn operation if OK, problem does NOT exist at this time. Resume normal operation.

3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Open front grille door (WP 0156). 5. Disconnect front lighting harness top horn connector G-C4 (WP 0018, Figure 156) from top horn (WP 0182). 6. Disconnect front lighting harness bottom horn connector G-C5 (WP 0018, Figure 157) from bottom horn (WP 0182). 7. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 8. With assistance, activate and HOLD horn switch (TM 5-2410241-10). 9. Using digital multimeter (WP 0296), measure for voltage between pins 1 and 2 on front lighting harness top horn connector G-C4 (WP 0018, Figure 156).

1. If 24 Volts is found, replace horns (WP 0182). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If voltage is NOT found, proceed to step 10.

10. Using digital multimeter (WP 0296), measure for voltage between pins 1 and 2 on front lighting harness bottom horn connector G-C5 (WP 0018, Figure 157).

1. If 24 Volts is found, replace horns (WP 0182) and front lighting harness (WP 0167). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If voltage is NOT found, proceed to step 11.

11. Release horn switch (TM 5-2410241-10).

0022-103

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Horn Does Not Operate Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

12. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 13. Remove Fuse #13 (Figure 10, Item 1) from fuse panel (TM 52410-241-10).

Figure 10. Fuse #13. 14. Using digital multimeter (WP 0296), test for continuity between blades of Fuse #13.

15. Connect front lighting harness top horn connector G-C4 (WP 0018, Figure 156) on top horn (WP 0182). 16. Connect front lighting harness bottom horn connector G-C5 (WP 0018, Figure 157) on bottom horn (WP 0182).

0022-104

0022

1. If continuity is found, install Fuse #13 on fuse panel (TM 5-2410241-10). Proceed to step 29. 2. If continuity is NOT found, replace Fuse #13 (TM 5-2410-241-10). Proceed to step 15.

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Horn Does Not Operate Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

17. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 18. Operate horn switch several times (TM 5-2410-241-10). 19. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 20. Remove Fuse #13 (Figure 11, Item 1) from fuse panel (TM 52410-241-10).

Figure 11. Fuse #13. 21. Using digital multimeter (WP 0296), test for continuity between blades of Fuse #13.

0022-105

0022

1. If continuity is found, and horn operates, install Fuse #13 on fuse panel (TM 5-2410-241-10). Resume normal operation. 2. If continuity is NOT found, replace Fuse #13 (TM 5-2410-241-10). Proceed to step 22.

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Horn Does Not Operate Continued

TEST OR INSPECTION

CORRECTIVE ACTION

22. Disconnect front lighting harness top horn connector G-C4 (WP 0018, Figure 156) from top horn (WP 0182). 23. Disconnect front lighting harness bottom horn connector G-C5 (WP 0018, Figure 157) from bottom horn (WP 0182). 24. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 25. Operate horn switch several times (TM 5-2410-241-10). 26. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 27. Remove Fuse #13 (Figure 11, Item 1) from fuse panel (TM 52410-241-10). 28. Using digital multimeter (WP 0296), test for continuity between blades of Fuse #13.

1. If continuity is found, replace horns (WP 0182). Install Fuse #13 on fuse panel (TM 5-2410-24110) 2. If continuity is NOT found, replace Fuse #13 (TM 5-2410-241-10). Proceed to step 29.

29. Disconnect engine harness connector V-C15 (WP 0018, Figure 99) from front lighting harness connector G-C1 (WP 0018, Figure 98). 30. Using digital multimeter (WP 0296), test for continuity between pin C on front lighting harness connector G-C1 (WP 0018, Figure 98) and pin 1 on front lighting harness top horn connector G-C4 (WP 0018, Figure 156).

0022-106

1. If continuity is found, proceed to step 31. 2. If continuity is NOT found, replace front lighting harness (WP 0167). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Horn Does Not Operate Continued

TEST OR INSPECTION

CORRECTIVE ACTION

31. Using digital multimeter (WP 0296), test for continuity between pin C on front lighting harness connector G-C1 (WP 0018, Figure 98) and pin 1 on front lighting harness bottom horn connector G-C5 (WP 0018, Figure 157).

1. If continuity is found, proceed to step 32. 2. If continuity is NOT found, replace front lighting harness (WP 0167). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

32. Using digital multimeter (WP 0296), test for continuity between pin A and C on front lighting harness connector G-C1 (WP 0018, Figure 98).

1. If continuity is NOT found, proceed to step 33. 2. If continuity is found, replace front lighting harness (WP 0167). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

33. Disconnect engine harness connector V-C1 (WP 0018, Figure 12) from platform harness connector MA-C22 (WP 0018, Figure 11). 34. Using digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 35. pin 6 on engine harness connec- 2. If continuity is NOT found, replace tor V-C1 (WP 0018, Figure 12) main engine harness (WP 0055). and pin C on engine harness conEnsure all harness connectors nector V-C15 (WP 0018, Figure are reconnected. Verify correct 99). operation of machine (TM 5-2410241-10). 35. Using digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 36. pin 3 on engine harness connec- 2. If continuity is NOT found, replace tor V-C1 (WP 0018, Figure 12) main engine harness (WP 0055). and pin A on engine harness conEnsure all harness connectors nector V-C15 (WP 0018, Figure are reconnected. Verify correct 99). operation of machine (TM 5-2410241-10). 36. Using digital multimeter (WP 0296), test for continuity between pin 6 on engine harness connector V-C1 (WP 0018, Figure 12) and pin 3 pins on engine harness connector V-C1 (WP 0018, Figure 12).

0022-107

1. If continuity is NOT found, proceed to step 37. 2. If continuity is found, replace main engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Horn Does Not Operate Continued

TEST OR INSPECTION

CORRECTIVE ACTION

37. Disconnect platform harness connector MA-C13 (WP 0018, Figure 158) from RH console harness connector RW-C3 (WP 0018, Figure 159). 38. Using digital multimeter check for continuity between pin 4 on platform harness MA-C13 (WP 0018, Figure 158) and pin 6 on platform harness MA-C13 (WP 0018, Figure 158).

1. If continuity is NOT found, proceed to step 39. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

39. Disconnect RH console harness connector R-C5 (WP 0018, Figure 160) from horn switch (WP 0208). 40. Using digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 41. pin 1 on RH console harness con- 2. If continuity is NOT found, replace nector R-C5 (WP 0018, Figure right cab switch panel harness 160) and pin 4 on RH console assembly (WP 0179). Ensure all harness connector RW-C3 (WP harness connectors are recon0018, Figure 159). nected. Verify correct operation of machine (TM 5-2410-241-10). 41. Using digital multimeter (WP 1. If continuity is NOT found, pro0296), test for continuity between ceed to step 42. pin 1 on RH console harness con- 2. If continuity is found, replace right nector R-C5 (WP 0018, Figure cab switch panel harness assem160) and ground. bly (WP 0179). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 42. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 43. Using digital multimeter (WP 0296), measure for voltage between pin 5 on platform harness connector MA-C13 (WP 0018, Figure 158) and ground. 44. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0022-108

1. If 24 Volts is found, proceed to step 44. 2. If 24 Volts is NOT found, proceed to step 46.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Horn Does Not Operate Continued

TEST OR INSPECTION

CORRECTIVE ACTION

45. Using digital multimeter (WP 1. If continuity is found, replace horn 0296), test for continuity between switch (WP 0208). Ensure all harpin 2 on RH console harness conness connectors are reconnected. nector R-C5 (WP 0018, Figure Verify correct operation of 160) and pin 5 on RH console machine (TM 5-2410-241-10). harness connector RW-C3 (WP 2. If continuity is NOT found, replace 0018, Figure 159). right cab switch panel harness assembly (WP 0179). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 46. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel harness connector A-C1 (WP 0018, Figure 22). 47. Using digital multimeter (WP 0296), test for continuity between pin 17 on platform harness connector MA-C3 (WP 0018, Figure 21) and pin 5 on platform harness connector MA-C13 (WP 0018, Figure 158).

1. If continuity is found, proceed to step 48. 2. If continuity is NOT found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

48. Using digital multimeter (WP 0296), test for continuity between pin 17 on platform harness connector MA-C3 (WP 0018, Figure 21) and pin 10 on platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is NOT found, proceed to step 49. 2. If continuity is found, replace platform harness (WP 0209). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

49. Open fuse panel door (TM 52410-241-10).

0022-109

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Horn Does Not Operate Continued

0022

TEST OR INSPECTION

CORRECTIVE ACTION

50. Using digital multimeter (WP 0296), test for continuity between pin 17 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and Fuse #13 (Figure 12, Item 1).

1. If continuity is found, proceed to step 51. 2. If continuity is NOT found, replace fuse panel wiring harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

Figure 12. Fuse #13.

0022

51. Using digital multimeter (WP 1. If continuity is NOT found, verify 0296), test for continuity between horn operation (TM 5-2410-241pin 17 on fuse panel wiring har10). ness connector A-C1 (WP 0018, 2. If continuity is found- Replace Figure 22) and pin 10 on fuse fuse panel wiring harness (WP panel wiring harness connector A0176). Ensure all harness conC1 (WP 0018, Figure 22). nectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022-110

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

There is Little or No COLD Airflow when Air Conditioning is On

1. Inspect A/C compressor drive belt for cracks, damage, and correct tension (WP 0096).

1. If drive belt cracked or damaged, replace A/C compressor drive belt (WP 0096). Verify correct operation of machine (TM 5-2410-24110). 2. If drive belt OK, proceed to step 2.

2. Connect refrigerant reclaimer (WP 0263). Monitor and record low pressure and high pressure gauge readings. Refer to A/C Performance - Test in (WP 0027) for normal operating pressures.

NOTE Refer to steps 3 through 10 for system pressure condition. 3. Low Pressure Gauge Reading and High Pressure Gauge Reading is Above Normal • Check condenser for blockage. If no blockage is found, A/C system is over charged.

Evacuate and recharge A/C system. Refer to A/C System Service (WP 0263).

4. Low Pressure Gauge Reading is Above Normal, and High Pressure Gauge Reading is Below Normal

1. If low and high pressure gauge readings are the same, perform malfunction A/C compressor Will Not Engage in this work package. 2. If low and high pressure gauge readings are NOT the same, replace A/C compressor (WP 0097). Verify correct operation of machine (TM 5-2410-241-10).

5. Low Pressure Gauge Reading is Below Normal, and High Pressure Gauge Reading is Above Normal

Replace receiver/dryer orifice tube (WP 0240). Verify correct operation of machine (TM 5-2410-241-10).

6. Low and High Pressure Readings are Both Below Normal • Inspect A/C system for leaks. Refer to Refrigerant Leakage - Test (WP 0036).

1. If leaks found, replace leaking components (WP 0263). Verify correct operation of machine (TM 5-2410-241-10). 2. If NO leaks are found, evacuate and recharge A/C system. Refer to A/C system service (WP 0263). Verify correct operation of machine (TM 5-2410-241-10).

0022-111

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

There is Little or No COLD Airflow when Air Conditioning is On - Continued

7. Low Pressure is Below Normal and High Pressure Reading Normal. • Remove high pressure hose (WP 0241) and inspect for a restriction.

1. If high pressure hose is NOT serviceable - Replace high pressure hose (WP 0241). Verify correct operation of machine (TM 5-2410241-10). 2. If high pressure hose is serviceable, replace receiver-dryer orifice tube (WP 0240). Verify correct operation of machine (TM 5-2410241-10).

8. Low Pressure is Normal and High Pressure Reading is Above Normal • Remove high pressure hose (WP 0241) and inspect for a restriction.

1. If high pressure hose is NOT serviceable, replace high pressure hose (WP 0241). Verify correct operation of machine (TM 5-2410241-10). 2. If high pressure hose is serviceable, replace receiver-dryer orifice tube (WP 0240). Verify correct operation of machine (TM 5-2410241-10).

9. Low Pressure is Normal and High Pressure Reading is BELOW Normal • Remove low pressure hose (WP 0242) and inspect for a restriction.

1. If low pressure hose is NOT serviceable, replace low pressure hose (WP 0242). Verify correct operation of machine (TM 5-2410241-10). 2. If low pressure hose is serviceable, replace A/C compressor (WP 0097). Verify correct operation of machine (TM 5-2410-24110).

10. Low Pressure Gauge Reading is Normal, and High Pressure Gauge Bounces, or Gauge is Unsteady a. Low pressure gauge reading is normal, but may drop into vacuum range during the test. b. High pressure gauge reading is normal, but the low pressure gauge reading is below normal.

Air is in the A/C system. Evacuate and recharge A/C system. Refer to A/C System Service (WP 0263). Verify correct operation of machine (TM 52410-241-10).

c.

Airflow from evaporator is very cold, but will become warm when low pressure gauge drops into vacuum.

0022-112

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Little or No Warm Airflow when Heater Control is Set for Maximum Heating

TEST OR INSPECTION

CORRECTIVE ACTION

1. Open left engine panel (TM 52410-241-10).

2. With an assistant, rotate temperature control from full warm to full cold (TM 5-2410-241-10) while observing the water valve and cable. Cable should fully extend and water valve should move through full range.

A/C Compressor will Not Engage

If cable does NOT extend or temperature control is difficult to operate, remove instrument cluster (WP 0262) and inspect cable attachment to temperature control valve for stripped and damaged components. a. If any components are damaged, replace temperature control (WP 0262). Verify correct operation of machine (TM 52410-241-10). b. If components are OK, replace water valve (WP 254). Verify correct operation of machine (TM 5-2410-24110).

NOTE This test assumes A/C system is properly charged. If A/C charge is suspected, refer to A/C and Heating System Tests, Inspections, and Adjustments (WP 0036) and verify A/C charge. 1. Start engine (TM 5-2410-241-10). 2. Verify operation of A/C system (TM 5-2410-241-10).

3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Disconnect A/C compressor harness connector CH-C3 (WP 0018, Figure 161) from A/C compressor clutch.

0022-113

1. If A/C system does NOT operate, proceed to step 3. 2. If A/C operates fine, problem does NOT exist at this time. Resume normal operation.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION A/C Compressor will Not Engage - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

5. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 6. Turn blower switch to ON position (TM 5-2410-241-10). 7. Activate A/C to MAX COOL (TM 5-2410-241-10). 8. Using digital multimeter (WP 0296), measure for voltage between pin 1 and pin 2 on A/C compressor harness connector CH-C3 (WP 0018, Figure 161).

1. If 24 Volts is found, replace A/C compressor (WP 0097). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If voltage is NOT found, proceed to step 9.

9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 10. Disconnect A/C compressor harness connector CH-C2 (WP 0018, Figure 162) from A/C compressor pressure switch. 11. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 12. Using digital multimeter (WP 0296), measure for voltage between pin 1 on A/C compressor harness connector CH-C2 (WP 0018, Figure 162) and ground.

1. If 24 Volts is found, proceed to step 13. 2. If voltage is NOT found, proceed to step 16.

13. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 14. Using digital multimeter (WP 0296), test for continuity between pin 2 on A/C compressor harness connector to compressor pressure switch CH-C2 (WP 0018, Figure 162) and pin 1 on A/C compressor harness connector to compressor clutch CH-C3 (WP 0018, Figure 161).

0022-114

1. If continuity is found, proceed to step 15. 2. If continuity is NOT found, replace A/C compressor harness (WP 0097). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

The A/C Compressor will Not Engage - Continued

15. Using digital multimeter (WP 0296), test for continuity between pin 1 on A/C compressor harness connector CH-C3 (WP 0018, Figure 161) and ground.

1. If continuity is found, replace A/C pressure switch (WP 0261) and diode (189-3758) (WP 0097). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, proceed to step 16.

16. Disconnect A/C compressor harness connector CH-C1 (WP 0018, Figure 164) from engine harness connector V-C13 (WP 0018, Figure 165). 17. Using digital multimeter (WP 0296), test for continuity between pin 1 on A/C compressor harness pressure switch connector CH-C2 (WP 0018, Figure 162) and pin 1 on A/C compressor harness connector CH-C1 (WP 0018, Figure 164).

1. If continuity is found, proceed to step 18. 2. If continuity is NOT found, replace A/C compressor harness (WP 0097). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

18. Using digital multimeter (WP 0296), test for continuity between pin 2 on A/C compressor harness clutch connector CH-C3 (WP 0018, Figure 161) and pin 2 on A/C compressor harness connector CHC1 (WP 0018, Figure 164).

1. If continuity is found, proceed to step 19. 2. If continuity is NOT found, replace A/C compressor harness (WP 0097). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

19. Disconnect engine harness connector V-C1 (WP 0018, Figure 12) from platform harness connector MA-C22 (WP 0018, Figure 11). 20. Using digital multimeter (WP 0296), test for continuity between pin 7 on engine harness connector V-C1 (WP 0018, Figure 12) and pin 1 on engine harness connector V-C13 (WP 0018, Figure 165).

0022-115

1. If continuity is found, proceed to step 21. 2. If continuity is NOT found, replace main engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION A/C Compressor will Not Engage - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

21. Using digital multimeter (WP 0296), test for continuity between pin 5 on engine harness connector V-C1 (WP 0018, Figure 12) and pin 2 on engine harness connector V-C13 (WP 0018, Figure 165).

1. If continuity is found, proceed to step 22. 2. If continuity is NOT found, replace main engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

22. Using digital multimeter (WP 0296), test for continuity between pin 7 on engine harness connector V-C1 (WP 0018, Figure 12) and all other pins in engine harness connector V-C1 (WP 0018, Figure 12).

1. If continuity is NOT found, proceed to step 23. 2. If continuity is found, replace main engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

23. Disconnect instrument panel harness connector E-C14 (WP 0018, Figure 166) from blower motor harness connector EE-C8 (WP 0018, Figure 167). 24. Using digital multimeter (WP 0296), test for continuity between pin 6 on instrument panel harness connector E-C14 (WP 0018, Figure 166) and pin 5 on platform harness connector MA-C22 (WP 0018, Figure 11).

1. If continuity is found, proceed to step 25. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

25. Using digital multimeter (WP 0296), test for continuity between pin 2 on instrument panel harness connector E-C14 (WP 0018, Figure 166) and ground.

1. If continuity is found, proceed to step 26. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

26. Using digital multimeter (WP 1. If continuity is NOT found, pro0296), test for continuity between ceed to step 27. pin 5 on platform harness connec- 2. If continuity is found, replace plattor MA-C22 (WP 0018, Figure 11) form harness (WP 0209) and and all other pins in platform harinstrument panel harness (WP ness connector MA-C22 (WP 0260). Ensure all harness con0018, Figure 11). nectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022-116

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

The A/C Compressor will Not Engage - Continued

27. Using digital multimeter (WP 0296), test for continuity between pin 2 on blower motor harness connector EE-C8 (WP 0018, Figure 167) and pin 6 on blower motor harness connector EE-C8 (WP 0018, Figure 167).

CORRECTIVE ACTION 1. If continuity is found, proceed to step 32. 2. If continuity is NOT found, proceed to step 28.

28. Disconnect 522 WHITE thermostat switch connector (WP 0018, Figure 168) from thermostat switch. 29. Using digital multimeter (WP 0296), test for continuity between pin 6 on blower motor harness connector EE-C8 (WP 0018, Figure 167) and 522 WHITE thermostat switch connector (WP 0018, Figure 168).

1. If continuity is found, proceed to step 30. 2. If continuity is NOT found, replace blower motor harness (WP 0219). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

30. Disconnect 200 BLACK thermostat switch connector (WP 0018, Figure 169) from thermostat switch. 31. Using digital multimeter (WP 1. If continuity is found, replace ther0296), test for continuity between mostat switch (WP 0219). Ensure pin 2 on blower motor harness all harness connectors are reconconnector EE-C8 (WP 0018, Fignected. Verify correct operation of ure 167) and 200 BLACK thermomachine (TM 5-2410-241-10). stat switch connector (WP 0018, 2. If continuity is NOT found, replace Figure 169). blower motor harness (WP 0219). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

0022-117

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

The A/C Compressor will Not Engage - Continued

32. Disconnect instrument panel harness connector E-C21 (WP 0018, Figure 170) from A/C switch (Figure 13, Item 1). 33. Using digital multimeter (WP 0296), test for continuity between pin 3 on instrument panel harness connector E-C21 (WP 0018, Figure 107) and pin 7 on platform harness connector MA-C22 (WP 0018, Figure 11).

Figure 13. A/C Switch.

0022-118

0022

CORRECTIVE ACTION

1. If continuity is found, proceed to step 34. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

The A/C Compressor will Not Engage - Continued

34. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 35. Using digital multimeter (WP 0296), measure for voltage between pin 3 on instrument panel harness connector E-C21 (WP 0018, Figure 170) and ground.

CORRECTIVE ACTION

1. If 24 Volts is found, replace A/C switch. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If voltage is NOT found, proceed to step 36.

36. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 37. Disconnect instrument panel harness connector E-C2 (WP 0018, Figure 171) from blower motor speed switch. 38. Using digital multimeter (WP 0296), test for continuity between pin 2 on instrument panel harness A/C switch connector E-C21 (WP 0018, Figure 170) and pin 2 on instrument panel harness blower motor speed switch connector EC2 (WP 0018, Figure 171).

1. If continuity is found, proceed to step 39. 2. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

39. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 40. Using digital multimeter (WP 0296), measure for voltage between pin 1 on instrument panel harness blower motor speed switch connector E-C2 (WP 0018, Figure 171) and ground. 41. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 42. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22).

0022-119

1. If 24 Volts is found, replace blower motor switch. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If voltage is NOT found, proceed to step 41.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

The A/C Compressor will Not Engage - Continued

43. Using digital multimeter (WP 0296), test for continuity between pin 36 on platform harness connector MA-C3 (WP 0018, Figure 21) and pin 1 on instrument panel harness blower motor speed switch connector E-C2 (WP 0018, Figure 171).

1. If continuity is found, proceed to step 44. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

44. Using digital multimeter (WP 0296), test for continuity between pin 36 on platform harness connector MA-C3 (WP 0018, Figure 21) and all other pins in platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is NOT found, proceed to step 45. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

45. Remove fuse box (WP 0176). 46. Using digital multimeter (WP 0296), test for continuity between pin 36 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and 124 GREEN fuse panel wire harness blower motor circuit breaker connector (WP 0018, Figure 172).

1. If continuity is found, proceed to step 47. 2. If continuity is NOT found, replace fuse panel wiring harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

47. Using digital multimeter (WP 1. If continuity is NOT found, pro0296), test for continuity between ceed to step 48. pin 36 on fuse panel wiring har2. If continuity is found, replace fuse ness connector A-C1 (WP 0018, panel wiring harness (WP 0176). Figure 22) and all other pins in Ensure all harness connectors fuse panel wiring harness connecare reconnected. Verify correct tor A-C1 (WP 0018, Figure 22). operation of machine (TM 5-2410241-10).

0022-120

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

The A/C Compressor will Not Engage - Continued

48. Using digital multimeter (WP 0296), test for continuity between 112 PURPLE blower motor supply power wire on plug 1 (WP 0018, Figure 174) and 112 PURPLE blower motor supply power wire on plug 2 (WP 0018, Figure 174).

1. If continuity is found, replace blower motor circuit breaker (WP 0176). Reinstall fuse box (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace 112 purple blower motor supply power wire (WP 0176).Reinstall fuse box (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

Blower Motor Does NOT Function in One or More Speeds

1. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 2. Inspect operation of blower motor (TM 5-2410-241-10). a. Turn blower motor switch to LOW (SPEED 1). b. Turn blower motor switch to MED (SPEED 2). c. Turn blower motor switch to HIGH (SPEED 3). d. Turn blower motor switch to MAX (SPEED 4).

3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Disconnect instrument panel harness connector E-C2 (WP 0018, Figure 171) from blower motor speed switch. 5. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0022-121

1. If blower motor does NOT operate in ANY SPEED, proceed to step 3. 2. If blower motor does NOT operate in LOW (SPEED 1), proceed to step 32. 3. If blower motor does NOT operate in MED (SPEED 2), proceed to step 44. 4. If blower motor does NOT operate in HIGH (SPEED 3), proceed to step 56. 5. If blower motor does NOT operate in MAX (SPEED 4), proceed to step 68. 6. If blower motor operation is OK, problem does NOT exist at this time. Resume normal operation.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Blower Motor Does NOT Function in One or More Speeds - Continued

TEST OR INSPECTION 6. Using digital multimeter (WP 0296), measure for voltage between pin 1 on instrument panel harness connector E-C2 (WP 0018, Figure 171) and ground.

CORRECTIVE ACTION 1. If 24 Volts is found, proceed to step 15. 2. If voltage is NOT found, proceed to step 7.

7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22). 9. Using digital multimeter (WP 0296), test for continuity between pin 36 on platform harness connector MA-C3 (WP 0018, Figure 21) and pin 1 on instrument panel harness connector E-C2 (WP 0018, Figure 171).

1. If continuity is found, proceed to step 10. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

10. Using digital multimeter (WP 0296), test for continuity between pin 36 on platform harness connector MA-C3 (WP 0018, Figure 21) and all other pins in platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is NOT found, proceed to step 11. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

11. Remove fuse box (WP 0176). 12. Using digital multimeter (WP 0296), test for continuity between pin 36 on fuse panel wiring harness connector A-C1(WP 0018, Figure 22) and 124 GREEN fuse panel wire harness blower motor circuit breaker connector (WP 0018, Figure 172).

0022-122

1. If continuity is found, proceed to step 13. 2. If continuity is NOT found, replace fuse panel wiring harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Blower Motor Does NOT Function in One or More Speeds - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

13. Using digital multimeter (WP 1. If continuity is NOT found, pro0296), test for continuity between ceed to step 14. pin 36 on fuse panel wiring har2. If continuity is found, replace fuse ness connector A-C1 (WP 0018, panel wiring harness (WP 0176). Figure 22) and all other pins in Ensure all harness connectors fuse panel wiring harness connecare reconnected. Verify correct tor A-C1 (WP 0018, Figure 22). operation of machine (TM 5-2410241-10). 14. Using digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between blower motor circuit breaker (WP POINT A on 112 PURPLE blower 0176). Reinstall fuse box (WP motor supply power wire (WP 0176). Ensure all harness con0018, Figure 174) and POINT B nectors are reconnected. Verify on 112 PURPLE blower motor correct operation of machine (TM supply power wire (WP 0018, Fig5-2410-241-10). ure 174). 2. If continuity is NOT found, replace 112 PURPLE blower motor supply power wire (WP 0176). Reinstall fuse box (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 15. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 16. Connect instrument panel harness blower motor speed switch connector E-C2 (WP 0018, Figure 171) to blower motor speed switch. 17. Disconnect instrument panel harness connector E-C14 (WP 0018, Figure 166) from blower motor harness connector EE-C8 (WP 0018, Figure 167). 18. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 19. Turn blower motor switch to LOW (SPEED 1) (TM 5-2410-241-10).

0022-123

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

Blower Motor Does NOT Function in One or More Speeds - Continued

20. Using digital multimeter (WP 0296), measure for voltage between pin 5 on instrument panel harness connector E-C14 (WP 0018, Figure 166) and pin 2 on instrument panel harness connector E-C14 (WP 0018, Figure 166).

CORRECTIVE ACTION 1. If 24 Volts is found, proceed to step 25. 2. If voltage is NOT found, proceed to step 21.

21. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 22. Using digital multimeter (WP 0296), test for continuity between pin 2 on instrument panel harness connector E-C14 (WP 0018, Figure 166) and ground

1. If continuity is found, proceed to step 23. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

23. Disconnect instrument panel harness blower motor speed switch connector E-C2 (WP 0018, Figure 171) from blower motor speed switch. 24. Using digital multimeter (WP 0296), test for continuity between pin 3 on instrument panel harness blower motor speed switch connector E-C2 (WP 0018, Figure 171) and pin 5 on instrument panel harness connector E-C14 (WP 0018, Figure 166), 25. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 26. Remove blower motor (WP 0227). 27. Disconnect blower motor harness resistor connector EE-C3 (WP 0018, Figure 174) from blower motor resistor.

0022-124

1. If continuity is found, proceed to step 25. 2. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Blower Motor Does NOT Function in One or More Speeds - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

28. Using digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 29. terminal 1 on blower motor har2. If continuity is NOT found, replace ness resistor connector EE-C3 blower motor harness (WP 0219). (WP 0018, Figure 174) and pin 5 Ensure all harness connectors on blower motor harness connecare reconnected. Verify correct tor EE-C8 (WP 0018, Figure 167). operation of machine (TM 5-2410241-10). 29. Disconnect blower motor harness blower motor connector EE-C4 (WP 0018, Figure 175) from blower motor. 30. Using digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 31. terminal 4 on blower motor har2. If continuity is NOT found, replace ness resistor connector EE-C3 blower motor harness (WP 0219). (WP 0018, Figure 174) and termiEnsure all harness connectors nal 1 on blower motor harness are reconnected. Verify correct blower motor connector EE-C4 operation of machine (TM 5-2410(WP 0018, Figure 175). 241-10). 31. Using digital multimeter (WP 0296), measure resistance between terminal 1 and terminal 4 on blower motor resistor (WP 0018, Figure 176).

32. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 33. Disconnect instrument panel harness connector E-C14 (WP 0018, Figure 166) from blower motor harness connector EE-C8 (WP 0018, Figure 167). 34. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 35. Turn blower motor switch to LOW (SPEED 1) (TM 5-2410-241-10).

0022-125

1. If resistance of 2.8 - 3.0 Ohms is found, replace blower motor. Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If resistance of 2.8 - 3.0 Ohms is NOT found, replace blower motor resistor (WP 0219). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

Blower Motor Does NOT Function in One or More Speeds - Continued

36. Using digital multimeter (WP 0296), measure for voltage between pin 5 on instrument panel harness connector E-C14 (WP 0018, Figure 166) and pin 2 on instrument panel harness connector E-C14 (WP 0018, Figure 166).

CORRECTIVE ACTION 1. If 24 Volts is found, proceed to step 40. 2. If voltage is NOT found, proceed to step 37.

37. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 38. Disconnect instrument panel harness blower motor speed switch connector E-C2 (WP 0018, Figure 171) from blower motor speed switch. 39. Using digital multimeter (WP 0296), test for continuity between pin 3 on instrument panel harness blower motor speed switch connector E-C2 (WP 0018, Figure 171) and pin 5 on instrument panel harness connector E-C14 (WP 0018, Figure 166).

40. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 41. Remove blower motor (WP 0227). 42. Disconnect blower motor harness resistor connector EE-C3 (WP 0018, Figure 174) from blower motor resistor.

0022-126

1. If continuity is found, replace blower motor switch (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Blower Motor Does NOT Function in One or More Speeds - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

43. Using digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between blower motor resistor (WP 0219). terminal 1 on blower motor harEnsure all harness connectors ness resistor connector EE-C3 are reconnected. Verify correct (WP 0018, Figure 174) and pin 5 operation of machine (TM 5-2410on blower motor harness connec241-10). tor EE-C8 (WP 0018, Figure 167). 2. If continuity is NOT found, replace blower motor harness (WP 0219). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 44. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 45. Disconnect instrument panel harness connector E-C14 (WP 0018, Figure 166) from blower motor harness connector EE-C8 (WP 0018, Figure 167). 46. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 47. Turn blower motor switch to MED (SPEED 2) (TM 5-2410-241-10). 48. Using digital multimeter (WP 0296), measure for voltage between pin 4 on instrument panel harness connector E-C14 (WP 0018, Figure 166) and pin 2 on instrument panel harness connector E-C14 (WP 0018, Figure 166). 49. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 50. Disconnect instrument panel harness connector E-C2 (WP 0018, Figure 171) from blower motor speed switch.

0022-127

1. If 24 Volts is found, proceed to step 52. 2. If voltage is NOT found, proceed to step 49.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Blower Motor Does NOT Function in One or More Speeds - Continued

51. Using digital multimeter (WP 0296), test for continuity between pin 4 on instrument panel harness connector E-C2 (WP 0018, Figure 171) and pin 4 on instrument panel harness connector E-C14 (WP 0018, Figure 166).

1. If continuity is found, replace blower motor switch (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

52. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 53. Remove blower motor (WP 0227). 54. Disconnect blower motor harness resistor connector EE-C3 (WP 0018, Figure 174) from blower motor resistor. 55. Using digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between blower motor resistor (WP 0219). pin B on blower motor harness Ensure all harness connectors resistor connector (WP 0018, Figare reconnected. Verify correct ure 174) and pin 4 on blower operation of machine (TM 5-2410motor harness connector EE-C8 241-10). (WP 0018, Figure 167). 2. If continuity is NOT found, replace blower motor harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 56. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 57. Disconnect instrument panel harness connector E-C14 (WP 0018, Figure 166) from blower motor harness connector EE-C8 (WP 0018, Figure 167). 58. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 59. Turn blower motor switch to HIGH (SPEED 3) (TM 5-2410-241-10).

0022-128

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

Blower Motor Does NOT Function in One or More Speeds - Continued

60. Using digital multimeter (WP 0296), measure for voltage between pin 1 on instrument panel harness connector E-C14 (WP 0018, Figure 166) and pin 2 on instrument panel harness connector E-C14 (WP 0018 Figure 166).

CORRECTIVE ACTION 1. If 24 Volts is found, proceed to step 64. 2. If voltage is NOT found, proceed to step 61.

61. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 62. Disconnect instrument panel harness blower motor speed switch connector E-C2 (WP 0018, Figure 171) from blower motor speed switch. 63. Using digital multimeter (WP 0296), test for continuity between pin 5 on instrument panel harness blower motor speed switch connector E-C2 (WP 0018, Figure 171) and pin 1 on instrument panel harness connector E-C14 (WP 0018, Figure 166).

64. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 65. Remove blower motor (WP 0227). 66. Disconnect blower motor harness resistor connector EE-C3 (WP 0018, Figure 174) from blower motor resistor.

0022-129

1. If continuity is found, replace blower motor switch (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Blower Motor Does NOT Function in One or More Speeds - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

67. Using digital multimeter (WP 1. If continuity is found, replace 0296), test for continuity between blower motor resistor (WP 0219). pin C on blower motor harness Ensure all harness connectors resistor connector (WP 0018, Figare reconnected. Verify correct ure 174) and pin 1 on blower operation of machine (TM 5-2410motor harness connector EE-C8 241-10). (WP 0018, Figure 167). 2. If continuity is NOT found, replace blower motor harness (WP 0219). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 68. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 69. Disconnect instrument panel harness connector E-C14 (WP 0018, Figure 166) from blower motor harness connector EE-C8 (WP 0018, Figure 167). 70. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 71. Turn blower motor switch to MAX (SPEED 4) (TM 5-2410-241-10). 72. Using digital multimeter (WP 0296), measure for voltage between pin 3 on instrument panel harness connector E-C14 (WP 0018, Figure 166) and pin 2 on instrument panel harness connector E-C14 (WP 0018, Figure 166). 73. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 74. Disconnect instrument panel harness blower motor speed switch connector E-C2 (WP 0018, Figure 171) from blower motor speed switch.

0022-130

1. If 24 Volts is found, proceed to step 76. 2. If voltage is NOT found, proceed to step 73.

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

Blower Motor Does NOT Function in One or More Speeds - Continued

75. Using digital multimeter (WP 0296), test for continuity between pin 6 on instrument panel harness blower motor speed switch connector E-C2 (WP 0018, Figure 171) and pin 3 on instrument panel harness connector E-C14 (WP 0018, Figure 166).

1. If continuity is found, replace blower motor switch (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 2. If continuity is NOT found, replace instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

76. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 77. Disconnect blower motor harness blower motor connector EE-C4 (WP 0018, Figure 175) from blower motor.

No Power with Ignition Switch ON

78. Using digital multimeter (WP 0296), test for continuity between pin 3 on blower motor harness connector EE-C8 (WP 0018, Figure 167) and pin 2 on blower motor harness blower motor connector EE-C4 (WP 0018, Figure 175).

1. If continuity is found, verify correct operation of blower (TM 5-2410241-10). 2. If continuity is NOT found, replace blower motor harness (WP 0219). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

1. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

1. If no power with ignition switch ON, proceed to step 2. 2. If ignition switch operation is OK, problem does NOT exist at this time. Resume normal operation.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Check batteries (WP 0030).

0022-131

1. If batteries are OK, proceed to step 4. 2. If batteries are NOT OK, replace batteries (WP 0157). Verify correct operation of machine (TM 52410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION No Power with Ignition Switch ON - Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

4. Remove Fuse #14 (Figure 14, Item 1) from fuse panel (TM 52410-241-10).

Figure 14. Fuse #14. 5. Using digital multimeter (WP 0296), test for continuity between blades of Fuse #14.

6. Turn battery disconnect switch to ON position (TM 5-2410-241-10). 7. Turn battery disconnect switch to OFF position (TM 5-2410-24110).

0022-132

0022

1. If continuity is found, install Fuse #14 on fuse panel (TM 5-2410241-10). Proceed to step 14. 2. If continuity is NOT found, replace Fuse #14 (TM 5-2410-241-10). Proceed to step 6.

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION No Power with Ignition Switch ON - Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

8. Remove Fuse #14 (Figure 15, Item 1) from fuse panel (TM 52410-241-10).

Figure 15. Fuse #14. 9. Using digital multimeter (WP 0296), test for continuity between blades of Fuse #14.

10. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 11. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 12. Remove Fuse #14 (Figure 15, Item 1) from fuse panel (TM 52410-241-10).

0022-133

0022

1. If continuity is found, install Fuse #14 on fuse panel (TM 5-2410241-10). Proceed to step 10. 2. If continuity is NOT found, replace Fuse #14 (TM 5-2410-241-10). Proceed to step 14.

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION No Power with Ignition Switch ON - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

13. Using digital multimeter (WP 0296), test for continuity between blades of Fuse #14.

1. If continuity is found and machine has power, install Fuse #14 on fuse panel (TM 5-2410-241-10). Resume normal operation. 2. If continuity is found and machine still has no power, install Fuse #14 on fuse panel (TM 5-2410-24110). Proceed to step 14. 3. If continuity is NOT found, replace Fuse #14 (TM 5-2410-241-10). Proceed to step 23.

14. Disconnect instrument panel harness ignition switch connector EC6 (WP 0018, Figure 163) from ignition switch. 15. Turn battery disconnect switch to ON position (TM 5-2410-241-10). 16. Using digital multimeter (WP 1. If 24 Volts is found, replace igni0296), measure for voltage tion switch (WP 0262). Ensure all between pin 4 on instrument harness connectors are reconpanel harness ignition switch connected. Verify correct operation of nector E-C6 (WP 0018, Figure machine (TM 5-2410-241-10). 163) and ground. 2. If 24 Volts is NOT found, proceed to step 17. 17. Turn battery disconnect switch to OFF position (TM 5-2410-24110). 18. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22). 19. Using digital multimeter (WP 0296), test for continuity between pin 19 on platform harness connector MA-C3 (WP 0018, Figure 21) and pin 4 on instrument panel harness ignition switch connector E-C6 (WP 0018, Figure 163).

0022-134

1. If continuity is found, proceed to step 20. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION No Power with Ignition Switch ON - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

20. Using digital multimeter (WP 0296), test for continuity between pin 19 on platform harness connector MA-C3 (WP 0018, Figure21) and all other pins in platform harness connector MAC3 (WP 0018 Figure 21).

1. If continuity is NOT found, proceed to step 21. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

21. Using digital multimeter (WP 0296), test for continuity between pin 19 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and right cavity of fuse #14 (Figure 23, item 2).

1. If continuity is found, proceed to step 22. 2. If continuity is NOT found, replace fuse panel wiring harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

22. Using digital multimeter 1. If continuity is NOT found, replace (WP 0296), test for continuity ignition switch (WP 0262). Ensure between pin 19 on fuse panel wirall harness connectors are reconing harness connector A-C1 nected. Verify correct operation of (WP 0018, Figure 22) and ground. machine (TM 5-2410-241-10). 2. If continuity is found, replace fuse panel wiring harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10). 23. Drop instrument panel and disconnect instrument panel harness ignition switch connector E-C6 (WP 0018, Figure 163) from ignition switch. 24. Disconnect engine harness connector V-C1 (WP 0018, Figure 12) from platform harness connector MA-C22 (WP 0018, Figure 11). 25. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22).

0022-135

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION No Power with Ignition Switch ON - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

26. Disconnect powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34) from platform harness connector MA-C14 (WP 0018, Figure 33). 27. Using digital multimeter (WP 0296), test for continuity between pin 1 on instrument panel harness ignition switch connector E-C6 (WP 0018, Figure 163) and pin 70 on platform harness connector MA-C14 (WP 0018, Figure 33)

1. If continuity is found, proceed to step 28. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

28. Using digital multimeter (WP 0296), test for continuity between pin 70 on platform harness connector MA-C14 (WP 0018, Figure 33) and all other pins in platform harness connector MA-C14 (WP 0018, Figure 33).

1. If continuity is NOT found, proceed to step 29. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

29. Using digital multimeter (WP 0296), test for continuity between pin 1 on instrument panel harness ignition switch connector E-C6 (WP 0018, Figure 163) and pin 26 on platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is found, proceed to step 30. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

30. Using digital multimeter (WP 0296), test for continuity between pin 26 on platform harness connector MA-C3 (WP 0018, Figure 21) and all other pins in platform harness connector MA-C3 (WP 0018, Figure 21).

1. If continuity is NOT found, proceed to step 31. 2. If continuity is found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

0022-136

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION No Power with Ignition Switch ON - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

31. Using digital multimeter (WP 0296), test for continuity between pin 1 on instrument panel harness ignition switch connector E-C6 (WP 0018, Figure 163) and pin 4 on platform harness connector MA-C22 (WP 0018, Figure 11).

1. If continuity is found, proceed to step 32. 2. If continuity is NOT found, replace platform harness (WP 0209) and instrument panel harness (WP 0260). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

32. Using digital multimeter (WP 1. If continuity is NOT found, pro0296), test for continuity between ceed to step 33. pin 4 on platform harness connec- 2. If continuity is found, replace plattor MA-C22 (WP 0018 Figure 11) form harness (WP 0209) and and all other pins in platform harinstrument panel harness (WP ness connector MA-C22 (WP 0260). Ensure all harness con0018, Figure 11). nectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 33. Disconnect engine ECM connector V-C4 (WP 0018, Figure 1) from ECM. 34. Using digital multimeter (WP 0296), test for continuity between pin 4 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and pin 70 on engine ECM connector V-C4 (WP 0018, Figure 1).

1. If continuity is found, proceed to step 35. 2. If continuity is NOT found, replace main engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

35. Using digital multimeter (WP 0296), test for continuity between pin 4 on engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12) and all other pins in engine harness (engine to platform) connector V-C1 (WP 0018, Figure 12).

1. If continuity is NOT found, proceed to step 36. 2. If continuity is found, replace main engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

36. Disconnect powertrain ECM connector X-C2 (WP 0018, Figure 4) from powertrain ECM.

0022-137

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION No Power with Ignition Switch ON - Continued

TEST OR INSPECTION

CORRECTIVE ACTION

37. Using digital multimeter (WP 0296), test for continuity between pin 1 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and pin 70 on powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 38. 2. If continuity is NOT found, replace steering harness (WP 0178). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

38. Using digital multimeter (WP 0296), test for continuity between pin 14 on powertrain ECM connector X-C2 (WP 0018, Figure 4) and pin 70 on powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is found, proceed to step 39. 2. If continuity is NOT found, replace steering harness (Figure 166). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

39. Using digital multimeter (WP 0296), test for continuity between pin 70 on powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34) and all other pins in powertrain ECM steering harness connector X-C1 (WP 0018, Figure 34).

1. If continuity is NOT found, proceed to step 40. 2. If continuity is found, replace steering harness (Figure 166). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

40. Remove fuse panel from machine (WP 0176). 41. Disconnect fuse panel harness main power relay connector A-C2 (WP 0018, Figure 177) from main power relay (WP 0018, Figure 178). 42. Using digital multimeter (WP 0296), test for continuity between pin 26 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and pin 1 on fuse panel harness main power relay connector A-C2 (WP 0018, Figure 177).

1. If continuity is found, proceed to step 43. 2. If continuity is NOT found, replace fuse panel wiring harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

43. Using digital multimeter (WP 1. If continuity is NOT found, pro0296), test for continuity between ceed to step 44. pin 26 on fuse panel wiring har2. If continuity is found, replace fuse ness connector A-C1 (WP 0018, panel wiring harness (WP 0176). Figure 22) and all other pins in Ensure all harness connectors fuse panel wiring harness connecare reconnected. Verify correct tor A-C1 (WP 0018, Figure 22). operation of machine (TM 5-2410241-10).

0022-138

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION No Power with Ignition Switch ON - Continued

Ether Aid Does Not Work

TEST OR INSPECTION

CORRECTIVE ACTION

44. Using digital multimeter (WP 0296), test for continuity between pin 10 on fuse panel wiring harness connector A-C1 (WP 0018, Figure 22) and PIN 2 on fuse panel harness main power relay connector A-C2 (WP 0018, Figure 177).

1. If continuity is NOT found, proceed to step 45. 2. If continuity is found, replace fuse panel wiring harness (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

45. Using digital multimeter (WP 0296), measure resistance between pins 1 and 2 on main power relay connector (WP 0018, Figure 178).

1. If resistance of 50.5 to 51.5 ohms NOT found, replace main power relay (WP 0176). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If resistance of 50.5 to 51.5 ohms is found, replace ignition switch (WP 0262). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

1. Connect MSD (WP 0016). Select 3176C D7 engine ECM and check for diagnostic codes or event codes (WP 0013)

1. If any active codes are present, troubleshoot the applicable code(s) (WP 0013). 2. If no active codes are present, proceed to step 2.

2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 3. Disconnect engine harness ether injector solenoid connector V-C2 (WP 0018, Figure 179) from ether injector solenoid (WP 0060). 4. Install digital multimeter (WP 0296) leads in Plug 1 and Plug 2 on engine harness ether injector solenoid connector V-C2 (WP 0018, Figure 179). 5. Remove ether bottle (WP 0060).

0022-139

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Ether Aid Does NOT Work Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

6. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 7. Using MSD, select 3176C D7 engine ECM on left side of screen. Select diagnostics (Figure 16, Item 1), diagnostics test (Figure 16, Item 2), and override parameter (Figure 16, Item 3).

Figure 16. Ether Override Parameters.

0022-140

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Ether Aid Does NOT Work Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

8. Highlight ether injection (Figure 17, Item 2) and select CHANGE button (Figure 17, Item 1).

Figure 17. Select Ether Injection.

0022-141

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Ether Aid Does NOT Work Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

NOTE Measurement must be taken within 10 seconds of selecting YES. 9. Select drop down arrow, highlight ON (Figure 18, Item 1), select OK button (Figure 18, Item 2). Select Yes button (Figure 18, Item 3) to change parameter.

Figure 18. Selection Box and Yes Box.

0022-142

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Ether Aid Does NOT Work Continued

0022

TEST OR INSPECTION

CORRECTIVE ACTION

10. Using digital multimeter (WP 0296), measure for voltage between pins 1 and 2 on engine harness ether injector solenoid connector V-C2 (WP 0018, Figure 179).

1. If 24 Volts is found, replace ether aid solenoid (WP 0060). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If 24 Volts is NOT found, proceed to step 11.

11. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 12. Remove digital multimeter (WP 0296) leads from Plug 1 and Plug 2 on engine harness ether injector solenoid connector V-C2 (WP 0018, Figure 179). 13. Remove Fuse #1 (Figure 19, Item 1) from fuse panel (TM 52410-241-10).

Figure 19. Fuse #1 14. Using digital multimeter (WP 0296), test for continuity between blades of Fuse #1.

0022-143

0022

1. If continuity is found, install Fuse #1 on fuse panel (TM 5-2410-24110). Proceed to step 22. 2. If continuity is NOT found, replace Fuse #1 (TM 5-2410-241-10). Proceed to step 15.

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Ether Aid Does NOT Work Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

15. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10). 16. Using MSD, select 3176C D7 engine ECM on left side of screen. Select diagnostics (Figure 20, Item 1), diagnostics test (Figure 20, Item 2), override parameter (Figure 20, Item 3).

Figure 20. Ether Override Parameters.

0022-144

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Ether Aid Does NOT Work Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

17. Highlight ether injection (Figure 21, Item 2) and select CHANGE button (Figure 21, Item 1).

Figure 21. Select Ether Injection.

0022-145

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Ether Aid Does NOT Work Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

18. Select drop down arrow, highlight ON (Figure 22, Item 1), select OK button (Figure 22, Item 2). Select Yes button (Figure 22, Item 3) to change parameter.

Figure 22. Selection Box and Yes Box. 19. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

0022-146

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Ether Aid Does NOT Work Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

20. Remove Fuse #1 (Figure 23, Item 1) from fuse panel (TM 52410-241-10).

Figure 23. Fuse #1. 21. Using digital multimeter (WP 0296), test for continuity between blades of Fuse #1.

22. Disconnect engine harness ether relay connector V-C18 (WP 0018, Figure 43) from ether relay. 23. Turn battery disconnect switch and ignition switch to ON position (TM 5-2410-241-10).

0022-147

0022

1. If continuity is found, replace ether aid solenoid (WP 0060). Install Fuse #1 on fuse panel (TM 5-2410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace main engine harness (WP 0055). Replace Fuse #1 (TM 5-2410241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Ether Aid Does NOT Work Continued

TEST OR INSPECTION

CORRECTIVE ACTION

24. Using digital multimeter (WP 0296), measure for voltage between pin 1 on engine harness ether relay connector V-C18 (WP 0018, Figure 43) and ground.

1. If 24 Volts is found, proceed to step 25. 2. If 24 Volts is NOT found, proceed to step 28.

25. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 26. Using digital multimeter (WP 0296), test for continuity between pin 4 on engine harness ether relay connector V-C18 (WP 0018, Figure 43) and pin 1 engine harness ether injector solenoid connector V-C2 (WP 0018, Figure 179).

1. If continuity is found, proceed to step 27. 2. If continuity is NOT found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

27. Using digital multimeter (WP 0296), test for continuity pin 2 on engine harness ether injector solenoid connector V-C2 (WP 0018, Figure 179) and ground.

1. If continuity is found, replace ether aid relay (WP 0060). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10). 2. If continuity is NOT found, replace engine harness (WP 0055). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410241-10).

28. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 29. Disconnect platform harness connector MA-C22 (WP 0018, Figure 11) from engine harness connector V-C1 (WP 0018, Figure 12). 30. Using digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 31. pin 24 on engine harness connec- 2. If continuity is NOT found, replace tor V-C1 (WP 0018, Figure 12) engine harness (WP 0055). and pin 1 engine harness ether Ensure all harness connectors relay connector V-C18 (WP 0018, are reconnected. Verify correct Figure 43). operation of machine (TM 5-2410241-10). 31. Disconnect platform harness connector MA-C3 (WP 0018, Figure 21) from fuse panel wiring harness connector A-C1 (WP 0018, Figure 22).

0022-148

0022

TM 5-2410-241-23-1

0022

Table 1. Cab Troubleshooting Procedures - Continued. MALFUNCTION Ether Aid Does NOT Work Continued

TEST OR INSPECTION

0022

CORRECTIVE ACTION

32. Using digital multimeter (WP 1. If continuity is found, proceed to 0296), test for continuity between step 33. pin 1 on platform harness connec- 2. If continuity is NOT found, replace tor MA-C3 (WP 0018, Figure 21) platform harness (WP 0209). and pin 24 platform harness conEnsure all harness connectors nector MA-C22 (WP 0018, Figure are reconnected. Verify correct 11). operation of machine (TM 5-2410241-10). 33. Remove Fuse #1 (Figure 24, Item 1) from fuse panel (TM 5-2410241-10).

Figure 24. Fuse #1. Ether Aid Does NOT Work Continued

0022

34. Using digital multimeter (WP 1. If continuity is found, Replace 0296), test for continuity between Fuse #1 (TM 5-2410-241-10). pin 1 on fuse panel wiring harness Ensure all harness connectors connector A-C1 (WP 0018, Figure are reconnected. Verify correct 22) and left cavity of Fuse #1 (Figoperation of machine (TM 5-2410ure 24, Item 1). 241-10). 2. If continuity is NOT found, replace fuse panel wiring harness (WP 0176). Replace Fuse #1 (TM 52410-241-10). Ensure all harness connectors are reconnected. Verify correct operation of machine (TM 5-2410-241-10).

END OF WORK PACKAGE

0022-149/(150 blank)

8 TM 5-2410-241-23-1

0023

FIELD MAINTENANCE

-

ENGINE MECHANICAL TESTS, INSPECTIONS, AND ADJUSTMENTS Manually Turning Engine by Hand, Finding Top Center Position for No. 1 and No. 6 Piston, Inspecting Vibration Damper, Testing and Inspecting Drive Belts and Pulley, Inspecting Cylinder Head 0 0 2

3

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Engine Turning Tool, Gear Group (WP 0302, Item 23) Handle, Ratchet, 3/4” DR, 17" Long KTC S0374 (WP 0302, Item 68) Pin, Straight Headed (WP 0302, Item 43) Adapter (Timing Pin) (WP 0302, Item 6) Timing Pin, Engine (WP 0302, Item 63) 0

0

0

0

0

0

Materials/Parts Rag, Wiping (WP 0303, Item 24) O-ring

0

0

0

References WP 0080 WP 0095 WP 0096 WP 0097 WP 0098 WP 0099 WP 0101 WP 0102 WP 0106 WP 0199 WP 0202 WP 0256 Equipment Condition Machine parked (TM 5-2410-240-10)

0023-1

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

TM 5-2410-241-23-1

MANUALLY TURNING ENGINE BY HAND

0023

00023

1. Remove engine enclosure left door guard (WP 0202). 2. Remove two bolts (Figure 1, Item 3), washers (Figure 1, Item 4), cover (Figure 1, Item 2) and O-ring (Figure 1, Item 5) from flywheel housing (Figure 1, Item 1). Discard O-ring.

CAUTION Never turn the engine by the crankshaft vibration damper. The crankshaft vibration damper is a precision part. Major engine failure may be caused by damage to the crankshaft vibration damper. 3. Install engine turning tool in flywheel housing (Figure 1, Item 1) in location where cover (Figure 1, Item 2) was removed.

NOTE Engine must be turned in direction of normal rotation. Normal rotation of the engine is clockwise viewed from front crankshaft. 4. Using engine turning tool, turn the engine clockwise.

Figure 1. Engine Turning Tool. END OF TASK

0023-2

0023

TM 5-2410-241-23-1

0023

FINDING TOP CENTER POSITION FOR NO. 1 AND NO. 6 PISTON

00023

1. Remove engine enclosure left door guard (WP 0202). 2. Remove lower right bolt and rubber bushing from ECM (WP 0101). 3. Remove plug (Figure 2, Item 6) from flywheel housing (Figure 2, Item 1). 4. Install timing pin adapter and timing pin on flywheel housing (Figure 2, Item 1) in location where plug (Figure 2, Item 6) was removed. 5. Remove two bolts (Figure 2, Item 3), washers (Figure 2, Item 4), cover (Figure 2, Item 2) and O-ring (Figure 2, Item 5) from flywheel housing (Figure 2, Item 1). Discard O-ring.

CAUTION Never turn the engine by the crankshaft vibration damper. The crankshaft vibration damper is a precision part. Major engine failure may be caused by damage to the crankshaft vibration damper. 6. Install engine turning tool in flywheel housing (Figure 2, Item 1) in location where cover (Figure 2, Item 2) was removed.

NOTE Engine must be turned in direction of normal rotation. Normal rotation of the engine is clockwise viewed from front crankshaft. 7. Using engine turning tool, turn the engine clockwise. Continue rotation clockwise until hole in flywheel aligns with timing pin. Timing pin will engage automatically.

Figure 2. Timing Pin Plug.

0023-3

0023

TM 5-2410-241-23-1

0023

FINDING TOP CENTER POSITION FOR NO. 1 AND NO. 6 PISTON – CONTINUED 8. Remove valve mechanism cover (WP 0106). 9. To inspect if No.1 piston (Figure 3, Item 2) is at top center position on the compression or exhaust stroke, proceed to step 10. To inspect if No. 6 piston (Figure 3, Item 2) is at top center position on the compression or exhaust stroke, proceed to step 12. 10. No. 1 piston (Figure 3, Item 2) is on the compression stroke if inlet and exhaust valves for the No. 1 cylinder are fully closed and the rocker arms (Figure 3, Item 3) can be moved by hand. If the rocker arms cannot be moved and the valves are slightly open, the No. 1 piston is on the exhaust stroke. 11. When the actual stroke position is identified, and the other stroke position is needed: a. Remove the timing pin from the hole in the flywheel. b. Then turn the flywheel by 360 degrees in the direction of normal engine rotation. c.

Install the timing pin into the hole in the flywheel. Repeat step 10.

12. No. 6 piston (Figure 3, Item 1) is on the compression stroke if inlet and exhaust valves for the No. 6 cylinder are fully closed and the rocker arms (Figure 3, Item 3) can be moved by hand. If the rocker arms cannot be moved and the valves are slightly open, the No. 6 piston is on the exhaust stroke. 13. When the actual stroke position is identified, and the other stroke position is needed: a. Remove the timing pin from the hole in the flywheel. b. Then turn the flywheel by 360 degrees in the direction of normal engine rotation. c.

Install the timing pin into the hole in the flywheel. Repeat step 12.

14. Remove timing pin and timing pin adapter. 15. Install rubber bushing and lower right bolt on ECM (WP 0101). 16. Install plug (Figure 2, Item 6) on flywheel housing (Figure 2, Item 1).

Figure 3. Timing Top Center Position. END OF TASK

0023-4

0023

TM 5-2410-241-23-1

0023

INSPECTING VIBRATION DAMPER

00023

1. Remove front engine bottom guard (WP 0199).

CAUTION Never turn the engine by the crankshaft vibration damper. The crankshaft vibration damper is a precision part. Major engine failure may be caused by damage to the crankshaft vibration damper. 2. Inspect crankshaft damper (Figure 4, Item 1) for dents, bends, cracks or damage. a. If crankshaft damper is dented, bent, cracked, or damaged, replace crankshaft damper (WP 0080). b. If crankshaft damper is OK, proceed to step 3. 3. Using hands, inspect crankshaft damper (Figure 4, Item 1) for looseness or movement from pulley (Figure 4, Item 2), loose or missing bolts, or damage to pulley. a. If bolts are loose or missing, tighten or replace (WP 0080). b. If pulley is damaged, replace as necessary (WP 0080). c.

If crankshaft damper has movement, replace crankshaft damper (WP 0080).

d. If all crankshaft damper components are OK, return to troubleshooting. .

Figure 4. Vibration Damper. END OF TASK

0023-5

0023

TM 5-2410-241-23-1

0023

TESTING AND INSPECTING DRIVE BELTS AND PULLEY

00023

NOTE If new belt is installed, re-inspect belt after 30 minutes of operation. 1. Inspect belts (Figure 5, Item 2 and Item 4) for stretching, damage, cracking, glazing, or wear. a. Replace drive belt if damaged, stretched, glazed, or worn. Refer to alternator V-belt set (WP 0098) and A/C compressor V-belt (WP 0096). b. If drive belts are OK, proceed to step 3. 2. Inspect drive belts (Figure 5, Item 2 and Item 4) for more than four cracks per inch (25.4 mm). a. Replace drive belt if more than four cracks per inch (25.4 mm). Refer to alternator V-belt set (WP 0098) and A/C compressor V-belt (WP 0096). b. If drive belts are OK, proceed to step 4. 3. Loosen compressor (WP 0096), rotate A/C compressor pulley (Figure 5, Item 1), and inspect for smooth operation. a. If A/C compressor pulley does not rotate smoothly, replace A/C compressor (WP 0097). b. If A/C compressor is OK, proceed to step 4. 4. Loosen alternator (WP 0098), rotate alternator pulley (Figure 5, Item 5), and inspect for smooth operation. a. If alternator does not spin smoothly inspect alternator hub and pulley. Replace alternator (WP 0099). b. If alternator is OK, proceed to step 5. 5. Rotate fan hub (Figure 5, Item 3) and inspect for smooth operation. a. If fan hub does not rotate smoothly inspect fan hub. Refer to fan hub pulley inspection (WP 0095). b. If fan hub is OK, tighten alternator V-belt set (WP 0098) and A/C compressor V-belt (WP 0096) and return to troubleshooting.

0023-6

TM 5-2410-241-23-1

TESTING AND INSPECTING DRIVE BELTS AND PULLEY – CONTINUED

Figure 5. Drive Belt Inspection. END OF TASK

0023-7

0023

00023

0023

TM 5-2410-241-23-1

INSPECTING CYLINDER HEAD

0023

00023

1. Remove cylinder head from engine (WP 0103). 2. Inspect cylinder head (Figure 6) for signs of combustion gas or Class III coolant leakage. 3. Clean and inspect cylinder head (WP 0256). 4. Use a straight edge and a feeler gauge to test cylinder head for flatness. a. Measure from side to side (A). Maximum permissible distortion 0.0012 in. (0.03 mm). b. Measure from end to end (B). Maximum permissible distortion 0.0020 in. (0.05 mm). c.

Measure from corner to corner (C). Maximum permissible distortion 0.0020 in. (0.05 mm).

Figure 6. Cylinder Head Flatness Test. END OF TASK END OF WORK PACKAGE

0023-8

0023

6 TM 5-2410-241-23-1

0024

FIELD MAINTENANCE

-

ENGINE LUBRICATION TESTS, INSPECTIONS, AND ADJUSTMENTS Engine Oil Pressure Test, Excessive Engine Oil Consumption Inspection 0 0 2

4

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Adapter Kit Test (WP 0302, Item 5) Test Set, Electronic (MSD) (WP 0302, Item 62) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) References WP 0016 WP 0019 WP 0057 WP 0062 WP 0079 WP 0081

0

0

0

0

0

0

0

0

References - Continued WP 0082 WP 0083 WP 0084 WP 0086 WP 0087 WP 0088 WP 0089 WP 0091 WP 0114 WP 0202 WP 0304

0

0

0

0

0

0

0

0

0

0

0

0

0

Equipment Condition

0

0

0

0

0

0

0024-1

Machine parked (TM 5-2410-241-10) Estimated Time To Complete 1.5 Hr

0

0

0

TM 5-2410-241-23-1

0024

ENGINE OIL PRESSURE TEST

00024

1. Change engine oil (WP 0114), and replace engine oil filter (WP 0083). 2. Assemble pressure gauge and lines (WP 0304). 3. Remove dust cap (Figure 1, Item 1) from oil pressure port (Figure 1, Item 2). 4. Install pressure gauge on engine oil pressure port (Figure 1, Item 2). 5. Connect MSD (WP 0016). 6. Start engine (TM 5-2410-241-10). Allow engine to reach normal operating temperature. 7. With assistance, observe and record pressure on gauge at 1,400 rpm and 2,100 rpm: a. Minimum oil pressure at 1,400 rpm speed is 18 psi (124 kPa). b. Minimum oil pressure at 2,100 rpm speed is 28 psi (193 kPa). c.

Maximum oil pressure is 100 psi (689 kPa).

8. Turn ignition switch and battery disconnect switch to the OFF position (TM 5-2410-241-10). 9. Remove pressure gauge from engine oil pressure port (Figure 1, Item 2). 10. Install dust cap (Figure 1, Item 1) on oil pressure port (Figure 1, Item 2). 11. Compare actual engine oil pressure gauge to Cat Mil ET. Review recorded oil pressures as follows: a. If oil pressure is lower than 18 psi (124 kPa) at 1,400 rpm engine speed, refer to Low Oil Pressure in this work package. b. If oil pressure is lower than 28 psi (124 kPa) at 2,100 rpm engine speed, refer to Low Oil Pressure in this work package. c.

If oil pressure is higher than 100 psi (689 kPa), refer to High Oil Pressure in this work package.

d. If actual oil pressure gauge is within specification, but does not reflect value from Cat Mil ET, verify correct operation of Cat Mil ET. If measurements are still incorrect, replace oil pressure sensor (WP 0091).

Figure 1. Engine Oil Pressure Test Port.

0024-2

0024

TM 5-2410-241-23-1

0024

ENGINE OIL PRESSURE TEST – CONTINUED

00024

Low Oil Pressure

00024

CAUTION Do not operate the engine with low oil pressure, or contaminated engine oil. Engine damage will result. If measured oil pressure is low, discontinue engine operation until the problem is corrected. 1. Rotors in oil pump are worn. Replace oil pump (WP 0088). 2. Test oil pressure. Refer to this work package. If machine still has low oil pressure, replace engine assembly (WP 0057). High Oil Pressure

00024

1. Oil pressure relief valve is stuck in the closed position. Replace oil filter engine base assembly (WP 0082). 2. Test oil pressure. Refer to this work package. a. If machine still has high oil pressure, replace engine assembly (WP 0057). END OF TASK

0024-3

TM 5-2410-241-23-1

0024

EXCESSIVE ENGINE OIL CONSUMPTION INSPECTION Engine Oil Leaks on Outside of Engine

00024

00024

1. Remove left engine guard from machine (WP 0202). 2. Remove right engine guard from machine (WP 0204). 3. Inspect turbo oil supply line (Figure 2, Item 1) and turbo oil drain line (Figure 2, Item 7) for Class III oil leaks. a. If oil leaks are present, replace turbo oil supply and drain line (WP 0062). b. If no leaks found at turbo oil supply line, proceed to step 4. 4. Inspect oil cooler (Figure 2, Item 6) for Class III oil leaks. a. If oil leaks are present, replace oil cooler (WP 0084). b. If no leaks found at oil cooler, proceed to step 5. 5. Inspect oil filter engine base (Figure 2, Item 5) for Class III oil leaks. a. If oil leaks are present, replace oil filter engine base (WP 0082). b. If no leaks found at oil filter engine base, proceed to step 6. 6. Inspect oil filter (Figure 2, Item 3) and oil filter lines (Figure 2, Item 4) for Class III oil leaks. a. If oil leaks are present at oil filter, replace oil filter (WP 0083). b. If oil leaks are present at oil filter lines, replace oil filter lines (WP 0083). c.

If no leaks are found at oil filter or oil filter lines, proceed to step 7.

7. Inspect engine oil pump (Figure 2, Item 2) for Class III oil leaks. a. If oil leaks are present, replace engine oil pump (WP 0088). b. If no leaks are found at engine oil pump, proceed to step 8.

Figure 2. Right Side Engine Oil Leaks.

0024-4

0024

TM 5-2410-241-23-1

0024

EXCESSIVE ENGINE OIL CONSUMPTION INSPECTION – CONTINUED 8. Inspect breather (Figure 3, Item 1), valve mechanism cover (Figure 3, Item 2), and valve mechanism cover base (Figure 3, Item 3) for Class III oil leaks. a. If oil leaks are present, replace breather, valve mechanism cover, and valve mechanism cover base (WP 0106). b. If no leaks are found at breather, valve mechanism cover, or valve mechanism cover base, proceed to step 9. 9. Inspect dipstick (Figure 3, Item 4) for Class III oil leaks. a. If oil leaks are present, replace dipstick (WP 0087). b. If no leaks are found at dipstick, proceed to step 10. 10. Inspect oil filler (Figure 3, Item 5) for Class III oil leaks. a. If oil leaks are present, replace oil filler (WP 0086). b. If no leaks are found at oil filler, proceed to step 11. 11. Inspect front cover assembly (Figure 3, Item 6) for Class III oil leaks. a. If oil leaks are present, replace front cover assembly (WP 0081). b. If no leaks are found at front cover assembly, proceed to step 12.

Figure 3. Left Side Engine Oil Leaks.

0024-5

0024

TM 5-2410-241-23-1

0024

EXCESSIVE ENGINE OIL CONSUMPTION INSPECTION – CONTINUED 12. Inspect front crankshaft seal (Figure 4, Item 1) for Class III oil leaks. a. If oil leaks are present, replace front crankshaft seal (WP 0079). b. If no leaks are found at front crankshaft seal, proceed to step 13. 13. Inspect oil pan (Figure 4, Item 4), oil pan drain valve (Figure 4, Item 3), and oil pan gasket (Figure 4, Item 2) for Class III oil leaks. a. If oil leaks are present, replace front oil pan, oil pan drain valve, and oil pan gasket (WP 0089). b. If no leaks are found at oil pan, oil pan drain valve, or oil pan gasket, proceed to step 14. 14. Inspect engine block assembly (Figure 4, Item 5) for Class III oil leaks. a. If oil leaks are present, replace engine assembly (WP 0057). b. If no leaks are found on engine assembly, return to troubleshooting (WP 0019).

Figure 4. Bottom Engine Oil Leaks. END OF TASK END OF WORK PACKAGE

0024-6

0024

30 TM 5-2410-241-23-1

0025

FIELD MAINTENANCE

-

FUEL SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS Fuel System Inspection, Fuel Quality Test, Fuel Prime Pump, Cylinder Cutout Test, Injector Solenoid Test, Fuel Pressure Test, Timing Sensor Calibration 0 0

2 5

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Adapter Kit, Test (WP 0302, Item 5) Adapter, Connector, 7/16 x 20 Straight Thread (WP 0302, Item 2) Cap, Protective, Dust and Moisture Seal (WP 0302, Item 15) Engine Turning Tool, Flywheel (WP 0302, Item 22) Gauge, Pressure (Fuel), Dial Indicating (WP 0302, Item 30) Handle, Ratchet, 3/4” Dr, 17" Long (S0374) (WP 0302, Item 68) Gasket (O-ring) (WP 0302, Item 40) Plug, Leakproof, Seal (WP 0302, Item 45) Test Set, Electronic (MSD) (WP 0302, Item 62) Timing Probe Cable (WP 0302, Item 64) Transducer, Pressure, Fluid-Hydraulic, 4.5” (11.4 cm) (WP 0302, Item 69) 0

0

Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring

0

0

0

0

0

0

0

0

0

0

0

0

0

0

References WP 0016 WP 0019 WP 0023 WP 0070 WP 0071 WP 0072 WP 0073 WP 0171 WP 0202 WP 0204 WP 0304

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0025-1

Equipment Condition Machine parked (TM 5-2410-241-10)

0

0

TM 5-2410-241-23-1

0025

FUEL SYSTEM INSPECTION

00025

WARNING

•

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel.

•

Allow engine to cool off before performing maintenance on fuel lines. Hot metal parts can cause severe burns. Wear eye, hand, and skin protection when working with heated parts.

•

Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow these warnings may result in injury or death to personnel, or damage to equipment.

1. Check fuel level in fuel tank (TM 5-2410-241-10). 2. Ensure vent cover (Figure 1, Item 2) on fuel cap (Figure 1, Item 1) is not filled with dirt and debris. Clean as required. 3. Ensure vent orifice (Figure 1, Item 3) is not plugged or restricted. Clean or remove debris as required.

Figure 1. Fuel Cap.

NOTE Cap and plug all hose connections to prevent contamination and leaks. 4. In the following steps, while checking fuel lines for leaks, fuel lines must be free from kinks, wear, or damage. Reposition fuel line or replace fuel lines if damage or wear is identified (WP 0157) and secure fuel line with new tiedown straps as needed.

0025-2

0025

TM 5-2410-241-23-1

0025

FUEL SYSTEM INSPECTION – CONTINUED 5. Check fuel line (Figure 2, Item 5) for leaks between secondary fuel filter base (Figure 2, Item 4) and fuel transfer pump (Figure 2, Item 7). 6. Check fuel line (Figure 2, Item 3) for leaks between primary fuel filter base (Figure 2, Item 2) and fuel transfer pump (Figure 2, Item 7).

Figure 2. Fuel Supply Line.

0025

7. Check fuel supply line (Figure 2, Item 1) for leaks between primary fuel filter base (Figure 2, Item 2) and fuel supply connection (Figure 3, Item 2) at fuel tank (Figure 3, Item 1).

Figure 3. Fuel Tank.

0025-3

0025

TM 5-2410-241-23-1

0025

FUEL SYSTEM INSPECTION – CONTINUED

00025

8. Visually inspect plug (Figure 4, Item 2) and all bolts (Figure 4, Item 3) at fuel manifold (Figure 4, Item 1) for leaks. If leaks are found, replace fuel manifold (WP 0071).

Figure 4. Fuel Manifold.

0025

9. Inspect primary fuel filter (Figure 5, Item 2) and secondary fuel filter (Figure 5, Item 1) for damage and leakage. Replace primary fuel filter (WP 0071) and secondary fuel filter (WP 0072) as necessary. 10. Return to Engine Troubleshooting (WP 0019).

Figure 5. Fuel Filters. END OF TASK

0025-4

0025

TM 5-2410-241-23-1

FUEL QUALITY TEST

0025

00025

WARNING

•

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel.

•

Allow engine to cool off before performing maintenance on fuel lines. Hot metal parts can cause severe burns. Wear eye, hand, and skin protection when working with heated parts.

•

Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow these warnings may result in injury or death to personnel, or damage to equipment.

1. Check for water in primary fuel filter/water separator bowl (Figure 5, Item 1). a. If contaminated, drain fuel/water separator (TM 5-2410-241-10). b. If not contaminated, proceed to step 2. 2. Position sample container under fuel tank drain hose (Figure 6, Item 1). 3. Slowly open fuel tank drain valve (Figure 6, Item 2) to allow a sample of fuel to drain into suitable, clean container.

Figure 6. Fuel Tank Drain Hose. 4. Close fuel drain valve (Figure 6, Item 2).

0025-5

0025

TM 5-2410-241-23-1

0025

FUEL QUALITY TEST – CONTINUED

00025

WARNING

•

When servicing this equipment, performing maintenance, or disposing of materials such as engine/hydraulic oils, coolant, and fuel, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance.

•

Engine/hydraulic oils, coolant, and fuel can be very slippery. Immediately wipe up any spills.

•

Failure to follow these warnings may result in injury to personnel.

5. Visually inspect fuel sample for contaminants. If fuel is black, brown, and/or similar to sludge, this can be an indication of growth of bacteria or oil contamination. In cold temperatures, cloudy fuel indicates fuel may not be suitable for operating conditions. a. If contamination is detected, drain fuel system (WP 0171) and replace primary fuel filter (WP 0071) and secondary fuel filter (WP 0072). b. If no contamination is detected, fuel quality is OK. END OF TASK FUEL PRIME PUMP

00025

1. Unlock priming pump plunger (Figure 7, Item 1). 2. Operate plunger until resistance is felt. 3. Push plunger in and hand tighten to lock plunger in place. 4. Start engine (TM 5-2410-241-10). 5. If engine fails to start, or if engine starts and misfires or excessive smoke comes from exhaust pipe, additional priming may be required. Repeat steps 1 through 4. 6. If engine runs rough, allow it to run at low idle until it runs smoothly.

Figure 7. Fuel Prime Pump. END OF TASK

0025-6

0025

TM 5-2410-241-23-1

CYLINDER CUTOUT TEST

0025

00025

1. Start engine and bring to operating temperature (TM 5-2410-241-10). 2. Connect MSD to machine (WP 0016). 3. Select engine ECM (Figure 8, Item 1) from left side of screen.

Figure 8. ECM Selection 3176C.

0025

4. Select Diagnostics (Figure 9, Item 1), Diagnostic Tests (Figure 9, Item 2), Cylinder Cutout Test (Figure 9, Item 3), and Start button appears on next screen.

Figure 9. Cylinder Cutout Test Select.

0025-7

0025

TM 5-2410-241-23-1

CYLINDER CUTOUT TEST – CONTINUED

0025

00025

NOTE The Manual Cylinder Cutout Test is also available. Access the manual test by selecting the Change button on the screen for the Cylinder Cutout test. 5. Start engine (TM 5-2410-241-10). 6. Select Start button (Figure 10, Item 1) for Cylinder Cutout Test.

Figure 10. Cylinder Cutout Test Start.

0025

7. The following screen will appear. As each cylinder (Figure 11, Item 1) is tested the word “Cutout” will appear in the mode column.

Figure 11. Cylinder Cutout in Process.

0025-8

0025

TM 5-2410-241-23-1

CYLINDER CUTOUT TEST – CONTINUED

0025

00025

8. When test is complete, the following Test Complete screen (Figure 12, Item 1) will appear. 9. If a failure is detected, the word “Failed” will appear next to the cylinder number.

Figure 12. Cylinder Cutout Complete. 10. Stop engine (TM 5-2410-241-10). 11. Remove MSD from machine (WP 0016). END OF TASK

0025-9

0025

TM 5-2410-241-23-1

INJECTOR SOLENOID TEST

0025

00025

1. Start engine and bring to operating temperature (TM 5-2410-241-10). 2. Connect MSD to machine (WP 0016). 3. Select ECM 3176C D7 (Figure 13, Item 1).

Figure 13. ECM Selection 3176C.

0025-10

0025

TM 5-2410-241-23-1

0025

INJECTOR SOLENOID TEST – CONTINUED 4. Select Diagnostics (Figure 14, Item 1), Diagnostics Tests, (Figure 14, Item 2), Injector Solenoid Test (Figure 14, Item 3).

Figure 14. Injector Solenoid Test Selection.

0025-11

0025

TM 5-2410-241-23-1

0025

INJECTOR SOLENOID TEST – CONTINUED

NOTE Injector solenoid test is used to actuate injector solenoids. The click of injector solenoids can be heard when engine is not running to determine if circuit is functioning properly. 5. Select Start (Figure 15, Item 2) to perform test. 6. As each solenoid is energized by the ECM an audible click can be heard at the valve cover. MSD will indicate the cylinder number (Figure 15, Item 1) of the solenoid being activated.

Figure 15. Injector Solenoid Test Starting.

0025-12

0025

TM 5-2410-241-23-1

0025

INJECTOR SOLENOID TEST – CONTINUED 7. Cylinder being tested (Figure 16, Item 1) will be highlighted.

Figure 16. Injector Solenoid Testing.

0025-13

0025

TM 5-2410-241-23-1

0025

INJECTOR SOLENOID TEST – CONTINUED 8. Select Stop (Figure 17, Item 2) to end test.

Figure 17. Injector Solenoid Test Complete. 9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 10. Remove MSD from machine (WP 0016). END OF TASK

0025-14

0025

TM 5-2410-241-23-1

FUEL PRESSURE TEST

0025

00025

WARNING

•

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel.

•

Allow engine to cool off before performing maintenance on fuel lines. Hot metal parts can cause severe burns. Wear eye, hand, and skin protection when working with heated parts.

•

Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow these warnings may result in injury or death to personnel, or damage to equipment.

NOTE Perform Fuel System Inspection, Fuel Quality Test, and Fuel Prime Pump in this work package prior to performing Fuel Pressure Test.

0025-15

TM 5-2410-241-23-1

0025

FUEL PRESSURE TEST – CONTINUED

00025

1. Remove cap (Figure 18, Item 1) from fitting (Figure 18, Item 2) on secondary fuel filter housing (Figure 18, Item 3). 2. Refer to Special Fabricated Tools (WP 0304) for fuel pressure gauge.

NOTE Ensure fitting is clean and free of debris prior to connecting gauge. 3. Connect fuel pressure gauge to fitting (Figure 18, Item 2).

NOTE If engine will not start, perform test by cranking engine for no more than 30 seconds. 4. Start engine (TM 5-2410-241-10) and record fuel pressure at low idle. Fuel pressure should be between 65 and 87 psi (448 and 600 kPa). 5. If fuel pressure is OK, refer to Engine Troubleshooting (WP 0019).

WARNING

•

When servicing this equipment, performing maintenance, or disposing of materials such as engine/hydraulic oils, coolant, and fuel, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance.

•

Engine/hydraulic oils, coolant, and fuel can be very slippery. Immediately wipe up any spills.

•

Failure to follow these warnings may result in injury to personnel.

6. If fuel pressure is below 65 psi (448 kPa) perform the following: a. Disconnect return line (Figure 18, Item 5) from secondary housing (Figure 18, Item 3) and install cap (Figure 18, Item 4) in secondary housing (Figure 18, Item 3). b. Install plug (Figure 18, Item 6) in return line (Figure 18, Item 5). c.

Start engine and record fuel pressure at low idle.

d. If pressure is lower than or equal to 87 psi (600 kPa), replace fuel transfer pump (WP 0073). e. If pressure is higher than or equal to 87 psi (600 kPa), replace secondary fuel filter base (WP 0073). 7. Remove plug (Figure 18, Item 4) from secondary housing (Figure 18, Item 3) and install return line (Figure 18, Item 5). 8. Disconnect fuel pressure gauge from fitting (Figure 18, Item 2) and install cap (Figure 18, Item 1) on fitting.

0025-16

TM 5-2410-241-23-1

FUEL PRESSURE TEST – CONTINUED

0025

00025

Figure 18. Fuel Pressure Test. END OF TASK

0025-17

0025

TM 5-2410-241-23-1

0025

TIMING SENSOR CALIBRATION

00025

1. Remove engine enclosure left door guard (WP 0202). 2. Remove engine enclosure right door guard (WP 0204). 3. Set engine to top center position for No. 1 or No. 6 (WP 0023). 4. Remove two bolts (Figure 19, Item 1), washers (Figure 19, Item 2), cover (Figure 19, Item 3), and O-ring (Figure 19, Item 7) from engine (Figure 19, Item 4). Discard O-ring.

CAUTION Never turn engine by crankshaft vibration damper. Crankshaft vibration damper is a precision part. Major engine failure may be caused by damage to crankshaft vibration damper. 5. Insert engine turning tool (Figure 19, Item 6) in gear (Figure 19, Item 5).

NOTE •

Engine must be turned in opposite direction of normal rotation. Normal rotation of engine is clockwise viewed from front crankshaft.

•

Rotate engine turning tool 1/8 revolution, not engine crankshaft.

6. Rotate engine turning tool (Figure 19, Item 6) counterclockwise 1/8 revolution. 7. Remove engine turing tool (Figure 19, Item 6) from gear (Figure 19, Item 5). 8. Install new O-ring (Figure 19, Item 7), cover (Figure 19, Item 3), two washers (Figure 19, Item 2), and bolts (Figure 19, Item 1) on engine (Figure 19, Item 4).

Figure 19. Rotate Engine.

0025-18

0025

TM 5-2410-241-23-1

0025

TIMING SENSOR CALIBRATION – CONTINUED 9. Remove plug (Figure 20, Item 3) and O-ring (Figure 20, Item 1) from engine (Figure 20, Item 2). Discard Oring.

Figure 20. Plug.

0025-19

0025

TM 5-2410-241-23-1

0025

TIMING SENSOR CALIBRATION – CONTINUED 10. Install new O-ring (Figure 21, Item 2) on transducer (Figure 21, Item 1). 11. Install adapter (Figure 21, Item 3) on engine (Figure 21, Item 4).

NOTE Transducer must bottom out on crankshaft. If transducer does not bottom out, crankshaft is not in the proper position. When crankshaft is in the proper position transducer will be half way in when bottomed out. 12. Fully insert transducer (Figure 21, Item 1) in adapter (Figure 21, Item 3) until it bottoms out on crankshaft. 13. Push O-ring (Figure 21, Item 2) against adapter (Figure 21, Item 3) on transducer (Figure 21, Item 1). 14. Pull transducer (Figure 21, Item 1) back until there is 0.040 in. (1 mm) between O-ring (Figure 21, Item 2) and adapter (Figure 21, Item 3). 15. Tighten adapter (Figure 21, Item 3) on transducer (Figure 21, Item 1).

Figure 21. Transducer.

0025-20

0025

TM 5-2410-241-23-1

0025

TIMING SENSOR CALIBRATION – CONTINUED 16. Install cable (Figure 22, Item 1) on transducer connector (Figure 22, Item 2).

CAUTION Position cable away from exhaust to prevent damage to cable. 17. Position cable (Figure 22, Item 2) over engine (Figure 22, Item 3).

Figure 22. Transducer Cable.

0025-21

0025

TM 5-2410-241-23-1

0025

TIMING SENSOR CALIBRATION – CONTINUED 18. Locate engine harness timing sensor calibration connector (Figure 23, Item 3). 19. Remove cap (Figure 23, Item 4) from engine harness timing sensor calibration connector (Figure 23, Item 3). 20. Connect transducer cable (Figure 23, Item 2) to engine harness timing sensor calibration connector (Figure 23, Item 3). 21. Connect engine harness timing sensor calibration connector (Figure 23, Item 3) to transducer cable connector (Figure 23, Item 1).

Figure 23. Transducer Cable to Engine Harness.

0025-22

0025

TM 5-2410-241-23-1

0025

TIMING SENSOR CALIBRATION – CONTINUED 22. Connect MSD to machine (WP 0016). 23. Start engine and bring to operating temperature (TM 5-2410-241-10). 24. Select 3176C D7 (Figure 24, Item 1) from left side of screen. 25. Select OK (Figure 24, Item 2).

Figure 24. ECM Selection 3176C.

0025-23

0025

TM 5-2410-241-23-1

0025

TIMING SENSOR CALIBRATION – CONTINUED 26. Select Service (Figure 25, Item 1), Calibrations (Figure 25, Item 2), and Timing Calibration (Figure 25, Item 3).

Figure 25. Timing Sensor Calibration Select.

0025

27. Set engine to 1000 rpm (TM 5-2410-241-10). 28. Select the Continue button (Figure 26, Item 1) for the timing calibration.

Figure 26. Timing Sensor Calibration Start.

0025-24

0025

TM 5-2410-241-23-1

0025

TIMING SENSOR CALIBRATION – CONTINUED 29. A message window will display “Please Wait......calculating the new timing reference” (Figure 27, Item 3). 30. The following screen will then appear and say “The ECM has calculated the Timing Reference” (Figure 27, Item 1). 31. Select Continue (Figure 27, Item 2).

Figure 27. Timing Sensor Calibration in Process.

0025-25

0025

TM 5-2410-241-23-1

0025

TIMING SENSOR CALIBRATION – CONTINUED

NOTE Do not exit Timing Calibration Complete screen until engine harness timing sensor calibration connector is disconnected from transducer cable connector. 32. When test is complete, Test Complete screen (Figure 28, Item 1) will appear.

Figure 28. Timing Sensor Calibration Complete.

0025-26

0025

TM 5-2410-241-23-1

0025

TIMING SENSOR CALIBRATION – CONTINUED 33. Disconnect engine harness timing sensor calibration connector (Figure 29, Item 3) from transducer cable connector (Figure 29, Item 1). 34. Stop engine (TM 5-2410-241-10). 35. Remove MSD from machine (WP 0016). 36. Install cap (Figure 29, Item 4) on engine harness timing sensor calibration connector (Figure 29, Item 3).

Figure 29. Transducer Cable to Engine Harness.

0025-27

0025

TM 5-2410-241-23-1

0025

TIMING SENSOR CALIBRATION – CONTINUED

NOTE Keep cable away from exhaust. 37. Remove cable (Figure 30, Item 2) from engine (Figure 30, Item 3). 38. Disconnect cable (Figure 30, Item 2) from transducer connector (Figure 30, Item 1).

Figure 30. Transducer Cable.

0025-28

0025

TM 5-2410-241-23-1

0025

TIMING SENSOR CALIBRATION – CONTINUED 39. Loosen adapter (Figure 31, Item 3) from transducer (Figure 31, Item 1). 40. Remove transducer (Figure 31, Item 1) from adapter (Figure 31, Item 3). 41. Remove adapter (Figure 31, Item 3) from engine (Figure 31, Item 4). 42. Remove and discard O-ring (Figure 31, Item 2) from transducer (Figure 31, Item 1).

Figure 31. Transducer.

0025-29

0025

TM 5-2410-241-23-1

0025

TIMING SENSOR CALIBRATION – CONTINUED 43. Install new O-ring (Figure 32, Item 1) and plug (Figure 32, Item 3) on engine (Figure 32, Item 2). 44. Install engine enclosure right door guard (WP 0204). 45. Install engine enclosure left door guard (WP 0202).

Figure 32. Plug. END OF TASK END OF WORK PACKAGE

0025-30

0025

18 TM 5-2410-241-23-1

0026

FIELD MAINTENANCE

-

COOLING SYSTEM INSPECTIONS Cooling System Inspection, Aftercooler Water Pump Inspection, Engine Water Pump Inspection, Head Gasket Inspection, Oil in Coolant Inspection 0

0 2 6

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Tester, Antifreeze Solution (S0699) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tape, Reflective (WP 0303, Item 35) Personnel Required Two References WP 0042 WP 0043

0

0

0

0

0

0

0

0

0

0

0

0

0026-1

References - Continued WP 0049 WP 0057 WP 0076 WP 0077 WP 0078 WP 0084 WP 0108 WP 0109 WP 0110 WP 0113 WP 0243 Equipment Condition Machine parked (TM 5-2410-241-10)

0

0

0

0

0

0

0

0

0

0

0

0

0

0

TM 5-2410-241-23-1

COOLING SYSTEM INSPECTION

0026

00026

WARNING

Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. Radiator and all lines to heaters or engine contain hot coolant or steam. Any contact can cause severe burns. Allow engine and coolant to cool before slowly removing filler cap to relieve cooling system pressure. Engine must be stopped and radiator cap is cool enough to touch with your bare hand. Failure to follow this warning may result in injury or death to personnel. 1. Verify engine cooling system has correct type, mixture, and level of engine coolant. Drain and fill engine coolant if coolant is suspect (WP 0113). 2. Open door (Figure 1, Item 2) remove cooling system cap (Figure 1, Item 1) from cooling system tank (Figure 1, Item 3). 3. Inspect cooling system cap (Figure 1, Item 1) for cracks or damage. a. If cooling system cap is cracked or damage replace cooling system cap. b. If cooling system cap is OK, proceed to step 4.

Figure 1. Coolant Tank and Hoses.

0026-2

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TM 5-2410-241-23-1

0026

COOLING SYSTEM INSPECTION – CONTINUED 4. Visually inspect coolant tank (Figure 2, Item 1), sight glass (Figure 2, Item 2), vent line (Figure 2, Item 3) and two clamps (Figure 2, Item 4) for Class III leaks and damage. a. If leak is at clamps (Figure 2, Item 4), tighten clamp. b. If vent line (Figure 2, Item 3) is leaking or damaged replace vent line (WP 0049). c.

If upper coolant tank (Figure 2, Item 1) or sight glass (Figure 2, Item 2) is leaking or damaged replace coolant tank (WP 0043).

d. If coolant tank (Figure 2, Item 1), sight glass (Figure 2, Item 2), vent line (Figure 2, Item 3) and two clamps (Figure 2, Item 4) are OK, proceed to step 5.

Figure 2. Coolant Tank and Hoses.

0026-3

0026

TM 5-2410-241-23-1

0026

COOLING SYSTEM INSPECTION – CONTINUED 5. Remove eight bolts (Figure 3, Item 4), washers (Figure 3, Item 5), and open two doors (Figure 3, Item 1) on machine. 6. Inspect 9 radiator cores (Figure 3, Item 6) for Class III leaks and damage. a. If Class III leak is on radiator core (Figure 3, Item 6), replace radiator core (WP 0109). b. If radiator cores are OK, proceed to step 7. 7. Inspect eight radiator core crossover hoses (Figure 3, Item 2) and 16 clamps (Figure 3, Item 3) for Class III leaks and damage. a. If Class III leak is at clamp (Figure 3, Item 3), tighten clamp. b. If radiator core crossover hose (Figure 3, Item 2) has Class III leak or damage, replace radiator core crossover hose (WP 0109). c.

If radiator core crossover hoses (Figure 3, Item 2) and 16 clamps (Figure 3, Item 3) are OK, proceed to step 8.

8. Inspect lower radiator tank (Figure 3, Item 7) for Class III leaks and damage. a. If Class III leak is on lower radiator tank (Figure 3, Item 7), replace lower radiator tank (WP 0110). b. If lower radiator tank (Figure 3, Item 7) is OK, proceed to step 9. 9. Close two doors (Figure 3, Item 1) and install eight washers (Figure 3, Item 5) and bolts (Figure 3, Item 4) on machine.

Figure 3. Radiator.

0026-4

0026

TM 5-2410-241-23-1

0026

COOLING SYSTEM INSPECTION – CONTINUED 10. Remove front engine bottom guard (WP 0199). 11. Inspect water pump inlet hose (Figure 5, Item 1) and two clamps (Figure 5, Item 2) for Class III leaks and damage. a. If leak is at clamps (Figure 5, Item 2), tighten clamp. b. If water pump inlet hose (Figure 5, Item 1) is leaking or damaged, replace water pump inlet hose (WP 0049). c.

If water temperature regulator outlet hose (Figure 5, Item 1) and clamps (Figure 5, Item 2) are OK, proceed to step 12.

12. Inspect water temperature regulator outlet hose (Figure 5, Item 4) and two clamps (Figure 5, Item 3) for Class III leaks and damage. a. If leak is at the clamps (Figure 5, Item 3) tighten clamps. b. If water temperature regulator outlet hose (Figure 5, Item 4) is leaking or damaged replace water temperature regulator outlet hose (WP 0049). c.

If water temperature regulator outlet hose (Figure 5, Item 4) and clamps (Figure 5, Item 3) are OK, proceed to step 13.

Figure 4. Lower Radiator Hoses.

0026-5

0026

TM 5-2410-241-23-1

0026

COOLING SYSTEM INSPECTION – CONTINUED 13. Inspect lower aftercooler water pump inlet hose (Figure 5, Item 7) and two clamps (Figure 5, Item 6) for Class III leaks and damage. a. If leak is at clamps (Figure 5, Item 6), tighten clamps. b. If lower aftercooler water pump inlet hose (Figure 5, Item 7) is leaking or damaged, replace aftercooler water pump inlet hose (WP 0049). c.

If aftercooler water pump inlet hose (Figure 5, Item 6) and clamps (Figure 5, Item 7) are OK, proceed to step 14.

14. Inspect radiator drain lines (Figure 5, Items 5, 9 and 12), five clamps (Figure 5, Items 8 and 11) and two valves (Figure 5, Item 10) for Class III leaks and damage. a. If leak is at valves (Figure 5, Item 10), tighten valve. b. If leak is at clamps (Figure 5, Item 8 and Item 11) tighten clamps. c.

If radiator drain lines (Figure 5, Items 5 and 12) are leaking or damaged, replace cooling system drain lines (WP 0049).

d. If radiator drain lines (Figure 5, Items 5, 9 and 12), five clamps (Figure 5, Items 8 and 11) and two valves (Figure 5, Item 10) are OK, proceed to step 15.

Figure 5. Lower Radiator Hoses.

0026-6

0026

TM 5-2410-241-23-1

0026

COOLING SYSTEM INSPECTION – CONTINUED

00026

15. Inspect aftercooler outlet hose (Figure 6, Item 2) and two clamps (Figure 6, Item 1) for Class III leaks and damage. a. If leak is at clamps (Figure 6, Item 1), tighten clamps. b. If aftercooler outlet hose (Figure 6, Item 2) is leaking or damaged, replace aftercooler outlet hose, refer to water temperature regulator outlet hose (WP 0049). c.

If aftercooler outlet hose (Figure 6, Item 2) and two clamps (Figure 6, Item 1) are OK, proceed to step 16.

16. Inspect upper water temperature regulator outlet hose (Figure 6, Item 3) and two clamps (Figure 6, Item 4) for Class III leaks and damage. a. If leak is at clamps (Figure 6, Item 4), tighten clamps. b. If upper water temperature regulator outlet hose (Figure 6, Item 3) is leaking or damaged, replace aftercooler outlet hose, refer to water temperature regulator outlet hose (WP 0049). c.

If upper water temperature regulator outlet hose (Figure 6, Item 3) and two clamps (Figure 6, Item 4) are OK, proceed to step 17.

Figure 6. Right Side Hoses.

0026-7

0026

TM 5-2410-241-23-1

0026

COOLING SYSTEM INSPECTION – CONTINUED

00026

17. Inspect water tank outlet hose (Figure 7, Item 5) and two clamps (Figure 7, Item 7) for Class III leaks and damage. a. If leak is at clamps (Figure 7, Item 7), tighten clamps. b. If water tank outlet hose (Figure 7, Item 3) is leaking or damaged, replace water tank outlet hose (WP 0049). c.

If water tank outlet hose (Figure 7, Item 5) and two clamps (Figure 7, Item 7) are OK, proceed to step 18.

18. Inspect water pump (Figure 7, Item 6) for Class III leaks and damage. a. If water pump (Figure 7, Item 3) is leaking or damaged, replace water pump (WP 0077). b. If water pump (Figure 7, Item 5) is OK, proceed to step 19. 19. Inspect water pump elbow (Figure 7, Item 8) for Class III leaks and damage. a. If water pump elbow (Figure 7, Item 8) is leaking or damaged, replace water pump elbow (WP 0076). b. If water pump elbow (Figure 7, Item 8) is OK, proceed to step 20. 20. Inspect water pump elbow (Figure 7, Item 8) for Class III leaks and damage. a. If water pump elbow (Figure 7, Item 8) is leaking or damaged, replace water pump elbow (WP 0076). b. If water pump elbow (Figure 7, Item 8) is OK, proceed to step 21. 21. Inspect two heater lines (Figure 7, Items 10 and 14) and two clamps (Figure 7, Items 9 and 13) for Class III leaks and damage. a. If leak is at clamps (Figure 7, Items 9 and 13), tighten clamps. b. If heater lines (Figure 7, Items 10 and 14) are leaking or damaged, replace heater lines (WP 0243). c.

If two heater lines (Figure 7, Items 10 and 14) and two clamps (Figure 7, Items 9 and 13) are OK, proceed to step 22.

22. Inspect oil cooler (Figure 7, Item 11) for Class III leaks and damage. a. If oil cooler (Figure 7, Item 11) is leaking or damaged, replace engine oil cooler (WP 0085). b. If oil cooler (Figure 7, Item 11) is OK, proceed to step 23. 23. Inspect transmission cooler (Figure 7, Item 15) for Class III leaks and damage. a. If transmission cooler (Figure 7, Item 15) is leaking or damaged, replace water pump (WP 0077). b. If transmission cooler (Figure 7, Item 15) is OK, proceed to step 24.

0026-8

TM 5-2410-241-23-1

0026

COOLING SYSTEM INSPECTION – CONTINUED 24. Inspect engine freeze plugs (Figure 7, Item 12) for Class III leaks and damage. a. If engine freeze plugs (Figure 7, Item 12) are leaking or damaged, replace engine (WP 0057). b. If engine freeze plugs (Figure 7, Item 12) are OK, proceed to step 25.

Figure 7. Right Side Hoses.

0026-9

0026

TM 5-2410-241-23-1

0026

COOLING SYSTEM INSPECTION – CONTINUED 25. Inspect water temperature regulator outlet pipe (Figure 8, Item 1) for Class III leaks and damage. a. If water temperature regulator outlet pipe (Figure 8, Item 1) is leaking or damaged, replace water temperature regulator outlet pipe (WP 0049). b. If water temperature regulator outlet pipe (Figure 8, Item 1) is OK, proceed to step 26. 26. Inspect water line pipe (Figure 8, Item 2), two hoses (Figure 8, Items 4 and 5) and four clamps (Figure 8, Items 3 and 6) for Class III leaks and damage. a. If leak is at clamps (Figure 8, Item 3 and Item 6), tighten clamps. b. If water line pipe (Figure 8, Item 2) is leaking or damaged, replace water line (WP 0047). c.

If hoses (Figure 8, Item 2) are leaking or damaged, replace water line hoses (WP 0047).

d. If water line pipe (Figure 8, Item 2), two hoses (Figure 8, Item 4 and Item 5) and four clamps (Figure 8, Items 3 and 6) are OK, proceed to step 27. 27. Inspect aftercooler water pump (Figure 8, Item 7) for Class III leaks and damage. a. If aftercooler water pump (Figure 8, Item 7) is leaking or damaged, replace aftercooler water pump (WP 0078). b. If aftercooler water pump (Figure 8, Item 7) is OK, proceed to step 28. 28. Inspect aftercooler water pump inlet hose (Figure 8, Item 8), aftercooler water pump inlet pipe (Figure 8, Item 10) and two clamps (Figure 8, Item 9) for Class III leaks and damage. a. If leak is at clamps (Figure 8, Item 9), tighten clamps. b. If aftercooler water pump inlet pipe (Figure 8, Item 10) is leaking or damaged, replace water pump inlet pipe (WP 0049). c.

If aftercooler water pump inlet hose (Figure 8, Item 8) is leaking or damaged, replace aftercooler water pump inlet hose (WP 0049).

d. If aftercooler water pump inlet hose (Figure 8, Item 8), aftercooler water pump inlet pipe (Figure 8, Item 10) and two clamps (Figure 8, Item 9) are OK, proceed to step 29.

0026-10

TM 5-2410-241-23-1

0026

COOLING SYSTEM INSPECTION – CONTINUED

Figure 8. Left Side Hoses.

0026-11

0026

TM 5-2410-241-23-1

COOLING SYSTEM INSPECTION – CONTINUED

0026

00026

29. Inspect water valve (Figure 9, Item 8) for Class III leaks and damage. a. If leak is at clamps (Figure 9, Item 9) tighten clamps. b. If water valve (Figure 9, Item 8) is leaking or damaged, replace water valve (WP 0244). c.

If water valve (Figure 9, Item 8) is OK, proceed to step 30.

30. Inspect three heater lines (Figure 9, Items 10 and 14), and two clamps (Figure 7, Item 9 and Item 13) for Class III leaks and damage. a. If leak is at clamps (Figure 9, Item 9 and item 13), tighten clamps. b. If heater lines (Figure 9, Items 10 and 14) are leaking or damaged, replace heater lines (WP 0243). c.

If two heater lines (Figure 9, Items 10 and 14), and two clamps (Figure 9, Items 9 and 13) are OK, proceed to step 31.

Figure 9. Heater Control Valve.

0026-12

0026

TM 5-2410-241-23-1

0026

COOLING SYSTEM INSPECTION – CONTINUED

00026

WARNING

Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. Radiator and all lines to heaters or engine contain hot coolant or steam. Any contact can cause severe burns. Allow engine and coolant to cool before slowly removing filler cap to relieve cooling system pressure. Engine must be stopped and radiator cap is cool enough to touch with your bare hand. Failure to follow this warning may result in injury or death to personnel. 31. Open door (Figure 10, Item 2) on machine. 32. Slowly remove cooling system cap (Figure 10, Item 1) from coolant tank (Figure 10, Item 3). 33. Start engine (TM 5-2410-2410-10). 34. Inspect engine cooling system for intrusion of combustion gases by observing cooling system for bubbles as engine warms. a. If bubbles are present in coolant, then combustion gases may be entering the engine cooling system. Perform Head Gasket Inspection in this work package. b. If no air bubbles are present, return to Troubleshooting.

Figure 10. Coolant Tank and Hoses. END OF TASK

0026-13

0026

TM 5-2410-241-23-1

0026

AFTERCOOLER WATER PUMP INSPECTION

00026

NOTE Water pump seal is lubricated by coolant in cooling system. It is normal for small amount of leakage to occur as engine cools down and parts contract. 1. Start and run the engine for at least 10 minutes (TM 5-2410-241-10). 2. Turn engine OFF (TM 5-2410-241-10). 3. Remove engine enclosure left door assembly (WP 0201). 4. Remove engine enclosure left door guard (WP 0202). 5. Inspect outside of water pump (Figure 11, Item 1) for Class III leaks. a. If leak is identified, replace aftercooler water pump (WP 0078). b. If no leaks are identified, proceed to step 6. 6. Remove felt plug (Figure 11, Item 2) at vent hole from water pump (Figure 11, Item 2). Inspect for any fluid leakage from vent hole. a. If leakage is identified, replace aftercooler water pump (WP 0078). b. If no leaks are identified, install felt plug (Figure 11, Item 2) at vent hole on water pump (Figure 11, Item 2) and return to Troubleshooting.

Figure 11. Aftercooler Water Pump Inspection. END OF TASK

0026-14

0026

TM 5-2410-241-23-1

0026

ENGINE WATER PUMP INSPECTION

NOTE Water pump seal is lubricated by coolant in cooling system. It is normal for a small amount of leakage to occur as engine cools down and parts contract. 1. Start and run the engine for at least 10 minutes (TM 5-2410-241-10). 2. Turn engine off (TM 5-2410-241-10). 3. Remove engine enclosure right door assembly (WP 0203). 4. Remove engine enclosure right door guard (WP 0204). 5. Inspect outside of water pump (Figure 12, Item 1) for Class III leaks. a. If leak is identified, replace water pump (WP 0076). b. If no leaks are identified, proceed to step 6.

NOTE If there is debris around vent hole, clean debris from vent hole. 6. Inspect water pump (Figure 12, Item 1) for leaks at vent hole (Figure 12, Item 2). a. If leak is identified, replace water pump (WP 0076). b. If no leaks are identified, return to Troubleshooting.

Figure 12. Water Pump Vent Hole. END OF TASK

0026-15

0026

TM 5-2410-241-23-1

0026

HEAD GASKET INSPECTION

00026

WARNING

Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. Radiator and all lines to heaters or engine contain hot coolant or steam. Any contact can cause severe burns. Allow engine and coolant to cool before slowly removing filler cap to relieve cooling system pressure. Engine must be stopped and radiator cap is cool enough to touch with your bare hand. Failure to follow this warning may result in injury or death to personnel. 7. Open door (Figure 13, Item 2) on machine. 8. Slowly remove cooling system cap (Figure 13, Item 1) from coolant tank (Figure 13, Item 3). 9. Start engine (TM 5-2410-241-10). 10. Inspect engine cooling system for intrusion of combustion gases by observing cooling system for bubbles as engine warms. a. If bubbles are present in coolant, then combustion gases may be entering the engine cooling system. Replace the cylinder head gasket (WP 0108). b. If no air bubbles are present, return to Troubleshooting.

Figure 13. Coolant Tank and Hoses. END OF TASK

0026-16

0026

TM 5-2410-241-23-1

OIL IN COOLANT INSPECTION

00026

WARNING

Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. Radiator and all lines to heaters or engine contain hot coolant or steam. Any contact can cause severe burns. Allow engine and coolant to cool before slowly removing filler cap to relieve cooling system pressure. Engine must be stopped and radiator cap is cool enough to touch with your bare hand. Failure to follow this warning may result in injury or death to personnel. 1. Open door (Figure 13, Item 2) on machine. 2. Slowly remove cooling system cap (Figure 13, Item 1) from coolant tank (Figure 13, Item 3). 3. Inspect coolant tank for oils. a. If oil is black and milky in coolant tank, replace engine oil cooler (WP 0084). b. If oil is brown in color and appears clean, replace transmission cooler (WP 0042). c.

0026

If no oil is present in coolant tank, return to Troubleshooting.

END OF TASK END OF WORK PACKAGE

0026-17/(18 blank)

12 TM 5-2410-241-23-1

0027

FIELD MAINTENANCE 0

0 2 7

-

AIR INLET AND EXHAUST TESTS, INSPECTIONS, AND ADJUSTMENTS Air Inlet and Exhaust System Inspection, Turbocharger Inspections

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) References WP 0019

0

0

0

0

0

References - Continued WP 0045 WP 0062 WP 0066 WP 0067 WP 0068 WP 0111

0

0

0

0

0

0

0

0

Equipment Condition

0

0

Machine parked (TM 5-2410-241-10)

0027-1

0

TM 5-2410-241-23-1

0027

AIR INLET AND EXHAUST SYSTEM INSPECTION

00027

WARNING

Hot engine components can cause injury from burns. Before performing maintenance on engine, allow engine and components to cool. Failure to follow this warning may result in severe burns to personnel. 1. Inspect pre-cleaner screen (Figure 1, Item 1) and pre-cleaner (Figure 1, Item 6) for debris and bent or cracked screen. a. Remove debris, or replace pre-cleaner screen and/or pre-cleaner (WP 0111) if bent or cracked. b. If pre-cleaner and pre-cleaner screen have none of these conditions, proceed to step 2. 2. Inspect air cleaner inlet hose (Figure 1, Item 10) for debris, kinks, worn spots, cracking, and tearing. a. Remove debris, or replace inlet hose (WP 0111) if kinked, worn, cracked, or torn. b. If air cleaner inlet hose has none of these conditions, proceed to step 3. 3. Inspect clamp (Figure 1, Item 5) and connection between air cleaner inlet hose (Figure 1, Item 10) and precleaner (Figure 1, Item 6) for looseness and damage. a. Tighten clamp if loose or replace clamp if damaged. b. If clamp and connection have neither of these conditions, proceed to step 4. 4. Inspect clamp (Figure 1, Item 16) and connection between air cleaner inlet hose (Figure 1, Item 10) and air cleaner housing (Figure 1, Item 8) for looseness and damage. a. Tighten clamp if loose or replace clamp if damaged. b. If clamp and connection have neither of these conditions, proceed to step 5. 5. Inspect engine air cleaner outlet hose (Figure 1, Item 2) and pre-cleaner hose (Figure 1, Item 3) for kinks, worn spots, cracking, and tearing. a. Replace air inlet hose (WP 0111) and/or pre-cleaner hose (WP 0111) if kinked, worn, cracked, or torn. b. If air inlet hose and pre-cleaner hose have none of these conditions, proceed to step 6. 6. Inspect clamp (Figure 1, Item 11) and connection between air cleaner outlet hose (Figure 1, Item 2) and air cleaner housing (Figure 1, Item 8) for looseness and damage. a. Tighten clamp if loose or replace clamp if damaged. b. If clamp and connection have neither of these conditions, proceed to step 7. 7. Inspect clamp (Figure 1, Item 14) and connection between air cleaner outlet hose (Figure 1, Item 2) and turbo (Figure 1, Item 13) for looseness and damage. a. Tighten clamp if loose or replace clamp if damaged. b. If clamp and connection have neither of these conditions, proceed to step 8. 8. Inspect clamp (Figure 1, Item 4) and connection between pre-cleaner hose (Figure 1, Item 3) and pre-cleaner housing (Figure 1, Item 6) for looseness and damage. a. Tighten clamp if loose or replace clamp if damaged. b. If clamp and connection have neither of these conditions, proceed to step 9.

0027-2

TM 5-2410-241-23-1

0027

AIR INLET AND EXHAUST SYSTEM INSPECTION – CONTINUED 9. Inspect clamp (Figure 1, Item 7) and connection between pre-cleaner hose (Figure 1, Item 3) and muffler (Figure 1, Item 9) for looseness and damage. a. Tighten clamp if loose or replace clamp if damaged. b. If clamp and connection have neither of these conditions, proceed to step 10. 10. Inspect turbocharger elbow (Figure 1, Item 15) and aftercooler housing (Figure 1, Item 12) for cracks, air leakage, and loose fasteners. a. If loose, tighten fasteners. b. Replace turbocharger elbow (WP 0062) and/or aftercooler housing (WP 0068) if cracked, or evidence of leakage is found. c.

If turbocharger elbow and aftercooler housing have none of these conditions, proceed to step 11.

11. Inspect turbocharger elbow (Figure 1, Item 15) and aftercooler housing (Figure 1, Item 12) for evidence of oil. a. If oil is found, inspect turbocharger to determine cause of oil. Refer to turbocharger inspection in this work package. b. If turbocharger elbow and aftercooler housing have no evidence of oil, proceed to step 12.

Figure 1. Air Hoses and Charge Air Cooler.

0027-3

0027

TM 5-2410-241-23-1

0027

AIR INLET AND EXHAUST SYSTEM INSPECTION – CONTINUED 12. Inspect engine air cleaner housing (Figure 2, Item 1), air cleaner primary element (Figure 2, Item 3), air cleaner secondary element (Figure 2, Item 2), air cleaner housing seal (Figure 2, Item 5), and air cleaner housing cover (Figure 2, Item 4) for the following: a. Inspect for debris in air cleaner housing cover, air cleaner primary element, air cleaner secondary element, and air cleaner housing. Remove debris from air cleaner housing cover, air cleaner primary element, air cleaner secondary element, and air cleaner housing. b. Inspect for rips, tears, dents, holes, cracks, and excess corrosion on air cleaner housing cover, air cleaner primary element, air cleaner secondary element, and air cleaner housing. Replace air cleaner housing cover, air cleaner primary element, air cleaner secondary element, and air cleaner housing (WP 0111) as necessary. c.

Inspect for dirt tracks visible on clean side of engine air cleaner element. If dirt tracks are observed, contaminants are flowing past engine air cleaner element and/or seal for engine air cleaner element. Replace air filter elements (WP 0111).

d. If air cleaner housing cover, air cleaner primary element, air cleaner secondary element, and air cleaner housing have none of these conditions, proceed to step 13.

Figure 2. Air Cleaner Housing.

0027-4

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TM 5-2410-241-23-1

0027

AIR INLET AND EXHAUST SYSTEM INSPECTION – CONTINUED 13. Inspect turbocharger inlet pressure sensor (Figure 3, Item 2) and fitting (Figure 3, Item 3) for looseness and damage. a. Tighten turbocharger inlet pressure sensor (WP 0066) and/or fitting (Figure 3, Item 1) if loose, or replace if damaged (Figure 3, Item 1). b. If turbocharger inlet pressure sensor and fitting have neither of these conditions, proceed to step 14.

Figure 3. Air Cleaner Housing.

0027-5

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TM 5-2410-241-23-1

0027

AIR INLET AND EXHAUST SYSTEM INSPECTION – CONTINUED 14. Inspect exhaust manifold (Figure 4, Item 6) for cracks, kinks, and excess corrosion. a. Replace exhaust manifold (WP 0067) if condition found. b. If exhaust manifold is OK, proceed to step 15. 15. Inspect elbow (Figure 4, Item 4), muffler (Figure 4, Item 2), and exhaust pipe (Figure 4, Item 1) for cracks, kinks, and excess corrosion. a. Replace elbow (WP 0062), muffler, and/or exhaust pipe (WP 0045) if condition found. b. If elbow, muffler, and exhaust pipe are OK, proceed to step 16. 16. Inspect for black soot between exhaust pipe (Figure 4, Item 1) and muffler (Figure 4, Item 2). a. If black soot is present, tighten clamp (Figure 4, Item 8) on muffler (WP 0045). b. If no black soot is found between exhaust pipe and muffler, proceed to step 17. 17. Inspect for black soot between muffler (Figure 4, Item 2) and elbow (Figure 4, Item 4). a. If black soot is present, tighten clamp (Figure 4, Item 3) on elbow (WP 0045). b. If no black soot is found between muffler and elbow, proceed to step 18. 18. Inspect for black soot between elbow (Figure 4, Item 4) and turbo (Figure 4, Item 5). a. If black soot is present, install new elbow on turbo (WP 0062). b. If no black soot is found between elbow and turbo, proceed to step 19. 19. Inspect for black soot between turbo (Figure 4, Item 5) and exhaust manifold (Figure 4, Item 6). a. If black soot is present, replace turbo to exhaust manifold gasket (WP 0062). b. If no black soot is found between turbo and exhaust manifold, proceed to step 20. 20. Inspect for black soot between exhaust manifold (Figure 4, Item 6) and engine (Figure 4, Item 7). a. If black soot is present, replace exhaust manifold to engine gasket (WP 0067). b. If no black soot is found between exhaust manifold (Figure 4, Item 6) and engine, return to troubleshooting (WP 0019).

Figure 4. Exhaust Manifold, Elbow, and Muffler. END OF TASK

0027-6

0027

TM 5-2410-241-23-1

TURBOCHARGER INSPECTIONS

0027

00027

WARNING

Hot engine components can cause injury from burns. Before performing maintenance on engine, allow engine and the components to cool. Failure to follow this warning may result in severe burns to personnel.

CAUTION Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTE Care must be taken to ensure fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of product. Be prepared to collect fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids in accordance with local regulations and mandates.

0027-7

TM 5-2410-241-23-1

0027

TURBOCHARGER INSPECTIONS – CONTINUED Compressor and Compressor Housing Inspection

00027

1. Remove turbocharger from machine (WP 0062). 2. Inspect compressor housing (Figure 5, Item 1) for dents, holes, and cracks. a. If damage is found on compressor housing, replace turbocharger (WP 0062). b. If no damage found on compressor housing, proceed to step 3. 3. Inspect compressor (Figure 5, Item 2) for contamination, dents, holes, and cracks.

NOTE If there is contamination, determine source of contamination, dents, holes, and cracks. a. If damage is found on compressor, replace turbocharger (WP 0062). b. If no damage found on compressor, proceed to step 4. 4. Rotate compressor (Figure 5, Item 2) by hand. Push assembly sideways while rotating compressor (Figure 5, Item 2). a. If compressor does not turn freely or rubs compressor housing, replace turbocharger (WP 0062). b. If assembly turns freely, and compressor (Figure 5, Item 2) does not rub compressor housing (Figure 5, Item 1), proceed to step 5. 5. Inspect compressor (Figure 5, Item 2) and compressor housing (Figure 5, Item 1) for oil leakage. a. If oil leakage is present, proceed to step 6. b. If no leakage is found on compressor housing or compressor, proceed to step 9.

CAUTION Oil leak from compressor may deposit oil in aftercooler. If oil is found in aftercooler, clean or replace aftercooler assembly (WP 0068).

0027-8

TM 5-2410-241-23-1

0027

TURBOCHARGER INSPECTIONS – CONTINUED 6. Inspect engine crankcase breather. Refer to Air Inlet and Exhaust System Inspection in this work package. If crankcase breather is OK, proceed to step 7. 7. Inspect turbocharger oil drain lines, Refer to Turbocharger Oil Supply and Oil Drain Lines in this work package. If turbocharger oil drain line is OK, proceed to step 8. 8. If steps 5 through 7 did not reveal source of oil leakage, turbocharger has internal damage and cannot be inspected further. Replace turbocharger (WP 0062).

Figure 5. Turbocharger Compressor.

0027-9

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TM 5-2410-241-23-1

0027

TURBOCHARGER INSPECTIONS – CONTINUED 9. Inspect turbine housing (Figure 6, Item 2) for dents, holes, and cracks. a. If damage is found on turbine housing, replace turbocharger (WP 0062). b. If no damage found on turbine housing, proceed to step 10. 10. Inspect turbine (Figure 6, Item 1) for contamination, dents, holes, and cracks.

NOTE If there is contamination, determine source of contamination, dents, holes, and cracks. a. If damage is found on turbine, replace turbocharger (WP 0062). b. If no damage found on turbine, proceed to step 11. 11. Inspect turbine housing (Figure 6, Item 2) and turbine (Figure 6, Item 1) for carbon and other foreign material. a. If carbon build-up is present, replace turbocharger (WP 0062). b. If no carbon build-up is present, proceed to step 12. 12. Rotate turbine (Figure 6, Item 1) by hand. Push assembly sideways while rotating turbine (Figure 6, Item 1). Assembly should turn freely. Turbine should not rub turbine housing (Figure 6, Item 2). a. If turbine does not turn freely or rubs turbine housing, replace turbocharger (WP 0062). b. If assembly turns freely, and turbine (Figure 6, Item 1) does not rub turbine housing (Figure 6, Item 2), proceed to step 13. 13. Inspect turbine housing (Figure 6, Item 1) and turbine (Figure 6, Item 2) for oil leakage. a. If housing has heavy oil, replace turbocharger (WP 0062). Inspect oil drain lines. Refer to Turbocharger Oil Supply and Oil Drain Lines in this work package. b. If no oil is found on turbine, return to troubleshooting (WP 0019).

Figure 6. Turbocharger Turbine. END OF TASK

0027-10

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TM 5-2410-241-23-1

0027

TURBOCHARGER INSPECTIONS – CONTINUED Turbocharger Oil Supply and Oil Drain Lines

00027

1. Check for excessive crankcase pressure. If crankcase pressure is high, or if turbocharger oil drain is restricted, pressure in center housing may be greater than pressure of turbine housing. Perform crankcase breather inspection. Refer to Air Inlet and Exhaust System Inspection in this work package. Correct any problems.

CAUTION If turbocharger oil supply line is damaged, turbocharger will be starved for oil, and damage will occur. 2. Check oil supply line (Figure 7, Item 1) for sharp restrictive bends and kinks. a. If turbocharger oil supply line (Figure 7, Item 1) is bent, kinked, or damaged, replace turbocharger oil supply line (WP 0062). b. If turbocharger oil supply line is OK, proceed to step 3.

CAUTION If turbocharger oil drain line is damaged, pressure in center turbocharger housing may be greater than pressure of turbine housing, and damage will occur. 3. Check turbocharger oil drain line (Figure 7, Item 2) for sharp restrictive bends and kinks. a. If turbocharger oil drain line (Figure 7, Item 1) has sharp restrictive bends, kinks or damage, replace turbocharger oil drain line (WP 0062). b. If turbocharger oil drain line is OK, return to troubleshooting (WP 0019).

Figure 7. Turbocharger Oil Lines. END OF TASK END OF WORK PACKAGE

0027-11/(12 blank)

0027

4 TM 5-2410-241-23-1

0028

FIELD MAINTENANCE 0 0 2

8

-

ALTERNATOR AND CHARGING SYSTEM TESTS

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Ammeter (WP 0302, Item 8) Materials/Parts Rag, Wiping (WP 0303, Item 24) Personnel Required Two

0

References WP 0099

0

0

0

Equipment Condition

0

0

0

Machine parked and engine at operating temperature (TM 5-2410-241-10) 0

0

0

0

0028-1

Estimated Time to Complete 0.5 Hr

0

0

TM 5-2410-241-23-1

0028

NOTE •

If battery has a low charge, do not perform first step.

•

If required, jump start engine or charge battery before engine is started.

1. Turn battery disconnect switch and ignition switch to the ON position, but do not start the engine.

NOTE Turn on the front and rear work lights, activate the headlights using the mode switch, activate the hazard flashers, activate the cab fan, and turn the cab dome light ON (TM 52410-241-10) to provide a drain on the batteries. 2. Partially drain batteries for 10 minutes by means of running cab accessories and lights with the ignition switch on and engine shut off. 3. Set the dial (Figure 1, Item 6) of the ammeter on the 400 DC amp scale (Figure 1, Item 1). Press the ZERO button (Figure 1, Item 2) to zero the meter. Make sure that HOLD (Figure 1, Item 3) is not displayed on ammeter screen (Figure 1, Item 4). If HOLD is displayed, press the HOLD button (Figure 1, Item 5) once.

Figure 1. Ammeter.

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TM 5-2410-241-23-1

0028

4. Connect clamp (Figure 2, Item 4) of ammeter (Figure 2, Item 1) around positive alternator cable (Figure 2, Item 2) connected to alternator (Figure 2, Item 3) with the arrow (Figure 2, Item 5) of the ammeter facing the direction of current flow (towards the alternator). 5. Start the engine (TM 5-2410-241-10), and fully depress and hold throttle pedal. 6. Operate engine with throttle fully depressed while an assistant monitors ammeter. a. If initial charging current is greater than 70 amps, proceed to step 7. b. If initial charging current is less than 70 amps, alternator is faulty. Replace alternator (WP 0099).

Figure 2. Ammeter Connection.

0028-3

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TM 5-2410-241-23-1

0028

7. Remove ammeter from machine. 8. Place multimeter positive lead on B+ terminal (Figure 3, Item 3) of alternator (Figure 3, Item 2). 9. Place multimeter negative lead on negative terminal (Figure 3, Item 1) of alternator (Figure 3, Item 2). 10. With engine still running, have an assistant monitor digital multimeter. Voltage reading should be 24-28 volts. a. If voltage is within specified range, alternator and charging system are OK. b. If voltage is less than 24 volts or more than 28 volts, then the alternator is faulty. Replace alternator (WP 0099).

Figure 3. Alternator. END OF TASK END OF WORK PACKAGE

0028-4

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16 TM 5-2410-241-23-1

0029

FIELD MAINTENANCE 0 0 2 9

-

BATTERY CABLES AND ALTERNATOR CABLES TESTS Test Step 1: Ground Cables, Test Step 2: Positive Cables

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Multimeter (S0252) (WP 0302, Item 68) Needle Tip (Tip G), (Multimeter) (WP 0302, Item 39) 0

0

0

Materials/Parts Rag, Wiping (WP 0303, Item 24) Glove Set, Chemical Protective (WP 0303, Item 13) Personnel Required Two

0

0

0

0

0

References WP 0045 WP 0049 WP 0159 WP 0160 WP 0162 WP 0163 WP 0164 WP 0230 WP 0287 WP 0296 Equipment Condition Machine parked (TM 5-2410-241-10) Estimated Time to Complete 2.0 Hr

0029-1

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

TM 5-2410-241-23-1

WARNING

•

To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating or electric shock, damage to equipment, and injury to personnel.

•

Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may result in death or injury to personnel. –

EYES. Flush with cold water for no less than 15 minutes and seek medical attention immediately.

–

SKIN. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required.

–

INTERNAL. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately.

–

CLOTHING/EQUIPMENT. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.

0029-2

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TM 5-2410-241-23-1

0029

TEST STEP 1: GROUND CABLES

00029

1. Verify all battery cable connections are clean and tight. 2. Turn battery disconnect switch to the ON position (TM 5-2410-241-10). 3. Using a digital multimeter (WP 0296), measure voltage between positive post (Figure 1, Item 1) and negative post (Figure 1, Item 2) of the batteries (Figure 1, Item 4). Monitor and record voltage. 4. Using a digital multimeter (WP 0296), measure voltage between positive post (Figure 1, Item 1) and machine ground at the starter motor (Figure 1, Item 3). Voltage drop should be within 1 volt of value recorded in step 3, or the ground is faulty. a. If voltage drop is greater than 1 volt of value recorded in step 3, proceed to step 5 to isolate ground fault. b. If voltage drop is within 1 volt of value recorded in step 3 machine negative battery cables are OK up to the starter, proceed to step 10 to check negative battery cables at alternator.

Figure 1. Positive and Negative Battery Voltage Test.

0029-3

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TM 5-2410-241-23-1

0029

TEST STEP 1: GROUND CABLES – CONTINUED 5. Remove engine enclosure left door guard (WP 0202). 6. Using a digital multimeter (WP 0296), measure voltage between positive battery post (Figure 2, Item 1) and ground stud on frame (Figure 2, Item 2) of starter ground strap (Figure 2, Item 1). Voltage drop should be within 1 volt of value recorded in step 3, or the ground is faulty. a. If voltage drop is greater than 1 volt of value recorded in step 3, proceed to step 7 to isolate ground fault. b. If voltage drop is within 1 volt of value recorded in step 3, machine ground strap to the starter is faulty. Replace ground strap to the starter (WP 0164).

Figure 2. Starter Ground Strap.

0029-4

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TM 5-2410-241-23-1

0029

TEST STEP 1: GROUND CABLES – CONTINUED 7. Using a digital multimeter (WP 0296), measure voltage between positive battery post (Figure 3, Item 1) and battery disconnect switch ground terminal (Figure 3, Item 2). Voltage drop should be within 1 volt of value recorded in step 3, or the ground is faulty. a. If voltage drop is greater than 1 volt of value recorded in step 3, proceed to step 8 to isolate ground fault. b. If voltage drop is within 1 volt of value recorded in step 3, grounding cable (Figure 3, Item 3) from frame to the battery disconnect switch is faulty. Replace grounding cable from frame to the battery disconnect switch (WP 0162). 8. Using a digital multimeter (WP 0296), measure voltage between positive battery post (Figure 3, Item 1) and battery disconnect switch ground to batteries (Figure 3, Item 1). Voltage drop should be within 1 volt of value recorded in step 3, or the ground cable is faulty. a. If voltage drop is greater than 1 volt of value recorded in step 3, ground cables from batteries are faulty. Replace battery ground cable to disconnect switch (WP 0160). b. If voltage drop is within 1 volt of value recorded in step 3, battery disconnect switch is faulty. Replace battery disconnect switch (WP 0162).

Figure 3. Battery Disconnect Switch.

0029-5

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TM 5-2410-241-23-1

0029

TEST STEP 1: GROUND CABLES – CONTINUED 9. Using a digital multimeter (WP 0296), measure voltage between positive post (Figure 4, Item 1) and engine ground terminal (Figure 4, Item 1). Voltage drop should be within 1 volt of value recorded in step 3 or the engine ground cable is faulty. a. If voltage drop is greater than 1 volt of value recorded in step 3, engine ground cable is faulty. Replace engine ground cable (WP 0049). b. If voltage drop is within 1 volt of value recorded in step 3, proceed to step 10.

Figure 4. Engine Ground Cable.

0029

10. Using a digital multimeter (WP 0296), measure voltage between positive post (Figure 5, Item 1) and alternator ground terminal (Figure 5, Item 1). Voltage drop should be within 1 volt of value recorded in step 3 or the alternator ground strap is faulty. a. If voltage drop is greater than 1 volt of value recorded in step 3, alternator ground strap is faulty. Replace alternator ground strap (WP 0163). b. If voltage drop is within 1 volt of value recorded in step 3, proceed to step 11.

Figure 5. Alternator Ground Connection.

0029-6

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TM 5-2410-241-23-1

0029

TEST STEP 1: GROUND CABLES – CONTINUED 11. Remove cover (Figure 6, Item 1) from NATO slave receptacle (Figure 6, Item 3). 12. Using a digital multimeter (WP 0296), measure voltage between positive post (Figure 1, Item 1) of battery and outer contact (Figure 6, Item 2) (negative side) of NATO slave receptacle (Figure 6, Item 3). Voltage drop should be within 1 volt of value recorded in step 3 or the NATO slave receptacle ground cable is faulty. a. If voltage drop is greater than 1 volt of value recorded in step 3, NATO slave receptacle ground cable is faulty. Replace NATO slave receptacle ground cable (WP 0045). b. If voltage drop is within 1 volt of value recorded in step 3, install NATO slave receptacle cover (Figure 6, Item 1) and proceed to step 13.

Figure 6. Negative Contact of NATO Slave Receptacle.

0029-7

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TM 5-2410-241-23-1

0029

TEST STEP 1: GROUND CABLES – CONTINUED 13. Release two latches (Figure 7, Item 1) on arctic kit battery cover (Figure 7, Item 2). 14. With an assistant, remove arctic kit battery cover (Figure 7, Item 2) from machine. 15. Turn battery disconnect switch to OFF position (TM 5-2410-241-10). 16. Disconnect negative arctic kit battery cable from negative post (Figure 7, Item 4) of arctic kit batteries (Figure 7, Item 5). 17. Turn battery disconnect switch to ON position (TM 5-2410-241-10). 18. Using a digital multimeter (WP 0296), measure voltage between positive post (Figure 7, Item 3) of battery and arctic kit battery cable connector disconnected from negative post (Figure 7, Item 4). Voltage should be within 1 volt of value recorded in step 3 or arctic kit negative battery cable is faulty. a. If voltage drop is greater than 1 volt of value recorded in step 3, arctic kit negative battery cable is faulty. Replace arctic kit negative battery cable (WP 0160). b. If voltage drop is within 1 volt of value recorded in step 3, with an assistant, install arctic kit battery cover (Figure 7, Item 2) and set two latches (Figure 7, Item 1) on arctic kit battery cover. Proceed to Test Step 2.

Figure 7. Arctic Kit Negative Battery Cable. END OF TASK

0029-8

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TM 5-2410-241-23-1

0029

TEST STEP 2: POSITIVE CABLES

00029

1. Using a digital multimeter (WP 0296), measure voltage between positive post (Figure 8, Item 1) and negative post (Figure 8, Item 2) of the batteries (Figure 8, Item 3). Monitor and record voltage.

Figure 8. Positive and Negative Battery Voltage Test.

0029

2. Using a digital multimeter (WP 0296), measure voltage between positive terminal (Figure 9, Item 1) of starter and ground terminal of starter (Figure 9, Item 2). Voltage drop should be within 1 volt of value recorded in step 1. a. If voltage drop is greater than 1 volt of value recorded in step 1, proceed to step 3. b. If voltage drop is within 1 volt of value recorded in step 1, proceed to step 5.

Figure 9. Starter Terminals. 3. Remove front floor plates (WP 0239).

0029-9

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TM 5-2410-241-23-1

TEST STEP 2: POSITIVE CABLES – CONTINUED

0029

00029

4. Using a digital multimeter (WP 0296), measure voltage between positive terminal (Figure 10, Item 3) of junction on left side of machine and machine ground (Figure 10, Item 1). Voltage drop should be within 1 volt of value recorded in step 1. a. If voltage drop is greater than 1 volt of value recorded in step 1, positive battery cable from positive battery post (Figure 10, Item 2) to junction block is faulty. Replace positive battery cable from positive battery post to junction block (WP 0159). b. If voltage drop is within 1 volt of value recorded in step 1, positive battery cable (Figure 10, Item 4) to starter is faulty. Replace positive battery cable to starter (WP 0164).

Figure 10. Left Side Positive Battery Cable Junction.

0029-10

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TM 5-2410-241-23-1

0029

TEST STEP 2: POSITIVE CABLES – CONTINUED

00029

5. Remove cover (Figure 11, Item 1) from NATO slave receptacle (Figure 11, Item 3). 6. Using a digital multimeter (WP 0296), measure voltage drop between inner contact (Figure 11, Item 2) (positive point) and outer contact (Figure 11, Item 4) of NATO slave receptacle (Figure 11, Item 3). Voltage drop should be within 1 volt of value recorded in step 1. a. If voltage drop is greater than 1 volt of value recorded in step 1, replace positive battery cable (Figure 11, Item 5) (WP 0045) of NATO slave receptacle (Figure 11, Item 3). b. If voltage drop is within 1 volt of value recorded in step 1, install cover (Figure 11, Item 1) on NATO slave receptacle (Figure 11, Item 3) and proceed to step 8.

Figure 11. Positive Contact of NATO Slave Receptacle.

0029-11

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TM 5-2410-241-23-1

TEST STEP 2: POSITIVE CABLES – CONTINUED

0029

00029

7. Remove two bolts (Figure 12, Item 2), washers (Figure 12, Item 3), and plate (Figure 12, Item 1) from machine. 8. Using a digital multimeter (WP 0296), measure voltage drop between breaker panel positive junction point (Figure 12, Item 4) and negative battery post (Figure 12, Item 6). Voltage drop should be within 1 volt of value recorded in step 1. a. If voltage drop is greater than 1 volt of value recorded in step 1, replace positive battery cable (Figure 12, Item 5) (WP 0159). b. If voltage drop is within 1 volt of value recorded in step 1, proceed to step 9.

Figure 12. Breaker Panel Positive Junction Point.

0029-12

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TM 5-2410-241-23-1

0029

TEST STEP 2: POSITIVE CABLES – CONTINUED

00029

9. Using a digital multimeter (WP 0296), measure voltage drop between alternator positive cable end (Figure 13, Item 2) and machine ground (Figure 13, Item 1). Voltage should be within 1 volt of value recorded in step 1. a. If voltage drop is greater than 1 volt of value recorded in step 1, replace alternator positive cable (Figure 13, Item 3) (WP 0163). b. If voltage drop is within 1 volt of value recorded in step 1, and arctic kit is installed, proceed to step 10; otherwise, all positive battery cables and positive alternator cables are OK.

Figure 13. Alternator Positive Cable.

0029-13

0029

TM 5-2410-241-23-1

0029

TEST STEP 2: POSITIVE CABLES – CONTINUED

00029

10. Release two latches (Figure 14, Item 1) from arctic kit battery cover (Figure 14, Item 2). 11. With an assistant, remove arctic kit battery cover (Figure 14, Item 2). 12. Turn battery disconnect switch to OFF position (TM 5-2410-241-10). 13. Disconnect arctic kit positive battery cable (Figure 14, Item 3) from arctic kit batteries (Figure 14, Item 5). 14. Turn battery disconnect switch to ON position (TM 5-2410-241-10). 15. Using a digital multimeter (WP 0296), measure voltage drop between arctic kit positive battery cable terminal (Figure 14, Item 3) and negative battery post (Figure 14, Item 4) of arctic kit battery (Figure 14, Item 5). Voltage drop should be within 1 volt of value recorded in step 1. a. If voltage drop is greater than 1 volt of value recorded in step 1, proceed to step 17. b. If voltage drop is within 1 volt of value recorded in step 1, positive battery cables and positive alternator cables are OK. c.

Turn battery disconnect switch to OFF position (TM 5-2410-241-10).

d. Connect arctic kit positive battery cable (Figure 14, Item 3) on arctic kit batteries (Figure 14, Item 5). e. With an assistant, install arctic kit battery cover (Figure 14, Item 2), and set two latches (Figure 14, Item 1) on arctic kit battery cover (Figure 14, Item 2).

Figure 14. Arctic Kit Positive Battery Cable.

0029-14

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TM 5-2410-241-23-1

0029

TEST STEP 2: POSITIVE CABLES – CONTINUED

00029

16. Using a digital multimeter (WP 0296), measure voltage drop between arctic kit junction block terminal (Figure 15, Item 3) and ground terminal (Figure 15, Item 2) of battery disconnect switch. Voltage drop should be within 1 volt of value recorded in step 1. a. If voltage drop is greater than 1 volt of value recorded in step 1, replace junction block cable (Figure 15, Item 4) (WP 0287). b. If voltage drop is within 1 volt of value recorded in step 1, replace arctic kit positive battery cable (Figure 15, Item 1) (WP 0287). c.

Turn battery disconnect switch to OFF position (TM 5-2410-241-10).

d. Connect arctic kit positive battery cable (Figure 15, Item 3) on arctic kit batteries (Figure 15, Item 5). e. With an assistant, install arctic kit battery cover (Figure 15, Item 2), and set two latches (Figure 15, Item 1) on arctic kit battery cover (Figure 15, Item 2).

Figure 15. Arctic Kit Battery Cable Junction Block. END OF TASK END OF WORK PACKAGE

0029-15/(16 blank)

0029

2 TM 5-2410-241-23-1

0030

FIELD MAINTENANCE 0 0 3 0

-

BATTERY TESTS AND BATTERY CHARGING

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Battery Analyzer (6130-01-510-9594) (WP 0302, Item 68) Battery Charger (6130-01-510-9594) (WP 0302, Item 68) Post Terminal Cleaner (S0136) (WP 0302, Item 68)

References WP 0155

0

0

0

Equipment Condition Machine parked (TM 5-2410-241-10)

0

Estimated Time to Complete

0

0

0

0

1.0 Hr

0

0

Materials/Parts

0

Rag, Wiping (WP 0303, Item 24)

0

BATTERY TESTS

00030

1. Turn ignition switch and battery disconnect switch to the OFF position (TM 5-2410-241-10). 2. Disconnect battery cables from each battery (WP 0155). 3. If equipped with arctic kit heater, disconnect battery cables from each arctic kit heater battery (WP 0155). 4. Clean battery post using battery terminal cleaner. 5. Using battery analyzer, test each battery. a. If battery analyzer displays GOOD BATTERY, battery is OK. Connect battery cables to each battery (WP 0155). If equipped with arctic kit heater, connect battery cables to each arctic kit heater battery (WP 0155). b. If battery analyzer displays GOOD RECHARGE, charge battery. Refer to Battery Charging in this work package. Connect battery cables to each battery (WP 0155). If equipped with arctic kit heater, connect battery cables to each arctic kit heater battery (WP 0155). c.

If battery analyzer displays CHARGE & RETEST, charge battery. Refer to Battery Charging in this work package. If battery failed retest, replace battery (WP 0155).

d. If battery analyzer displays REPLACE BATTERY, battery failed test. Replace battery (WP 0155). END OF TASK BATTERY CHARGING

00030

1. Connect positive (red) clip of battery charger to positive post on battery, and connect negative clip of battery charger to chassis ground. 2. Turn battery charger switch ON. 3. Charge battery until the green Charge Complete LED is illuminated. 4. Charge will terminate when charge current drops below one ampere. 5. When charge is complete, test battery. Refer to Battery Tests in this work package. END OF TASK END OF WORK PACKAGE

0030-1/(2 blank)

8 TM 5-2410-241-23-1

0031

FIELD MAINTENANCE 0 0 3 1

-

STARTING SYSTEM TESTS

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Ammeter (WP 0302, Item 8) Multimeter (WP 0302, Item 38) Needle Tip (Tip G), (Multimeter) (WP 0302, Item 39) 0

0

0

0

Materials/Parts Rag, Wiping (WP 0303, Item 24) Personnel Required Two

0

0

References - Continued WP 0029 WP 0030 WP 0055 WP 0057 WP 0061 WP 0100 WP 0155 WP 0176 WP 0209

WP 0022 WP 0023

0

0

0

0

0

0

0

0

0

0

Equipment Condition

0

0

Machine parked (TM 5-2410-241-10) References

0

0

0

Estimated Time to Complete

0

0

0.5 Hr 0

0031-1

0

TM 5-2410-241-23-1

0031

STARTING SYSTEM TESTS

00031

Test Step 1. Measure Voltage of Battery

00031

NOTE Do not measure voltage across cable post clamps. 1. Release latch (Figure 1, Item 1) and open battery box door (Figure 1, Item 2) on machine. 2. Lift protective boot (Figure 1, Item 6) from negative battery terminal (Figure 1, Item 5). 3. Lift protective boot (Figure 1, Item 4) from positive battery terminal (Figure 1, Item 3). 4. Using a digital multimeter, measure voltage between the positive (Figure 1, Item 3) and negative (Figure 1, Item 5) battery posts while cranking engine or attempting to crank engine. a. If voltage is 17 to 26 volts, proceed to Test Step 2. b. If battery voltage is less than 17 volts, continue diagnostics.

Figure 1. Battery Test Points.

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TM 5-2410-241-23-1

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STARTING SYSTEM TESTS – CONTINUED

00031

5. Test batteries (WP 0030) and replace battery or batteries as necessary (WP 0157). 6. Verify correct operation of machine (TM 5-2410-241-10). a. If engine cranks, but will not start. return to troubleshooting (WP 0019). b. If machine does not have key switch power, diagnose and repair No Power with Ignition Switch ON malfunction (WP 0022). c.

If engine fails to crank, proceed to Test Step 2.

Test Step 2. Check Engine Rotation

00031

1. Manually rotate engine by hand to ensure that crankshaft is not stuck. Refer to Manually Turning Engine by Hand (WP 0023). a. If crankshaft is stuck or difficult to turn, replace engine (WP 0057). b. If engine is not difficult to turn, proceed to Test Step 3.

0031-3

TM 5-2410-241-23-1

0031

STARTING SYSTEM TESTS – CONTINUED Test Step 3. Measure Current Sent to Starting Motor Solenoid from Positive Post of Battery.

00031

1. Connect clamp of ammeter (Figure 2, Item 2) around positive battery cable (Figure 2, Item 5) connected to starter motor (Figure 2, Item 6) with the arrow (Figure 2, Item 1) on the ammeter clamp facing in the direction of current flow (towards starter). 2. Set the dial on the ammeter (Figure 2, Item 3) on the 1200 DC amp scale. Press the zero button (Figure 2, Item 4) to zero the meter.

Figure 2. Starter Cable.

0031

CAUTION Do not crank engine for more than 30 seconds. Allow starter to cool for two minutes before cranking again. Never turn disconnect switch off while engine is running. Failure to follow this caution may result in damage to equipment. 3. With an assistant, monitor and record the maximum amperage on ammeter (Figure 2, Item 3), while attempting to crank the engine (TM 5-2410-241-10). a. If current is 65 to 750 amps, remove and inspect starter for wear and damage (WP 0061). Also, inspect flywheel for wear and damage (WP 0100). Replace starter and/or flywheel as necessary. b. If current is greater than 750 amps, replace starter motor (WP 0061). c.

If current is less than 65 amps, proceed to Test Step 4.

0031-4

TM 5-2410-241-23-1

0031

STARTING SYSTEM TESTS – CONTINUED Test Step 4. Measure Voltage to Starter and Starting Motor Solenoid.

00031

1. Position boot (Figure 3, Item 3) aside to access starter motor positive terminal (Figure 3, Item 1) and starting motor solenoid S terminal (Figure 3, Item 2). 2. Monitor and record the digital multimeter and measure voltage between the starter motor positive terminal (Figure 3, Item 1) and ground. a. If voltage is 17 to 26 volts, proceed to step 3. b. If voltage is less than 17 volts, perform Battery Cables and Alternators Cables Test (WP 0029). 3. With assistance, monitor and record the digital multimeter and measure voltage between the starting motor solenoid S terminal (Figure 3, Item 2) and ground while attempting to crank the engine (TM 5-2410-241-10). a. If voltage is 17 to 26 volts, replace starter motor (WP 0061). b. If voltage is less than 17 volts, proceed to Test Step 5.

Figure 3. Measuring Voltage at Starter.

0031-5

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TM 5-2410-241-23-1

0031

STARTING SYSTEM TESTS – CONTINUED Test Step 5. Testing Starting Motor Solenoid Supply Circuit.

00031

1. Disconnect platform wiring harness connector VC-19 (Figure 4, Item 1) from engine main wiring harness connector MA-C8 (Figure 4, Item 2). 2. With assistance, monitor the digital multimeter and record voltage between the platform wiring harness connector VC-19 (Figure 4, Item 1) and ground while attempting to crank the engine (TM 5-2410-241-10). a. If voltage is 17 to 26 volts, replace engine main wiring harness (WP 0055). b. If voltage is less than 17 volts, proceed to step 3.

Figure 4. Harness Connector VC-19 and MA-C8.

0031-6

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TM 5-2410-241-23-1

0031

STARTING SYSTEM TESTS – CONTINUED 3. Turn ignition and battery disconnect switch OFF (TM 5-2410-241-10). 4. Open fuse panel access door (Figure 5, Item 3). 5. Disconnect platform wiring harness connector MA-C3 (Figure 5, Item 2) from fuse panel harness connector AC1 (Figure 5, Item 1). 6. Monitor and record the digital multimeter and measure resistance between platform wiring harness connector MA-C3 terminal 6 (Figure 5, Item 4) and platform harness connector VC-19 (Figure 5, Item 1). 7. Monitor and record the digital multimeter and measure resistance between platform wiring harness connector MA-C3 terminal 7 (Figure 5, Item 5) and platform harness connector VC-19 (Figure 5, Item 1). 8. Monitor and record the digital multimeter and measure resistance between platform wiring harness connector MA-C3 terminal 8 (Figure 5, Item 6) and platform harness connector VC-19 (Figure 5, Item 1). a. If resistance is 5.0 ohms or greater for any measurement, replace platform wiring harness (WP 0209). b. If resistance is less than 5.0 ohms for all measurements, proceed to step 9.

Figure 5. Harness Connector A-C1 and MA-C3.

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TM 5-2410-241-23-1

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STARTING SYSTEM TESTS – CONTINUED 9. Remove fuse box (Figure 6, Item 8) from machine (WP 0176). 10. Remove nut (Figure 6, Item 6), eyelet (Figure 6, Item 4), and washer (Figure 6, Item 7) from starter relay (Figure 6, Item 5). 11. Monitor and record the digital multimeter and measure resistance between fuse box harness connector A-C1 terminal 6 (Figure 6, Item 3) and eyelet (Figure 6, Item 4). 12. Monitor and record the digital multimeter and measure resistance between fuse box harness connector A-C1 terminal 7 (Figure 6, Item 2) and eyelet (Figure 6, Item 4). 13. Monitor and record the digital multimeter and measure resistance between fuse box harness connector A-C1 terminal 8 (Figure 6, Item 1) and eyelet (Figure 6, Item 4). a. If resistance is 5.0 ohms or greater for any measurement, replace fuse box wiring harness (WP 0176). b. If resistance is less than 5.0 ohms for all measurements, replace starter relay (WP 0176).

Figure 6. Harness Connector A-C1 and Starter Relay. END OF TASK END OF WORK PACKAGE

0031-8

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22 TM 5-2410-241-23-1

0032

FIELD MAINTENANCE

-

IMPLEMENT CYLINDER TESTS Blade Lift Cylinder Pressure Test, Blade Tilt Cylinder Pressure Test, Ripper Lift Cylinder Pressure Test, Ripper Tilt Cylinder Pressure Test, Blade Lift Cylinder Cycle Test, Blade Tilt Cylinder Cycle Test, Ripper Lift Cylinder Cycle Test, Ripper Tilt Cylinder Cycle Test, Blade Lift Cylinder Drift Test, Blade Tilt Cylinder Drift Test, Ripper Lift Cylinder Drift Test, Ripper Tilt Cylinder Drift Test 0 0 3

2

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Cap, Grease (WP 0302, Item 14) (2) Gauge Kit, Pressure, Dial Indicating (WP 0302, Item 28) 177-7862 Hose Assembly, Non-Metallic; 6,000 psi (41,500 kPa) 1/8-27-NPTF, 14 ft (427 cm) long (Part of Gauge, Pressure, Dial Indicating Kit [1U5796]) (WP 0302, Item 35) 177-7861 Hose Assembly; 6,000 psi (41,500 kPa), 1/8-27-NPTF, 18 ft (549 cm) long (WP 0302, Item 34) Pan, Drain (S0255) (WP 0302, Item 68) Plug (WP 0302, Item 44) (2) Seal Guard (WP 0302, Item 51) (2) Tape Measure (S0697) (WP 0302, Item 68) Wrench, Adjustable, Automotive, 18” (S0980) (WP 0302, Item 68) Wrench, Combination, 1 3/4” (S0796) (WP 0302, Item 68) 0

0

0

0

0

0

0

Tools and Special Tools - Continued Wrench, Combination, 1 7/8” (S0798) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) O-ring (2) Personnel Two References WP 0211 WP 0212 WP 0266 WP 0267 WP 0277

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Equipment Condition Machine parked (TM 5-2410-241-10) Hydraulic system pressure released (WP 0186)

0

0

0

0

Estimated Time to Complete 1.5 Hr

0032-1

0

0

TM 5-2410-241-23-1

0032

BLADE LIFT CYLINDER PRESSURE TEST

00032

WARNING

Ensure hydraulic system pressure is released before starting testing. Failure to do so may result in injury to personnel. 1. Install 177-7862 hose (Figure 1, Item 3) and 177-7861 hose (Figure 1, Item 4) on 1U5793 pressure differential gauge (Figure 1, Item 2). 2. Install 8T0861 pressure gauge (Figure 1, Item 1) on 1U5793 pressure differential gauge (Figure 1, Item 2).

Figure 1. Test Equipment.

0032-2

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TM 5-2410-241-23-1

0032

BLADE LIFT CYLINDER PRESSURE TEST – CONTINUED 3. Open door (Figure 2, Item 2) (TM 5-2410-241-10).

NOTE Transmission filter shown removed for clarity. 4. Remove protective cap (Figure 2, Item 3) from fitting (Figure 2, Item 6). 5. Remove protective cap (Figure 2, Item 4) from fitting (Figure 2, Item 5). 6. Connect 177-7861 hose (Figure 2, Item 8) coming from implement pump discharge pressure port (Figure 2, Item 9) to fitting (Figure 2, Item 6). 7. Connect 177-7862 hose (Figure 2, Item 7) coming from signal pressure port (Figure 2, Item 1) to fitting (Figure 2, Item 5).

Figure 2. Test Equipment Installation.

0032-3

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TM 5-2410-241-23-1

0032

BLADE LIFT CYLINDER PRESSURE TEST – CONTINUED

NOTE Steps 8 through 13 will address right cylinder. Repeat steps for left cylinder. 8. Ensure that blade is at rest flat on the ground (TM 5-2410-241-10). 9. Position drain pan underneath cylinder (Figure 3, Item 1). 10. Loosen tube nut (Figure 3, Item 7) and position line (Figure 3, Item 8) aside from fitting (Figure 3, Item 6). Leave O-ring (Figure 3, Item 2) in place until after test. 11. Install seal 6V-8400 (Figure 3, Item 4) on plug 6V-9513 (Figure 3, Item 3). 12. Install plug 6V-9513 (Figure 3, Item 3) on line (Figure 3, Item 8). 13. Install cap 6V-9834 (Figure 3, Item 5) on fitting (Figure 3, Item 6).

Figure 3. Front Lift Cylinder.

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TM 5-2410-241-23-1

0032

BLADE LIFT CYLINDER PRESSURE TEST – CONTINUED 14. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 15. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 16. Slowly engage blade lift control to the LIFT position (TM 5-2410-241-10).

NOTE Do not hold control lever in the LIFT position longer than 15 to 20 seconds. 17. Hold blade lift control in the LIFT position (TM 5-2410-241-10) and record pressure shown on the pressure gauge (Figure 4, Item 1). 18. Pressure gauge (Figure 4, Item 1) should read 3,255 to 3,345 psi (22,450 to 23,050 kPa). 19. If pressure is out of specification, replace bulldozer lift control valve (WP 0211 with Ripper) (WP 0212 with Winch). 20. Return blade lift control to the CENTER position (TM 5-2410-241-10).

Figure 4. Test Equipment Installation.

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TM 5-2410-241-23-1

0032

BLADE LIFT CYLINDER PRESSURE TEST - CONTINUED 21. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). 22. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 23. Release hydraulic system pressure (WP 0186). 24. Position drain pan underneath cylinder (Figure 5, Item 1) 25. Remove cap 6V-9834 (Figure 5, Item 5) and O-ring (Figure 5, Item 2) from fitting (Figure 5, Item 6). Discard Oring. 26. Remove plug 6V-9513 (Figure 5, Item 3) and seal 6V-8400 (Figure 5, Item 4) from line (Figure 5, Item 8). 27. Install new O-ring (Figure 5, Item 2) on fitting (Figure 5, Item 6). 28. Position line (Figure 5, Item 8) on fitting (Figure 5, Item 6). 29. Tighten tube nut (Figure 5, Item 7) on fitting (Figure 5, Item 6). 30. Remove gauges. 31. Reinstall protective caps. 32. Close door (TM 5-2410-241-10).

Figure 5. Front Lift Cylinder. END OF TASK

0032-6

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TM 5-2410-241-23-1

0032

BLADE TILT CYLINDER PRESSURE TEST

00032

WARNING

Ensure hydraulic system pressure is released before starting testing. Failure to do so may result in injury to personnel. 1. Install 177-7862 hose (Figure 6, Item 3) and 177-7861 hose (Figure 6, Item 4) on 1U5793 pressure differential gauge (Figure 6, Item 2). 2. Install 8T0861 pressure gauge (Figure 6, Item 1) on 1U5793 pressure differential gauge (Figure 6, Item 2).

Figure 6. Test Equipment.

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TM 5-2410-241-23-1

0032

BLADE TILT CYLINDER PRESSURE TEST – CONTINUED

00032

3. Open door (Figure 7, Item 2) (TM 5-2410-241-10).

NOTE Transmission filter shown removed for clarity. 4. Remove protective cap (Figure 7, Item 3) from fitting (Figure 7, Item 6). 5. Remove protective cap (Figure 7, Item 4) from fitting (Figure 7, Item 5). 6. Connect 177-7861 hose (Figure 7, Item 8) coming from implement pump discharge pressure port (Figure 7, Item 9) to fitting (Figure 7, Item 6). 7. Connect 177-7862 hose (Figure 7, Item 7) coming from signal pressure port (Figure 7, Item 1) to fitting (Figure 7, Item 5).

Figure 7. Test Equipment Installation.

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TM 5-2410-241-23-1

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BLADE TILT CYLINDER PRESSURE TEST – CONTINUED

00032

8. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 9. Raise blade 2 feet (0.6 m) off the ground (TM 5-2410-241-10). 10. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 11. Slowly engage blade tilt control to the FULL TILT position (TM 5-2410-241-10).

NOTE Do not hold control lever in the TILT position longer than 15 to 20 seconds. 12. Hold blade tilt control in the TILT position (TM 5-2410-241-10) and record pressure shown on the pressure gauge (Figure 8, Item 1). 13. Pressure gauge (Figure 8, Item 1) should read 2,455 to 2,545 psi (14,225 to 20,225 kPa). If pressure is out of specification, replace bulldozer tilt control valve (WP 0211 with Ripper) (WP 0212 with Winch). 14. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). 15. Lower blade to the ground (TM 5-2410-241-10). 16. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 17. Release hydraulic system pressure (WP 0186). 18. Remove gauges. 19. Reinstall protective caps. 20. Close door (TM 5-2410-241-10).

Figure 8. Test Equipment Installation. END OF TASK

0032-9

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TM 5-2410-241-23-1

0032

RIPPER LIFT CYLINDER PRESSURE TEST

00032

WARNING

Ensure hydraulic system pressure is released before starting testing. Failure to do so may result in injury to personnel. 1. Install 177-7862 hose (Figure 9, Item 3) and 177-7861 hose (Figure 9, Item 4) on 1U5793 pressure differential gauge (Figure 9, Item 2). 2. Install 8T0861 pressure gauge (Figure 9, Item 1) on 1U5793 pressure differential gauge (Figure 9, Item 2).

Figure 9. Test Equipment.

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TM 5-2410-241-23-1

RIPPER LIFT CYLINDER PRESSURE TEST - CONTINUED

0032

00032

3. Open door (Figure 10, Item 2) (TM 5-2410-241-10).

NOTE Transmission filter shown removed for clarity. 4. Remove protective cap (Figure 10, Item 3) from fitting (Figure 10, Item 6). 5. Remove protective cap (Figure 10, Item 4) from fitting (Figure 10, Item 5). 6. Connect 177-7861 hose (Figure 10, Item 8) coming from implement pump discharge pressure port (Figure 10, Item 9) to fitting (Figure 10, Item 6). 7. Connect 177-7862 hose (Figure 10, Item 7) coming from signal pressure port (Figure 10, Item 1) to fitting (Figure 10, Item 5).

Figure 10. Test Equipment Installation.

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TM 5-2410-241-23-1

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RIPPER LIFT CYLINDER PRESSURE TEST - CONTINUED

00032

8. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 9. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 10. Slowly engage ripper control to the FULL LIFT position (TM 5-2410-241-10).

NOTE Do not hold control lever in the LIFT position longer than 15 to 20 seconds. 11. Hold ripper lift control in the FULL LIFT position (TM 5-2410-241-10) and record pressure shown on the pressure gauge (Figure 11, Item 1). 12. Pressure gauge (Figure 11, Item 1) should read 3,255 to 3,345 psi (22,450 to 23,050 kPa). If pressure is out of specification, replace ripper lift control valve (WP 0211). 13. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). 14. Lower ripper to the ground (TM 5-2410-241-10). 15. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 16. Release hydraulic system pressure (WP 0186). 17. Remove gauges. 18. Reinstall protective caps. 19. Close door (TM 5-2410-241-10).

Figure 11. Test Equipment Installation. END OF TASK

0032-12

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TM 5-2410-241-23-1

RIPPER TILT CYLINDER PRESSURE TEST

0032

00032

WARNING

Ensure hydraulic system pressure is released before starting testing. Failure to do so may result in injury to personnel. 1. Install 177-7862 hose (Figure 12, Item 3) and 177-7861 hose (Figure 12, Item 4) on 1U5793 pressure differential gauge (Figure 12, Item 2). 2. Install 8T0861 pressure gauge (Figure 12, Item 1) on 1U5793 pressure differential gauge (Figure 12, Item 2).

Figure 12. Test Equipment.

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TM 5-2410-241-23-1

RIPPER TILT CYLINDER PRESSURE TEST – CONTINUED

0032

00032

3. Open door (Figure 13, Item 2) (TM 5-2410-241-10).

NOTE Transmission filter shown removed for clarity. 4. Remove protective cap (Figure 13, Item 3) from fitting (Figure 13, Item 6). 5. Remove protective cap (Figure 13, Item 4) from fitting (Figure 13, Item 5). 6. Connect 177-7861 hose (Figure 13, Item 8) coming from implement pump discharge pressure port (Figure 13, Item 9) to fitting (Figure 13, Item 6). 7. Connect 177-7862 hose (Figure 13, Item 7) coming from signal pressure port (Figure 13, Item 1) to fitting (Figure 13, Item 5).

Figure 13. Test Equipment Installation.

0032-14

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TM 5-2410-241-23-1

0032

RIPPER TILT CYLINDER PRESSURE TEST – CONTINUED

00032

8. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 9. Raise ripper 2 feet (0.6 m) off the ground (TM 5-2410-241-10). 10. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 11. Slowly engage ripper tilt control to the FULL TILT position (TM 5-2410-241-10).

NOTE Do not hold control lever in the LIFT position longer than 15 to 20 seconds. 12. Hold ripper tilt control in the FULL TILT position (TM 5-2410-241-10) and record pressure shown on the pressure gauge (Figure 14, Item 1). 13. Pressure gauge (Figure 14, Item 1) should read 3,255 to 3,345 psi (22,450 to 23,050 kPa). If pressure is out of specification, replace ripper tilt control valve (WP 0211). 14. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). 15. Lower ripper to the ground (TM 5-2410-241-10). 16. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 17. Release hydraulic system pressure (WP 0186). 18. Remove gauges. 19. Reinstall protective caps. 20. Close door (TM 5-2410-241-10).

Figure 14. Test Equipment Installation. END OF TASK

0032-15

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TM 5-2410-241-23-1

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BLADE LIFT CYLINDER CYCLE TEST

00032

1. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 2. Ensure that blade is at rest flat on the ground (TM 5-2410-241-10). 3. Fully engage blade lift control to the FULL LIFT position (TM 5-2410-241-10). Blade should travel from GROUND position to FULL LIFT position in 4.3 seconds or less. 4. Lower blade to the ground (TM 5-2410-241-10). 5. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). END OF TASK BLADE TILT CYLINDER CYCLE TEST

00032

1. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 2. Ensure that blade is at rest, flat on the ground (TM 5-2410-241-10). 3. Engage blade lift control to raise blade approximately 2 feet (0.6 m) off the ground (TM 5-2410-241-10). 4. Fully engage blade tilt control to move blade to FULL TILT RIGHT position (TM 5-2410-241-10). 5. Fully engage blade tilt control to the FULL TILT LEFT position (TM 5-2410-241-10). Blade should travel from FULL TILT RIGHT position to FULL TILT LEFT position in 2.4 seconds or less. 6. Lower blade to the ground (TM 5-2410-241-10). 7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). END OF TASK RIPPER LIFT CYLINDER CYCLE TEST

00032

1. Remove three ripper shanks from machine (WP 0281). 2. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 3. Ensure that ripper frame is at rest on the ground. 4. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 5. Fully engage ripper lift control to the FULL LIFT position (TM 5-2410-241-10). Ripper should travel from GROUND position to FULL LIFT position in 2.8 seconds or less. 6. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). 7. Lower ripper to the ground (TM 5-2410-241-10). 8. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). END OF TASK

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TM 5-2410-241-23-1

0032

RIPPER TILT CYLINDER CYCLE TEST

00032

1. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 2. Fully engage ripper lift control to the FULL LIFT position (TM 5-2410-241-10). 3. Fully engage ripper tilt control to the FULL TILT OUT position (cylinders IN) (TM 5-2410-241-10). 4. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 5. Fully engage ripper tilt control to the FULL TILT IN position (cylinders OUT) (TM 5-2410-241-10). Ripper Frame should travel from FULL TILT IN position to FULL TILT OUT position in 3.8 seconds or less. 6. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). 7. Lower ripper to the ground (TM 5-2410-241-10). 8. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). END OF TASK

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TM 5-2410-241-23-1

0032

BLADE LIFT CYLINDER DRIFT TEST

00032

1. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 2. Ensure implement lockout switch is in UNLOCK position and blade is at rest, flat on the ground (TM 5-2410241-10). 3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Measure length of cylinder shaft (Figure 15, Item 1) and mark shaft at 1/2 the distance. 5. Start machine (TM 5-2410-241-10). 6. Raise blade to marked position (TM 5-2410-241-10). 7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Cylinder shaft (Figure 15, Item 1) should NOT DRIFT OVER 1.5 inches (38.1 mm) within 5 minutes. If cylinders DRIFT OVER 1.5 inches (38.1 mm) within 5 minutes, replace blade lift cylinders (WP 0266). 9. Start machine (TM 5-2410-241-10). 10. Lower blade to the ground (TM 5-2410-241-10). 11. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

Figure 15. Blade Lift Cylinder Drift Test. END OF TASK

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TM 5-2410-241-23-1

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BLADE TILT CYLINDER DRIFT TEST

00032

1. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 2. Raise blade 2 feet (0.6 m) off the ground (TM 5-2410-241-10). 3. Engage blade tilt control to extend blade tilt to FULL LEFT position (TM 5-2410-241-10). 4. Turn ignition switch and battery disconnect switch to OFF position. (TM 5-2410-241-10). 5. Measure length of cylinder shaft (Figure 16, Item 1) and mark shaft at the midpoint. 6. Start machine (TM 5-2410-241-10). 7. Engage blade tilt control to move blade to 1/2 RIGHT TILT position (TM 5-2410-241-10). 8. Turn ignition switch and battery disconnect switch to OFF position. (TM 5-2410-241-10). 9. Cylinder shaft (Figure 16, Item 1) should NOT DRIFT OVER 1/2 inch (12.7 mm) within 5 minutes. If cylinders DRIFT OVER 1/2 inch (12.7 mm) within 5 minutes, replace blade tilt cylinder (WP 0267). 10. Start machine (TM 5-2410-241-10). 11. Engage blade tilt control to center blade tilt (TM 5-2410-241-10). 12. Lower blade to the ground (TM 5-2410-241-10). 13. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

Figure 16. Blade Tilt Cylinder Drift Test. END OF TASK

0032-19

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TM 5-2410-241-23-1

0032

RIPPER LIFT CYLINDER DRIFT TEST

00032

1. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 2. Ensure that ripper frame is at rest on the ground (TM 5-2410-241-10). 3. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 4. Measure length of cylinder shaft (Figure 17, Item 1) and mark shaft at the midpoint. 5. Start machine (TM 5-2410-241-10). 6. Raise ripper to marked position (TM 5-2410-241-10). 7. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 8. Cylinder shaft (Figure 17, Item 1) should NOT DRIFT OVER 1/2 inch (12.7 mm) within 5 minutes. If cylinders DRIFT OVER 1/2 inch (12.7 mm) within 5 minutes, replace ripper lift cylinders (WP 0277). 9. Start machine (TM 5-2410-241-10). 10. Lower ripper to the ground (TM 5-2410-241-10). 11. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

Figure 17. Ripper Lift Cylinder Drift Test. END OF TASK

0032-20

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TM 5-2410-241-23-1

0032

RIPPER TILT CYLINDER DRIFT TEST 1. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 2. Engage ripper lift control to lift ripper 2 feet (0.6 m) off ground (TM 5-2410-241-10). 3. Engage ripper tilt control to position ripper to FULL OUT TILT position. 4. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 5. Measure length of tilt cylinder shaft (Figure 18, Item 1) and mark shaft at midpoint. 6. Start machine (TM 5-2410-241-10). 7. Engage ripper tilt control to tilt ripper to marked position (TM 5-2410-241-10). 8. Engage ripper lift control to lower ripper and raise machine off the ground (TM 5-2410-241-10). 9. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 10. Cylinder shaft (Figure 18, Item 1) should NOT DRIFT OVER 1/2 inch (12.7 mm) within 5 minutes or less. If cylinders DRIFT OVER 1/2 inch (12.7 mm) within 5 minutes, replace ripper tilt cylinders (WP 0278). 11. Start machine (TM 5-2410-241-10). 12. Engage ripper lift control to raise ripper and lower machine to the ground (TM 5-2410-241-10). 13. Engage ripper tilt control and lift control to rest ripper frame on the ground (TM 5-2410-241-10). 14. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

Figure 18. Ripper Tilt Cylinder Drift Test. END OF TASK END OF WORK PACKAGE

0032-21/(22 blank)

0032

10 TM 5-2410-241-23-1

0033

FIELD MAINTENANCE 0 0

3 3

-

IMPLEMENT PUMP DISCHARGE TESTS AND ADJUSTMENTS

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Gauge, Pressure (Pilot), Dial Indicating (WP 0302, Item 31) Gauge Kit, Pressure, Dial Indicating (WP 0302, Item 28) 177-7862 Hose Assembly; 6,000 psi (41,500 kPa), 1/8-27-NPTF, 18 ft (549 cm) long (WP 0302, Item 34) 177-7861 Hose Assembly, Non-Metallic; 6,000 psi (41,500 kPa) 1/8-27-NPTF, 14 ft (427 cm) long (Part of Gauge, Pressure, Dial Indicating Kit [1U5796]) (WP 0302, Item 35) Wrench, Torque, Dial, 3/8” Drive, 300 lb-in. (WP 0302, Item 74)

Personnel Required Two

0

0

0

0

0

0

0

0

Materials/Parts Rag, Wiping (WP 0303, Item 24) O-ring (2)

0

0

0

0033-1

References WP 0186 WP 0230 Equipment Condition

0

0

0

0

Machine parked (TM 5-2410-241-10) Hydraulic system pressure released (WP 0186)

0

0

Estimated Time to Complete 1.6 Hr

0

0

TM 5-2410-241-23-1

0033

IMPLEMENT PUMP DISCHARGE TESTS

0033

Low Pressure Standby Pressure Test

0033

1. Install 177-7862 hose (Figure 1, Item 3) and 177-7861 hose (Figure 1, Item 4) on 1U5793 pressure differential gauge (Figure 1, Item 2). 2. Install 8T0856 pressure gauge (Figure 1, Item 1) on 1U5793 pressure differential gauge (Figure 1, Item 2).

Figure 1. Test Equipment.

0033-2

0033

TM 5-2410-241-23-1

0033

IMPLEMENT PUMP DISCHARGE TESTS – CONTINUED Low Pressure Standby Pressure Test - Continued

0033

NOTE Transmission filter shown removed for clarity. 3. Open door (Figure 2, Item 2) (TM 5-2410-241-10). 4. Remove protective cap (Figure 2, Item 3) from fitting (Figure 2, Item 6). 5. Remove protective cap (Figure 2, Item 4) from fitting (Figure 2, Item 5). 6. Connect 177-7861 hose (Figure 2, Item 8) coming from implement pump discharge pressure port (Figure 2, Item 9) to fitting (Figure 2, Item 6). 7. Connect 177-7862 hose (Figure 2, Item 7) coming from signal pressure port (Figure 2, Item 1) to fitting (Figure 2, Item 5).

Figure 2. Test Equipment Installation.

0033-3

0033

TM 5-2410-241-23-1

0033

IMPLEMENT PUMP DISCHARGE TESTS – CONTINUED Low Pressure Standby Pressure Test - Continued

CAUTION DO NOT OPERATE ANY CONTROLS as gauge can be damaged. 8. Ensure parking brake is engaged and implement lockout switch is in LOCK position (TM 5-2410-241-10). 9. Start machine and allow it to run for 15 minute to reach normal operating temperature (TM 5-2410-241-10). 10. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 11. Pressure gauge (Figure 3, Item 1) should gradually increase to 520 psi (3,600 kPa). Record pressure reading on gauge. 12. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). 13. Turn ignition switch and battery disconnect switch to OFF position. (TM 5-2410-241-10).

Figure 3. Pressure Gauge.

0033-4

0033

TM 5-2410-241-23-1

0033

IMPLEMENT PUMP DISCHARGE TESTS – CONTINUED Margin Pressure Test and Adjustment 14. Remove 8T0856 pressure gauge (Figure 4, Item 1) from 1U5793 pressure differential gauge fitting (Figure 4, Item 2). 15. Install 8T0861 pressure gauge (Figure 4, Item 1) on 1U5793 pressure differential gauge fitting (Figure 4, Item 2). 16. Ensure parking brake is engaged and implement lockout switch is in UNLOCK position (TM 5-2410-241-10). 17. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 18. Ensure that blade is at rest, flat on the ground (TM 5-2410-241-10). 19. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 20. Move bulldozer blade control handle half way into the RAISE position and record pressure shown on the differential pressure gauge (Figure 4, Item 3). 21. Differential pressure gauge (Figure 4, Item 3) should read 290 to 320 psi (2,000 to 2,200 kPa) while blade is in motion. a. If pressure is NOT within specification, proceed to step 22. b. If pressure is within specification, proceed to step 36.

Figure 4. Test Equipment Installation.

0033-5

0033

TM 5-2410-241-23-1

0033

IMPLEMENT PUMP DISCHARGE TESTS – CONTINUED Margin Pressure Test and Adjustment - Continued

0033

22. Ensure all implements are lowered to the ground (TM 5-2410-241-10). 23. Release hydraulic system pressure (WP 0186). 24. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 25. Remove front floor plate (WP 0230). 26. Hold adjustment screw (Figure 5, Item 2) and loosen nut (Figure 5, Item 1) on pump control valve (Figure 5, Item 3). 27. If margin pressure is high, turn adjustment screw (Figure 5, Item 2) counterclockwise to decrease margin pressure. 28. If margin pressure is low, turn adjustment screw (Figure 5, Item 2) clockwise to increase margin pressure. 29. Hold adjustment screw (Figure 5, Item 2) and tighten nut (Figure 5, Item 1) on pump control valve (Figure 5, Item 3). Tighten nut to 144 lb-in. (16 Nm).

Figure 5. Flow Compensator Adjustment.

0033-6

0033

TM 5-2410-241-23-1

0033

IMPLEMENT PUMP DISCHARGE TESTS – CONTINUED Margin Pressure Test and Adjustment - Continued

0033

30. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 31. Ensure parking brake switch is in ON position (TM 5-2410-241-10). 32. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 33. Ensure blade is positioned on the ground (TM 5-2410-241-10). 34. Move bulldozer blade control handle halfway into the RAISE position and record pressure shown on the differential pressure gauge (Figure 6, Item 1). 35. Differential pressure gauge (Figure 6, Item 1) should read 290 to 320 psi (2,000 to 2,200 kPa) while blade is in motion. a. If pressure is NOT within specification, repeat steps 22 through 34. b. If pressure is within specified range, proceed to step 36.

Figure 6. Differential Pressure Gauge.

0033-7

0033

TM 5-2410-241-23-1

0033

IMPLEMENT PUMP DISCHARGE TESTS – CONTINUED High Pressure Cutoff Test

0033

36. Release parking brake (TM 5-2410-241-10). 37. Ensure lockout switch is in LOCK position (TM 5-2410-241-10). 38. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 39. Apply service brake (TM 5-2410-241-10).

WARNING Ensure service brake is fully applied prior to position steering control handle in MID STEER LEFT position. Failure to follow this warning may result in injury or death to personnel. 40. Slowly apply steering control handle to MID STEER LEFT position (TM 5-2410-241-10). 41. Pressure gauge (Figure 7, Item 1) should read 5,485 to 5,685 psi (37,800 to 39,200 kPa). Record pressure readings on gauge. a. If pressure reading is NOT within specification, proceed to step 42. b. If pressure reading is within specification, proceed to step 61. 42. Return steering control handle to NEUTRAL STEER position (TM 5-2410-241-10). 43. Release service brake (TM 5-2410-241-10). 44. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). 45. Apply parking brake (TM 5-2410-241-10). 46. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

Figure 7. Pressure Gauge.

0033-8

0033

TM 5-2410-241-23-1

0033

IMPLEMENT PUMP DISCHARGE TESTS – CONTINUED High Pressure Cutoff Test - Continued

0033

47. Ensure all implements are lowered to the ground (TM 5-2410-241-10). 48. Release hydraulic system pressure (WP 0186). 49. Turn ignition switch and battery disconnect switch to OFF position. (TM 5-2410-241-10). 50. Hold adjustment screw (Figure 8, Item 2) and loosen nut (Figure 8, Item 1) on pump control valve (Figure 8, Item 3). 51. If high pressure cutoff is high, turn adjustment screw (Figure 8, Item 2) counterclockwise to decrease margin pressure. 52. If high pressure cutoff is low, turn adjustment screw (Figure 8, Item 2) clockwise to increase margin pressure. 53. Hold adjustment screw (Figure 8, Item 2) and tighten nut (Figure 8, Item 1) on pump control valve (Figure 8, Item 3). Tighten nut to 144 in-lb (16 Nm).

Figure 8. Pressure Compensator Adjustment.

0033-9

0033

TM 5-2410-241-23-1

0033

IMPLEMENT PUMP DISCHARGE TESTS – CONTINUED High Pressure Cutoff - Continued

0033

54. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 55. Release parking brake (TM 5-2410-241-10). 56. Ensure implement lockout switch is in the LOCK position (TM 5-2410-241-10) 57. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 58. Apply service brake (TM 5-2410-241-10). 59. Slowly apply steering control handle to MID STEER LEFT position (TM 5-2410-241-10). 60. Pressure gauge (Figure 9, Item 1) should read 5,485 to 5,685 psi (37,800 to 39,200 kPa). Record pressure readings on gauge. a. If pressure is out of specification, repeat steps 47 through 53. b. If pressure is within specification, proceed to step 61. 61. Return steering control handle to NEUTRAL STEER position (TM 5-2410-241-10). 62. Release service brake (TM 5-2410-241-10). 63. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). 64. Apply parking brake (TM 5-2410-241-10). 65. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 66. Install front floor plate (WP 0230). 67. Remove test equipment from machine.

Figure 9. Pressure Cutoff. END OF TASK END OF WORK PACKAGE

0033-10

0033

4 TM 5-2410-241-23-1

0034

FIELD MAINTENANCE

-

0034PILOT PRESSURE TESTS AND ADJUSTMENTS INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) 0 Coupling, Hose (1/4” NPT, Internal Thread) (WP 0302, Item 17) (2) 0 Gauge, Pressure (Pilot), Dial Indicating (WP 0302, Item 31) 0 177-7862 Hose Assembly; 6,000 psi (41, 500 kPa), 1/8-27-NPTF, 18 ft (549 cm) long (WP 0302, Item 34) 0 Wrench, Torque, Dial, 3/8” Drive, 300 lb-in. (WP 0302, Item 74) 0 Materials/Parts Rag, Wiping (WP 0303, Item 24)

0 0

0034-1

Personnel

0

Two

0

References

0

WP 0033 WP 0112 WP 0216 Equipment Condition Machine parked (TM 5-2410-241-10) Estimated Time to Complete 1.0 Hr

0 0 0 0 0 0 0

TM 5-2410-241-23-1

0034

PILOT PRESSURE TESTS AND ADJUSTMENTS

00034

1. Open door (Figure 1, Item 4) on machine (TM 5-2410-241-10). 2. Remove protective cap (Figure 1, Item 8) from pilot pressure port (Figure 1, Item 9). 3. Install coupler (Figure 1, Item 5) on pilot pressure gauge (Figure 1, Item 3). 4. Connect hose (Figure 1, Item 1) on coupler (Figure 1, Item 5) and pilot pressure port (Figure 1, Item 9). 5. Ensure parking brake is engaged and implement lockout switch is in OFF position (TM 5-2410-241-10). 6. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 7. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 8. Pilot pressure gauge (Figure 1, Item 3) should read 450–500 psi (3,100–3,450 kPa). Record pressure readings on gauge. 9. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). a. If pressure is not within specified range, proceed to step 10. b. If pressure is within specified range, proceed to step 16. 10. Hold adjustment screw (Figure 1, Item 6) and loosen nut (Figure 1, Item 7) on control manifold (Figure 1, Item 2). 11. If pilot pressure is too high, turn adjustment screw (Figure 1, Item 6) counterclockwise to decrease pilot pressure. 12. If pilot pressure is too low, turn adjustment screw (Figure 1, Item 6) clockwise to increase pilot pressure. 13. Hold adjustment screw (Figure 1, Item 6) and tighten nut (Figure 1, Item 7) on control manifold (Figure 1, Item 2). Tighten nut to 144 in-lb (16 Nm) 14. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 15. Pilot pressure gauge should read 450–500 psi (3,100–3,450 kPa). Record pressure readings on gauge. If pilot pressure will not adjust to specified range, perform the following: a. If pilot pressure is ABOVE 450–500 psi (3,100–3,450 kPa) and cannot be adjusted down, replace control manifold (WP 0216). b. If pilot pressure is BELOW 450–500 psi (3,100–3,450 kPa) and cannot be adjusted up, perform implement pump discharge pressure tests (WP 0033). (1) If implement pump discharge pressures are within specified range, replace control manifold (WP 0216). (2) If implement pump discharge pressures are NOT with in specified range, replace implement pump (WP 0112). 16. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). 17. Turn ignition switch and battery disconnect switch to OFF position. (TM 5-2410-241-10). 18. Remove test equipment from machine. 19. Install protective cap (Figure 1, Item 8) on pilot pressure port (Figure 1, Item 9). 20. Close door (Figure 1, Item 4) on machine (TM 5-2410-241-10).

0034-2

TM 5-2410-241-23-1

PILOT PRESSURE TESTS AND ADJUSTMENTS – CONTINUED

Figure 1. Test Equipment Installation. END OF TASK END OF WORK PACKAGE

0034-3/(4 blank)

0034

00034

034

12 TM 5-2410-241-23-1

0035

FIELD MAINTENANCE

-

0035STEERING HYDRAULIC CIRCUIT TESTS AND ADJUSTMENTS INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) 0 Gauge, Pressure (Pilot), Dial Indicating (WP 0302, Item 31) 0 Gauge Kit, Pressure, Dial Indicating (WP 0302, Item 28) 0 177-7861 Hose Assembly, Non-Metallic; 6,000 psi (41,500 kPa) 1/8-27-NPTF, 14 ft (427 cm) long (Part of Gauge, Pressure, Dial Indicating Kit [1U5796]) (WP 0302, Item 35) 0 177-7862 Hose Assembly; 6,000 psi (41,500 kPa), 1/8-27-NPTF, 18 ft (549 cm) long (WP 0302, Item 34) 0 Wrench, Torque, Dial, 3/8” Drive, 300 lb-in. (WP 0302, Item 74) 0

0035-1

Materials/Parts Rag, Wiping (WP 0303, Item 24) O-ring (2) Personnel Required

0 0 0 0

Two

0

References

0

WP 0230 Equipment Condition

0 0

Machine parked (TM 5-2410-241-10) 0 Hydraulic system pressure released (WP 0186) 0 Estimated Time to Complete 1.6 Hr

0 0

TM 5-2410-241-23-1

0035

STEERING HYDRAULIC CIRCUIT TESTS

00035

Low Pressure Standby Pressure Test

00035

1. Install 177-7862 hose (Figure 1, Item 3) and 177-7861 hose (Figure 1, Item 4) on 1U5793 pressure differential gauge (Figure 1, Item 2). 2. Install 8T0856 pressure gauge (Figure 1, Item 1) on 1U5793 pressure differential gauge (Figure 1, Item 2).

Figure 1. Test Equipment.

0035-2

035

TM 5-2410-241-23-1

0035

STEERING HYDRAULIC CIRCUIT TESTS – CONTINUED Low Pressure Standby Pressure Test - Continued

00035

00035

NOTE Transmission filter shown removed for clarity. 3. Open door (Figure 2, Item 2) (TM 5-2410-241-10). 4. Remove protective cap (Figure 2, Item 3) from fitting (Figure 2, Item 6). 5. Remove protective cap (Figure 2, Item 4) from fitting (Figure 2, Item 5). 6. Connect 177-7861 hose (Figure 2, Item 8) coming from implement pump discharge pressure port (Figure 2, Item 9) to fitting (Figure 2, Item 6). 7. Connect 177-7862 hose (Figure 2, Item 7) coming from signal pressure port (Figure 2, Item 1) to fitting (Figure 2, Item 5).

Figure 2. Test Equipment Installation.

0035-3

035

TM 5-2410-241-23-1

0035

STEERING HYDRAULIC CIRCUIT TESTS – CONTINUED Low Pressure Standby Pressure Test - Continued

00035

00035

NOTE DO NOT OPERATE ANY CONTROLS as gauge can be damaged. 8. Ensure parking brake is engaged and implement lockout switch is in LOCK position (TM 5-2410-241-10). 9. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 10. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 11. Pressure gauge (Figure 3, Item 1) should gradually increase to 520 psi (3,600 kPa). Record pressure reading on gauge. 12. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). 13. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

Figure 3. Pressure Gauge.

0035-4

035

TM 5-2410-241-23-1

0035

STEERING HYDRAULIC CIRCUIT TESTS – CONTINUED Margin Pressure Test and Adjustment

00035

00035

14. Remove 8T0856 pressure gauge (Figure 4, Item 1) from 1U5793 pressure differential gauge fitting (Figure 4, Item 2). 15. Install 8T0861 pressure gauge (Figure 4, Item 1) on 1U5793 pressure differential gauge fitting (Figure 4, Item 2). 16. Ensure parking brake is engaged and implement lockout switch is in LOCK position (TM 5-2410-241-10). 17. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 18. Ensure that blade is at rest flat on the ground (TM 5-2410-241-10). 19. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 20. Move bulldozer blade control handle half way into the RAISE position and record pressure shown on the differential pressure gauge (Figure 4, Item 3). 21. Differential pressure gauge (Figure 4, Item 3) should read 290 to 320 psi (2,000 to 2,200 kPa) while blade is in motion. a. If pressure is NOT in specification, proceed to step 22. b. If pressure is within specification, proceed to step 36.

Figure 4. Test Equipment Installation.

0035-5

035

TM 5-2410-241-23-1

0035

STEERING HYDRAULIC CIRCUIT TESTS – CONTINUED Margin Pressure Test and Adjustment - Continued

00035

00035

22. Ensure all implements are lowered to the ground (TM 5-2410-241-10). 23. Release hydraulic system pressure (WP 0186). 24. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 25. Remove front floor plate (WP 0230). 26. Hold adjustment screw (Figure 5, Item 2) and loosen nut (Figure 5, Item 1) on pump control valve (Figure 5, Item 3). 27. If margin pressure is high, turn adjustment screw (Figure 5, Item 2) counterclockwise to decrease margin pressure. 28. If margin pressure is low, turn adjustment screw (Figure 5, Item 2) clockwise to increase margin pressure. 29. Hold adjustment screw (Figure 5, Item 2) and tighten nut (Figure 5, Item 1) on pump control valve (Figure 5, Item 3). Tighten nut to 144 lb-in. (16 Nm).

Figure 5. Flow Compensator Adjustment.

0035-6

035

TM 5-2410-241-23-1

0035

STEERING HYDRAULIC CIRCUIT TESTS – CONTINUED Margin Pressure Test and Adjustment - continued

00035

00035

30. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 31. Ensure park brake switch is in ON position (TM 5-2410-241-10). 32. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 33. Ensure blade is positioned on the ground (TM 5-2410-241-10). 34. Move bulldozer blade control handle half way into the RAISE position and record pressure shown on the differential pressure gauge (Figure 6, Item 1). 35. Differential pressure gauge (Figure 6, Item 1) should read 290 to 320 psi (2,000 to 2,200 kPa) while blade is in motion. a. If pressure is NOT within specification, repeat steps 22 through 34. b. If pressure is within specified range, proceed to step 36.

Figure 6. Differential Pressure Gauge.

0035-7

035

TM 5-2410-241-23-1

0035

STEERING HYDRAULIC CIRCUIT TESTS – CONTINUED High Pressure Cutoff Test

00035

00035

36. Ensure implement lockout switch is in LOCK position. Release parking brake (TM 5-2410-241-10). 37. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 38. Apply service brake (TM 5-2410-241-10).

WARNING Ensure service brake is fully applied prior to position steering control handle in MID STEER LEFT or RIGHT position. Failure to follow this warning may result in injury or death to personnel. 39. Slowly apply steering control handle to MID STEER LEFT position (TM 5-2410-241-10). 40. Pressure gauge (Figure 7, Item 1) should read 5,485 to 5,685 psi (37,800 to 39,200 kPa). Record pressure readings on gauge. 41. Return steering control handle to NEUTRAL STEER position (TM 5-2410-241-10). 42. Slowly apply steering control handle to MID STEER RIGHT position (TM 5-2410-241-10). 43. Pressure gauge (Figure 7, Item 1) should read 5,485 to 5,685 psi (37,800 to 39,200 kPa). Record pressure readings on gauge. 44. Return steering control handle to NEUTRAL STEER position (TM 5-2410-241-10). 45. Release service brake (TM 5-2410-241-10). 46. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). 47. Apply parking brake (TM 5-2410-241-10). 48. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 49. If STEER LEFT pressure readings are different from STEER RIGHT pressure readings, replace counterbalance valve (WP 0217). 50. If STEER LEFT pressure readings and STEER RIGHT pressure readings are the same, but not within specified range, proceed to step 51.

0035-8

TM 5-2410-241-23-1

STEERING HYDRAULIC CIRCUIT TESTS – CONTINUED High Pressure Cutoff Test - Continued

0035

00035

00035

Figure 7. Pressure Gauge.

0035-9

035

TM 5-2410-241-23-1

0035

STEERING HYDRAULIC CIRCUIT TESTS – CONTINUED High Pressure Cutoff Test - Continued

00035

00035

51. Ensure all implements are lowered to the ground (TM 5-2410-241-10). 52. Release hydraulic system pressure (WP 0186). 53. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 54. Hold adjustment screw (Figure 8, Item 2) and loosen nut (Figure 8, Item 1) on pump control valve (Figure 8, Item 3). 55. If high pressure cutoff is high, turn adjustment screw (Figure 8, Item 2) counterclockwise to decrease margin pressure. 56. If high pressure cutoff is low, turn adjustment screw (Figure 8, Item 2) clockwise to increase margin pressure. 57. Hold adjustment screw (Figure 8, Item 2) and tighten nut (Figure 8, Item 1) on pump control valve (Figure 8, Item 3). Tighten nut to 144 lb-in. (16 Nm).

Figure 8. Pressure Compensator Adjustment.

0035-10

035

TM 5-2410-241-23-1

0035

STEERING HYDRAULIC CIRCUIT TESTS – CONTINUED High Pressure Cutoff Test - Continued

00035

00035

58. Start machine and allow it to run for 15 minutes to reach normal operating temperature (TM 5-2410-241-10). 59. Release parking brake (TM 5-2410-241-10). 60. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 61. Apply service brake (TM 5-2410-241-10).

WARNING Ensure service brake is fully applied prior to position steering control handle in MID STEER LEFT or RIGHT position. Failure to follow this warning may result in injury or death to personnel. 62. Pressure gauge (Figure 9, Item 1) should read 5,485 to 5,685 psi (37,800 to 39,200 kPa). Record pressure readings on gauge. 63. Return steering control handle to NEUTRAL STEER position (TM 5-2410-241-10). 64. Slowly apply steering control handle to MID STEER RIGHT position (TM 5-2410-241-10). 65. Pressure gauge (Figure 9, Item 1) should read 5,485 to 5,685 psi (37,800 to 39,200 kPa). Record pressure readings on gauge.

Figure 9. Pressure Gauge.

0035-11

035

TM 5-2410-241-23-1

0035

STEERING HYDRAULIC CIRCUIT TESTS – CONTINUED High Pressure Cutoff Test - Continued

00035

66. Return steering control handle to NEUTRAL STEER position (TM 5-2410-241-10). 67. Release service brake (TM 5-2410-241-10). 68. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). 69. Apply parking brake (TM 5-2410-241-10). 70. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). a. If STEER LEFT pressure readings are different from STEER RIGHT pressure readings, replace counterbalance valve (WP 0217). b. If STEER LEFT pressure readings and STEER RIGHT pressure readings are the same, but not within specified range, repeat steps 51 through 57. c.

00035

If STEER LEFT pressure readings and STEER RIGHT pressure readings are the same and are within specified range, proceed to step 71.

d. If pressure cut off setting is HIGH and CANNOT BE LOWERED, replace implement pump (WP 0112). 71. Install front floor plate (WP 0230). 72. Remove test equipment from machine. END OF TASK END OF WORK PACKAGE

0035-12

4 TM 5-2410-241-23-1

0036

FIELD MAINTENANCE 0

0 3 6

-

A/C AND HEATING TESTS, INSPECTIONS, AND ADJUSTMENTS Refrigerant System: Evacuate, Refrigerant Leakage: Test, Refrigerant System: Charge, A/C Performance: Test

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Adapter Kit Test (WP 0302, Item 5) Software Kit (Mil ET) (WP 0302, Item 55) Remover, Electrical Contact, Red (WP 0302, Item 47) Test Set, Electronic (MSD) (WP 0302, Item 62) Tool Kit, Service, Refrigeration, Ordnance (WP 0302, Item 66) 0

Personnel Required 91C10 91L10

0

0

0

0

References

0

0

0

0

WP 0044 WP 0096 WP 0220 WP 0263 Equipment Condition

0

0

0

0

0

0

Machine parked (TM 5-2410-241-10) Materials/Parts Rag, Wiping (WP 0303, Item 24)

0

0

0

REFRIGERANT SYSTEM: EVACUATE

00036

Evacuate refrigerant system (WP 0263). END OF TASK REFRIGERANT LEAKAGE: TEST

00036

Leak test refrigerant system (WP 0263). END OF TASK REFRIGERANT SYSTEM: CHARGE

00036

Charge refrigerant system (WP 0263). END OF TASK

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TM 5-2410-241-23-1

A/C PERFORMANCE: TEST

0036

00036

WARNING

•

This system is under pressure at all times, even if the engine is not running. Heat should never be applied to a charged system.

•

Contact with refrigerant can cause frostbite. Keep face and hands away.

•

Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.

•

Always use caution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, evacuate the system recovering the refrigerant before removing the fitting.

•

Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.

•

Before any checks of the air conditioning and heating system are made, move the machine to a smooth horizontal surface. Lower all implements to the ground. Make sure the machine is in neutral or park and that the parking brake is engaged. Keep all other personnel away from the machine or where they can be seen.

•

Failure to follow these warnings may result in injury or death to personnel.

NOTE Ambient temperature must be at least 70°F (21°C) in order to conduct A/C performance test. 1. Inspect fresh air filter and recirculation air filter, and replace if dirty or damaged (TM 5-2410-241-10). 2. Inspect condenser (WP 0044) and evaporator (WP 0220). a. Clear away anything that will obstruct airflow such as dirt, insects, plastic bags, etc. b. Make sure condensate drain tube on evaporator is not obstructed. 3. Check refrigerant compressor belt tension (WP 0096). 4. Inspect refrigerant lines and hoses. a. Inspect for damage from excessive heat or rubbing. b. Inspect for oily surfaces along hose and coupling connections. This can indicate a refrigerant leak. 5. Install recovery station (WP 0263). 6. Start and run engine (TM 5-2410-241-10). 7. Set engine idle speed at 1,000 RPM (low idle) (TM 5-2410-241-10). 8. Set cab temperature control knob to MAXIMUM cool position (TM 5-2410-241-10). 9. Turn air conditioning ON (TM 5-2410-241-10). 10. Set cab fan speed switch on HIGH position (TM 5-2410-241-10). 11. After 10 to 15 minutes of operation, adjust engine idle speed to approximately 1,300 to 1,400 rpm (TM 5-2410241-10).

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TM 5-2410-241-23-1

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A/C PERFORMANCE: TEST – CONTINUED

00036

12. From recovery station, record discharge (high side) pressure gauge reading and suction (low side) pressure gauge reading. 13. Compare discharge (high side) pressure gauge reading and suction (low side) pressure gauge reading to pressures listed in Table 1, Pressure Range Table to determine if system is functioning correctly at current ambient temperature.

NOTE •

Pressure Range Table is for reference only.

•

Pressures listed are before clutch disengagement.

•

During normal A/C system operation at 70°F (21°C) ambient temperature, discharge (high side) pressure will be 120 to 190 psi (820 to 1,300 kPa). Suction (low side) pressure will be 10 to 20 psi (70 kPa to 130 kPa).

•

Ambient temperature and humidity affect pressures.

•

If ambient temperature is high, discharge (high side) pressure will be high.

•

In very hot weather, discharge (high side) pressure and suction (low side) pressure will be high.

•

In cooler weather, discharge (high side) pressure and suction (low side) pressure will either be normal or low.

Table 1. Pressure Range Table. Ambient Air Temperature F°(C°)

0036

Discharge (High Side) Pressure psi (kPa)

Suction (Low Side) Pressure psi (kPa)

70°F (21°C)

120 to 190 (820 to 1,300)

10 to 20 (70 to 138)

80°F (27°C)

140 to 210 (950 to 1,450)

10 to 25 (70 to 173)

90°F (32°C)

170 to 240 (1,175 to 1,650)

15 to 30 (105 to 210)

100°F (38°C)

190 to 270 (1,300 to 1,850)

15 to 30 (105 to 210)

110°F (43°C)

210 to 300 (1,450 to 2,075)

15 to 30 (105 to 210)

END OF TASK END OF WORK PACKAGE

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4 TM 5-2410-241-23-1

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FIELD MAINTENANCE 0 0 3 7

-

SERVICE BRAKE PEDAL LIMIT SWITCH TESTS AND ADJUSTMENTS Tests, Adjustments

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Test Set, Electronic (MSD) (WP 0302, Item 62)

Personnel Required Two

0

0

0

0

Materials/Parts

0

Gasket

0

References WP 0016 Equipment Condition Machine parked (TM 5-2410-241-10) Estimated Time to Complete 1.0 Hr

TESTS

0

0

0

0

0

0

00037

1. Connect MSD to machine (WP 0016). 2. Select powertrain D7 ECM (Figure 1, Item 1).

Figure 1. Powertrain ECM Selection.

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TM 5-2410-241-23-1

TESTS – CONTINUED

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00037

3. Select status tool (Figure 2, Item 1).

Figure 2. Select Status Tool.

0037

4. Select status group #1 (Figure 3, Item 1).

Figure 3. Select Status Group #1.

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TM 5-2410-241-23-1

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TESTS – CONTINUED

00037

5. With service brake pedal released (Figure 4, Item 2) as indicated on service brake pedal switch row, record service brake pedal position sensor duty cycle value (Figure 4, Item 1), for example 22.

Figure 4. Service Brake Pedal Released.

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6. Slowly depress brake pedal until Depressed (Figure 5, Item 2) is indicated on service brake pedal switch row. Record service brake pedal position sensor duty cycle value (Figure 5, Item 1), for example 44.

Figure 5. Service Brake Pedal Depressed.

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TM 5-2410-241-23-1

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TESTS – CONTINUED

00037

7. Determine duty cycle value. The correct value should be 15–21%. For example, recorded value with pedal depressed is 44, and recorded value with pedal released is 22. 44 minus 22 equals 22. 22 is outside the 15–21% value and the service brake pedal limit switch would need adjustment. 8. If value is within the correct 15–21% range, no service brake pedal limit switch adjustment is required. 9. If value is not within range, adjustment to the service brake pedal limit switch is required. Refer to Adjustment in this WP. END OF TASK ADJUSTMENTS

00037

1. Remove six bolts (Figure 6, Item 1), plate (Figure 6, Item 2) and gasket (Figure 6, Item 3) from brake pedal housing (Figure 6, Item 4). Discard gasket 2. Adjust setscrew (Figure 6, Item 5). 3. Repeat steps 5 through 7 of the Test portion in this WP. 4. If necessary, adjust setscrew (Figure 6, Item 5) and repeat steps 5 through 7 of the Test portion in this WP until value is within the correct 15 - 21% range. 5. Install new gasket (Figure 6, Item 3), plate (Figure 6, Item 2) and bolts (Figure 6, Item 1) on brake pedal housing (Figure 6, Item 4). 6. Remove MSD from machine (WP 0016). 7. Verify correct operation of machine (TM 5-2410-241-10).

Figure 6. Adjustment. END OF TASK END OF WORK PACKAGE

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2 TM 5-2410-241-23-1

CHAPTER 3 PMCS MAINTENANCE INSTRUCTIONS

4 TM 5-2410-241-23-1

0038

OPERATOR MAINTENANCE 0 0 3 8

-

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION

GENERAL

00038

1. To ensure that the D7R Dozer is ready for operation at all times, it must be inspected on a regular basis so that defects may be found and corrected before they result in injury, damage, or equipment failure. 2. The PMCS table in WP 0039 contains systematic instructions on inspections, lubrications, services, tests, and corrections to be performed to keep the equipment in good operating condition and ready for its primary mission. EXPLANATION OF TABLE ENTRIES

00038

1. Item No. Column. Numbers in this column are for reference. When completing DA Form 2404 or DA Form 5988-E (Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indicating a fault. Item numbers also appear in the order that you must perform checks and services for the interval listed. 2. Interval Column. This column tells you when you must perform the procedure in the Procedure column: a. When Required procedures must be done when environmental conditions exist or wear is evident and attention is required. b. Every 250 Hours or Monthly procedures must be done once every month or after every 250 hours of machine operation. c.

Initial 500 Hours procedures must be done after the first 500 hours of machine operation.

d. Every 500 Hours or 3 Months procedures must be done every three months or after every 500 hours of machine operation. e. Every 1,000 Hours or 6 Months procedures must be done every six months or after 1,000 hours of machine operation. f.

Every 2,000 Hours or Annually procedures must be done every year or after 2,000 hours of machine operation.

g. Every 3,000 Hours or 2 Years procedure must be done every 2 years or after every 3,000 hours of machine operation. h. Every 3 years after date of installation or every 5 years after date of manufacture procedure must be done based on installation or manufacture date of component mentioned in Item to Check/Service column. i.

Every 12,000 hours or every 6 years procedure must be done every 6 years or after every 12,000 hours of machine operation.

3. Item to Check/Service Column. This column lists the item to be checked or serviced.

0038-1

TM 5-2410-241-23-1

0038

EXPLANATION OF TABLE ENTRIES – CONTINUED

NOTE The WARNINGs and CAUTIONs appearing in your PMCS table should always be observed. WARNINGs and CAUTIONs appear before applicable procedures. You must observe these WARNINGs to prevent injury or death to yourself and others, and CAUTIONs to prevent your equipment from being damaged. 4. Procedure Column. This column provides the steps required to perform, check, or service the item listed in the Item to Check/Service column. Follow the steps to make the equipment ready or available for its intended mission. You must perform the procedure at the time stated in the Interval column. 5. Not Fully Mission Capable If: Column. Information in this column tells you what faults will keep your equipment from being capable of performing its primary mission. If you perform check/service procedures that show faults listed in this column, the equipment is not mission capable. Follow standard operating procedures for maintaining the equipment or reporting equipment failure. GENERAL PMCS PROCEDURES

00038

1. Intervals (on-condition or hardtime) and the related man-hour times are based on normal operation. The manhour time specified is the time you need to do all the services prescribed for a particular interval. Change the hardtime interval if your lubricants are contaminated or if you are operating the equipment under adverse operating conditions, including longer-than-usual operating hours. The hardtime interval may be extended during periods of low activity. If extended, adequate preservation precautions must be taken. 2. The lowest level of maintenance authorized to lubricate a point is indicated by one of the following symbols as appropriate: Operator/Crew (C). 3. The time specified is the time required to perform all services at the particular interval (on-condition or hardtime). 4. Always perform PMCS in the same order so it gets to be a habit. Once you have had some practice, you will spot anything wrong in a hurry. If the equipment does not perform as required, refer to the appropriate troubleshooting procedure in Chapter 2. 5. If anything looks wrong and you can not fix it, write it on your DA Form 2404 or DA Form 5988-E. If you find something seriously wrong, IMMEDIATELY report it to your supervisor. 6. Before performing PMCS, read all the checks required for the applicable interval and prepare all that is needed to make all the checks. You will always need a Rag, Wiping (WP 0303, Item 24) or two.

WARNING

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may cause injury or death to personnel.

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TM 5-2410-241-23-1

0038

GENERAL PMCS PROCEDURES – CONTINUED

CAUTION Be especially careful when cleaning electrical system components including lighting. Damage or impaired operation could result if this caution is not observed. a. Keep Equipment Clean. Dirt, grease, oil, and debris may cover up a serious problem. Clean as you work and as needed. Use Cleaning Compound, Solvent, Type III (WP 0303, Item 6) on all metal surfaces. Use Detergent, General Purpose, Liquid (WP 0303, Item 8) and water when you clean rubber, plastic, and painted surfaces. Spot paint as required to prevent corrosion. b. Bolts, Nuts, and Screws. Ensure that they are not loose, missing, bent, or broken. Report loose, missing, or damaged bolts, nuts, and screws to your supervisor. c.

Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. Report bad welds to your supervisor.

d. Electrical Wires and Connectors. Look for cracked or broken insulation, bare wires, and loose or broken connectors. Report loose connections and faulty wiring to your supervisor. e. Hoses, Lines, and Fittings. Look for wear and damage. Check for loose clamps and fittings. Report any worn, damaged, or loose hoses, lines, and fittings to your supervisor.

CAUTION Operation is allowable with Class I and Class II leakage. WHEN IN DOUBT, NOTIFY YOUR SUPERVISOR. When operating with Class I or Class II leaks, check fluid levels more frequently. Class III leaks must be reported immediately to your supervisor. Failure to do this will result in damage to machine and/or components.

Leakage Definitions for PMCS Class I

Leakage indicated by wetness or discoloration, but not great enough to form drops.

Class II

Leakage great enough to form drops, but not enough to cause drops to drip from the item being checked/inspected.

Class III

Leakage great enough to form drops that fall from the item being checked/inspected.

NOTE Refer to Lubrication Order 5-2410-241-13 for tables, localized views, and procedural notes. 1. Recommended intervals are based on normal conditions of operation, temperature, and humidity. When operating under extreme conditions, lubricants should always be changed more frequently. When in doubt, notify your supervisor. 2. Keep all lubricants in a closed container and store in a clean, dry place away from extreme heat or cold. Keep container covers clean and DO NOT allow dust, dirt, or other foreign material to mix with lubricants. Keep all lubrication equipment clean and ready for use. 3. Maintain a good record of all lubrication performed and report any problems noted during lubrication. Refer to DA PAM 750-8 for maintenance forms and procedures to record and report any findings.

0038-3

TM 5-2410-241-23-1

0038

GENERAL PMCS PROCEDURES – CONTINUED 4. Keep all external parts of equipment not requiring lubrication free of lubricants. Before lubrication, wipe lubrication fittings with a clean Rag, Wiping (WP 0303, Item 24). After lubrication, wipe off excess oil or grease to prevent accumulation of foreign matter. 5. Refer to FM 9-207 for lubrication instructions in cold weather. 6. Refer to AR 70-12 for use of standardized lubricants. END OF WORK PACKAGE

0038-4

26 TM 5-2410-241-23-1

0039

FIELD MAINTENANCE

-

0039PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) 0 Handle, Sliding T, 3/4” Drive, 17” Long, (S0375) (WP 0302, Item 68) 0 Extension, 3/4” Drive, 4” Long, (S0376) (WP 0302, Item 68) 0 Materials/Parts

0

Antifreeze, Permanent, Ethylene Glycol, Inhibited (WP 0303, Item 1) 0 Cleaning Compound, Solvent, Type III (WP 0303, Item 6) 0 Detergent, General Purpose, Liquid (WP 0303, Item 8) 0 Diesel Fuel (WP 0303, Item 9) 0 Grease, Automotive and Artillery (GAA) (WP 0303, Item 12) 0 Oil, Lubricating OEA, Arctic (WP 0303, Item 17) 0 Oil, Lubricating OE/HDO-10 (WP 0303, Item 18) 0 Oil, Lubricating OE/HDO-30 (WP 0303, Item 19) 0 Oil, Lubricating OE/HDO-40 (WP 0303, Item 20) 0 Oil, Lubricating OE/HDO 15/40 (WP 0303, Item 21) 0 Rag, Wiping (WP 0303, Item 24) 0 Gasket 0 O-ring (3) 0

0039-1

References LO 5-2410-241-13 WP 0071 WP 0072 WP 0074 WP 0095 WP 0096 WP 0097 WP 0098 WP 0107 WP 0113 WP 0114 WP 0127 WP 0130 WP 0134 WP 0151 WP 0152 WP 0184 WP 0185 WP 0199 WP 0200 WP 0225 WP 0237 WP 0240 WP 0247 WP 0280 Equipment Conditions Machine parked on level ground (TM 5-2410-241-10)

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS). LOCATION

ITEM NO.

INTERVAL

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

WARNING

If the machine is parked indoors during the performance of PMCS, DO NOT run the engine unless exhaust fumes are vented to the outside. Failure to follow this warning may cause injury or death to personnel due to carbon monoxide poisoning.

CAUTION When servicing this machine, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids or batteries, and CARC paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. If further information is needed, please contact The Army Environmental Hotline at 1-800-872-3845.

NOTE • Review all WARNINGs, CAUTIONs, and NOTEs before performing PMCS on the D7R Dozer with Winch or D7R Dozer with Ripper. • Unless otherwise indicated, perform all preventive maintenance and lubrication with machine parked on level ground, engine shut down, parking brake engaged, and hydraulic system pressure relieved. • Perform Operator PMCS prior to or in conjunction with Field PMCS if: –

There is a delay between daily operation of the machine and Field PMCS.

–

The regular operator is not assisting.

• If leakage is detected during performance of PMCS, further investigation is required to determine location and cause of leak. • Walk around machine and look for any obvious leaks or damage. • Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with a suitable containers before opening any compartment or disassembling any component containing fluids. • Dispose of all fluids IAW local regulations and mandates.

0039-2

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TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 1

INTERVAL When Required

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Inspect radiator core area for Radiator plugged with dirt or Radiator Core - obstruction by dirt or debris. debris. Clean b. Remove eight bolts (Figure 1, Item 1) and washers (Figure 1, Item 2) from grill doors (Figure 1, Item 3) and open grill doors. c. Use compressed air or high pressure water to remove dirt and debris from radiator core Figure 1, Item 4). d. Close grill doors Figure 1, Item 3) and install eight washers Figure 1, Item 2) and bolts Figure 1, Item 1).

Figure 1. Radiator Grill.

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TM 5-2410-241-23-1

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Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO.

INTERVAL

2

When Required

3

250 Hours or Monthly

ITEM TO CHECK/ SERVICE Ripper Tip Inspect/ Replace Equalizer Bar End Pins Oil Level - Check

NOT FULLY MISSION CAPABLE IF:

PROCEDURE If ripper tip is worn close to shank, replace ripper tip. Refer to WP 0280.

Tip damaged or missing.

CAUTION • Apply oil with hand pump only; pressure operated lubricating equipment will damage seals. • Before and after the equalizer bar end pin is filled with oil, seal must be flush with the equalizer bar. If the seals are not flush, damage to the seals can result by over filling. a. Clean area around end pin (Figure Equalizer bar oil level low. 2, Item 5) and inspect seals (Figure 2, Item 1) for leaks. Make sure seals are in neutral position and not pushed out. b. Remove plug (Figure 2, Item 2) from equalizer bar (Figure 2, Item 4). c. Check oil level. Oil should be at top of the hex head on the fitting. d. Refer to LO 5-2410-241-13 for correct amount and type of oil. If oil level is low, apply gear oil through fitting (Figure 2, Item 3) until oil reaches top of the hex head on fitting. Remove any excess oil. e. Make sure seals (Figure 2, Item 1) are not pushed out. f. Install plug (Figure 2, Item 2) on equalizer bar (Figure 2, Item 4).

0039-4

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO.

INTERVAL

3 250 Hours (Cont.) or Monthly

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Equalizer Bar End Pins Oil Level - Check

Figure 2. Equalizer Bar Oil Levels.

0039-5

0039

TM 5-2410-241-23-1

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Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 4

INTERVAL 250 Hours or Monthly

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

WARNING

Final Drive Oil Level -Check

• Contact with oil can damage skin. Wear gloves when handling engine oil. If oil contacts skin, wash it off immediately. • Lubricating oil is very slippery. Immediately wipe up any spills. • Failure to follow these warnings may cause injury or death to personnel. a. Position one final drive so oil level mark (Figure 3, Item 1) is horizontal and drain plug (Figure 2, Item 3) is at bottom. b. Remove oil filler plug (Figure 2, Item 2) and O-ring. c. The oil level should be at bottom of the filler plug opening. Refer to LO 52410-241-13 for correct amount and type of final drive oil. If necessary, add oil. d. Clean oil fill plug with clean rag. Inspect O-ring. If O-ring is not damaged it may be reused until oil change. e. Install oil filler plug (Figure 3, Item 2) and O-ring. f. Repeat steps to check oil level on other final drive.

0039-6

Final drive oil level low.

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO.

INTERVAL

4 250 Hours (Cont.) or Monthly

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Final Drive Oil Level -Check

Figure 3. Final Drive Oil Level.

0039-7

0039

TM 5-2410-241-23-1

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Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 5

INTERVAL 250 Hours or Monthly

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

WARNING

Track - Check Adjust

• Personal injury or death can result from grease under pressure. • Grease coming out of the relief valve under pressure can penetrate the body causing injury or death. • Do not watch the relief valve to see if grease is escaping. Watch the track or track adjustment cylinder to see if track is being loosened. • Failure to follow these warnings may result in injury or death to personnel.

NOTE • Loosen the relief valve one turn only. • If track does not loosen, close the relief valve and refer to WP 0127 for track service. Inspect and adjust track for proper tension and adjustment, refer to WP 0134.

0039-8

Too tight or too loose.

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 6

INTERVAL 250 Hours or Monthly

ITEM TO CHECK/ SERVICE Drive Belt

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Inspect drive belts. Replace belt if excessively cracked, worn, or damaged, refer to WP 0096, or WP 0098.

Belt has excessive cracking, wear, or damage.

b. Inspect for loose or damaged pulley, refer to WP 0095.

Pulley is loose or damaged.

Figure 4. Drive Belts. 7

Initial 500 Hours

8

Every 500 Hours or 3 months

Winch Oil and Breather Change/Clean Engine Crankcase Breather Clean

0039

Refer to Winch Oil Service (WP 0274).

a. Remove clamp (Figure 5, Item 2) and hose (Figure 5, Item 1) from crankcase breather assembly (Figure 5, Item 3). b. Remove bolt (Figure 5, Item 4), clamp (Figure 5, Item 5) and position harness (Figure 5, Item 8) aside. c. Remove four bolts (Figure 5, Item 6), washers (Figure 5, Item 7), and crankcase breather assembly (Figure 5, Item 3) from valve cover base (Figure 5, Item 10). d. Remove gasket (Figure 5, Item 9) from crankcase breather assembly (Figure 5, Item 3). Discard gasket.

0039-9

Breather missing or damaged.

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO.

INTERVAL

8 Every 500 (Cont.) Hours or 3 months

ITEM TO CHECK/ SERVICE Engine Crankcase Breather Clean

PROCEDURE e. Remove breather element from crankcase breather assembly and wash in nonflammable solvent. Dry breather element with compressed air. f. Install breather element in crankcase breather assembly. g. Install new gasket (Figure 5, Item 9), crankcase breather assembly (Figure 5, Item 3), four washers (Figure 5, Item 7), and bolts (Figure 5, Item 6) on valve cover base (Figure 5, Item 10). h. Position harness (Figure 5, Item 8) and clamp (Figure 5, Item 5). Install bolt (Figure 5, Item 4). i. Install hose (Figure 5, Item 1) and clamp (Figure 5, Item 2) on crankcase breather assembly (Figure 5, Item 3).

0039-10

NOT FULLY MISSION CAPABLE IF:

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO.

INTERVAL

8 Every 500 (Cont.) Hours or 3 months

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Engine Crankcase Breather Clean

Figure 5. Engine Crankcase Breather.

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0039

TM 5-2410-241-23-1

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Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO.

INTERVAL

9

Every 500 Service Hours or 3 months

10

Every 500 Service Hours or 3 months

ITEM TO CHECK/ SERVICE

PROCEDURE

Replace engine oil and filter, refer to Engine Oil and WP 0114. Filter - Change

Fuel System Primary Fuel Filter - Clean/ Replace

NOT FULLY MISSION CAPABLE IF: Oil level low.

WARNING

• DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel. • Allow engine to cool before performing maintenance on fuel filter. Hot metal parts can cause severe burns. Wear eye, hand, and skin protection when working with heated parts. • Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. • Failure to follow these warnings may result in injury or death to personnel. Replace fuel system primary fuel filter, refer to WP 0071.

0039-12

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 11

INTERVAL Every 500 Service Hours or 3 months

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

WARNING

Fuel System Secondary Fuel Filter Clean/Replace

• DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel. • Allow engine to cool before performing maintenance on fuel filter. Hot metal parts can cause severe burns. Wear eye, hand, and skin protection when working with heated parts. • Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. • Failure to follow these warnings may result in injury or death to personnel. Replace fuel system secondary fuel filter, refer to WP 0072. 12

500 Hours or every 3 Months

13

Every 500 Service Hours or 3 months

Replace hydraulic system oil filter, Hydraulic refer to WP 0185. System Oil Filter - Replace

Hydraulic oil level low.

WARNING

Recoil Spring Compartment Oil Level Check

• Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. • Lubricating oil is very slippery. Immediately wipe up any spills. • Failure to follow these warnings may cause injury or death to personnel. a. Clean area around cover plate Recoil spring oil level low. (Figure 6, Item 3) on top of track roller frame (Figure 6, Item 4).

0039-13

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO.

INTERVAL

13 Every 500 (Cont.) Service Hours or 3 months

ITEM TO CHECK/ SERVICE Recoil Spring Compartment Oil Level Check

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

b. Remove four bolts (Figure 6, Recoil Spring Compartment oil Item 1), washers (Figure 6, Item 2), O- level low. ring (Figure 6, Item 4) and cover plate (Figure 6, Item 3) from track roller frame (Figure 6, Item 5). Discard Oring. c. Maintain oil level to the bottom of flange (Figure 6, Item 6). Refer to LO 5-2410-241-13 for proper type and quantity of oil. d. Install new O-ring (Figure 6, Item 4, cover plate (Figure 6, Item 3), four washers (Figure 6, Item 2), and bolts (Figure 6, Item 1) on track roller frame (Figure 6, Item 5). e. Repeat steps for other recoil spring compartment.

Figure 6. Recoil Spring Oil Level.

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0039

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO.

INTERVAL

14

Every 500 Service Hours or 3 months

15

Every 1,000 Service Hours or six months

ITEM TO CHECK/ SERVICE

PROCEDURE

Change transmission system oil filter, Transmission refer to WP 0152. System Oil Filter - Replace

NOT FULLY MISSION CAPABLE IF: Transmission oil level low.

WARNING

Torque Converter Scavenge Screen - Clean

• Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. • Lubricating oil is very slippery. Immediately wipe up any spills. • Failure to follow these warnings may cause injury or death to personnel. a. Clean torque converter scavenge screen when transmission oil is changed. b. Remove middle bottom guards, refer to WP 0199.

0039-15

Torque converter scavenge screen plugged.

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO.

INTERVAL

15 Every 1,000 (Cont) Service Hours or six months

ITEM TO CHECK/ SERVICE Torque Converter Scavenge Screen - Clean

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

NOTE Scavenge screen may fall out of hose when removed from torque converter housing.

c. Remove four bolts (Figure 7, Item 3), washers (Figure 7, Item 2), two split clamps and hose (Figure 7, Item 1) from torque converter housing (Figure 7, Item 4). d. Remove torque converter washer and scavenge screen (Figure 7, Item 5) from hose (Figure 7, Item 1). e. Wash screen (Figure 7, Item 5) in nonflammable solvent and dry screen with compressed air. f. Install washer and screen (Figure 7, Item 5) in torque converter housing (Figure 7, Item 4). g. Connect hose (Figure 7, Item 1), two split clamps, four washers (Figure 7, Item 2), and bolts (Figure 7, Item 3) to torque converter housing (Figure 7, Item 4). h. Install middle bottom guards, refer to WP 0199.

0039-16

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO.

INTERVAL

15 Every 1,000 (Cont) Service Hours or six months

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Torque Converter Scavenge Screen - Clean

Figure 7. Torque Converter Screen.

0039-17

0039

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 16

INTERVAL Every 1,000 Service Hours or six months

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Clean transmission magnetic Magnetic screen plugged. Transmission screen when transmission oil is Magnetic changed. Screen - Clean b. Remove middle bottom guards, (WP 0199). c. Remove four nuts (Figure 8, Item 1), cover (Figure 8, Item 2), Oring (Figure 8, Item 4) and spring washer (Figure 8, Item 5) from housing (Figure 8, Item 3). d. Remove screen (Figure 8, Item 7) and magnetic assembly (Figure 8, Item 8) from housing (Figure 8, Item 3). e. Clean screen (Figure 8, Item 7) and magnetic assembly (Figure 8, Item 8) in nonflammable solvent. f. Install new O-ring (Figure 8, Item 4) on cover (Figure 8, Item 2). g. Install screen (Figure 8, Item 7) and magnetic assembly (Figure 8, Item 8) in housing (Figure 8, Item 3). h. Install spring washer (Figure 8, Item 5), cover (Figure 8, Item 2), and four nuts (Figure 8, Item 1) on housing (Figure 8, Item 3). i. Install middle bottom guards, (WP 0199).

0039-18

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO.

INTERVAL

16 Every 1,000 (Cont.) Service Hours or six months

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Transmission Magnetic Screen - Clean

Figure 8. Transmission Magnetic Screen. 17

Every 1,000 Service Hours or six months

Cleaning transmission scavenge Transmission screen is part of transmission system Scavenge oil change, refer to WP 0151. Screen - Clean

18

Every 1,000 Service Hours or six months

Transmission System Oil Change

19

Every 1,000 Service Hours or six months

Winch Oil and Breather Change/ Clean

Change transmission system oil, refer Transmission oil level low. to WP 0151.

Refer to Winch Oil Service (WP 0274).

0039-19

0039

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO.

20

INTERVAL

1,000 Hours or SemiAnnually

ITEM TO CHECK/ SERVICE

Rollover Protective Structure (ROPS)

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Inspect Rollover Protective Structure for bolts that are missing, loose, or damaged. Replace missing or damaged bolts. Replace ROPS if cracks in welds and seams are detected (WP 0225).

Loose, missing, or damaged bolts. Cracks in welds and seams.

Do not weld reinforcement plates to ROPS/FOPS in order to straighten ROPS/FOPS structure. 21

Every 2,000 Service Hours Annually

Engine Valve Lash - Check/ Adjust

CAUTION Operating the engine with improper valve adjustments will reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.

NOTE Measure valve clearance with engine stopped. To obtain an accurate measurement, allow at least 20 minutes for valves to cool to engine cylinder head and engine block temperature. a. Check valve bridge before setting Valves not adjustable or worn. valve lash. Ensure that valve bridge is seated equally on both valve stems. Refer to WP 0107. b. Check engine valve lash and adjust as required, refer to WP 0107. 22

Every 2,000 Service Hours annually

Engine Valve Rotators Inspect

a. Improperly operating valve rotor will Valve rotator worn or damaged. shorten valve life because of accelerated wear on valves. Metal particles from a damaged valve rotator could fall into cylinder and damage to piston head and cylinder head may result. Refer to WP 0107. b. Start engine and run at low idle. Watch top surface of each valve rotator. Whenever an inlet valve or exhaust valve closes, each valve rotator should turn. Refer to WP 0107. c. Check engine valve lash and adjust as required, refer to WP 0107.

0039-20

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 23

INTERVAL 2,000 Hours or Annually

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

WARNING

Final Drive Oil Change

• Oil should be warm to ensure it drains completely from final drive assembly. Use caution to protect against burns when draining oil. • Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. • Lubricating oil is very slippery. Immediately wipe up any spills. • Failure to follow these warnings may cause injury or death to personnel. a. Position one final drive so oil level mark (Figure 9, Item 1) is horizontal. Drain plug (Figure 9, Item 3) will be positioned at bottom of final drive. b. Remove drain plug (Figure 9, Item 3) and O-ring. Allow oil to drain into a suitable container. Discard O-ring. c. Replace O-ring. d. Install drain plug (Figure 9, Item 3) and new O-ring. e. Remove oil fill plug (Figure 9, Item 2) and O-ring. Discard O-ring.

0039-21

Final drive oil level low.

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO.

INTERVAL

23 2,000 Hours (Cont.) or Annually

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

NOTE

Final Drive Oil Change

Clean oil fill plug with clean cloth. f. Fill final drive with correct type of oil to bottom of filler plug (Figure 9, Item 2) opening. Refer to LO 5-2410241-13 for type and quantity of lubricants. g. Inspect the oil fill plug for damage, replace plug if damaged. h. Install new O-ring and oil fill plug (Figure 9, Item 2). i. Repeat steps for other final drive.

Figure 9. Final Drive Oil Change.

0039-22

0039

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 24

INTERVAL 2,000 Hours or Annually

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

WARNING

Hydraulic System Oil Change

• Oil should be warm to ensure it drains completely from hydraulic tank. Use caution to protect against burns when draining oil. • Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. • Lubricating oil is very slippery. Immediately wipe up any spills. • At operating temperature, the hydraulic tank is hot and under pressure. • Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. • Remove the filler cap slowly only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly to relieve pressure. • Failure to follow these warnings may cause injury or death to personnel. Change hydraulic system oil, refer to WP 0184. 25

2,000 Hours or Annually

26

3,000 Hours or 2 years

Refrigerant Dryer Replace Cooling System Water Temperature Regulator Replace

Hydraulic oil level low.

Refrigerant dryer is located on left side Refrigerant dryer missing. of engine. Dryer should be changed once per year even though indicator remains blue. Refer to WP 0240. Replace cooling system water temperature regulator, refer to WP 0074.

0039-23

TM 5-2410-241-23-1

0039

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO.

INTERVAL

ITEM TO CHECK/ SERVICE

27

Every 3 Seat Belt years after Replace date of installation or every 5 years after date of manufacture

28

12,000 Hours or Every 6 years

PROCEDURE Replace seat belt, refer to WP 0247.

Drain, flush, and fill engine coolant, Engine Coolant refer to WP 0113. - Replace

0039-24

NOT FULLY MISSION CAPABLE IF: Seat belt is damaged. Date on belt is more than three years old.

Engine coolant level low.

TM 5-2410-241-23-1

0039

Table 2. D7R Dozer with Ripper and D7R Dozer with Winch PMCS Mandatory Replacement Parts List.

0039

ITEM NO.

INTERVAL

PART NUMBER

1

Initial 250 Hours

111-2645

Filter Fluid, Engine Oil

1

2

500 Hours or Quarterly

111-2645

Filter Fluid, Engine Oil

1

3

500 Hours or Quarterly

176-5618

Primary Fuel Filter Assembly

1

4

500 Hours or Quarterly

1R-0749

Secondary Fuel Filter Assembly

1

5

1,000 Hours or Semi-Annually

1R0777

Hydraulic, Powertrain, Winch Filter

1

6

1,000 Hours or Semi-Annually

328-3685

Powertrain Filter

1

7

2,000 Hours or Annually

3E3535

Receiver Dryer

1

8

3,000 Hours or Every 2 Years

248-5513

Water Temperature Regulator

1

9

Every 3 Years

222-0345

Seat Belt

1

NSN

NOMENCLATURE

END OF TASK END OF WORK PACKAGE

0039-25/(26 blank)

QTY

2 TM 5-2410-241-23-1

CHAPTER 4 MAINTENANCE INSTRUCTIONS

2 TM 5-2410-241-23-1

0040

FIELD MAINTENANCE

-

SERVICE UPON RECEIPT General, Inspection Instructions, Servicing Instructions 0 0 4

0

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0303, Item 6) Rag, Wiping (WP 0303, Item 24) References TB 43-0242

0

References - Continued TM 43-0139 TM 5-2410-241-10 WP 0001 WP 0038 WP 0039 DA Form 2404 DA Form 5988-E DD Form 1397 SF Form 364

0

0

0

0

0

0

Equipment Conditions

0

Machine parked (TM 5-2410-241-10)

0

0

0

0

0

0

0

0

0

0

0

0

0

GENERAL

0040

1. When a new or reconditioned D7R Dozer, Type I with Winch or D7R Dozer, Type II with Ripper is first received, determine whether it has been properly prepared for service and is in condition to perform its mission. 2. Follow these inspection and servicing instructions to assess the dozer’s condition. INSPECTION INSTRUCTIONS

0040

1. Read and follow all precautions and instructions on DD Form 1397, Processing and Deprocessing Record for Shipment, Storage, and Issue of Vehicles and Spare Engines. 2. Remove all packing and shipping material, such as tape, tiedown straps, protective covers, and shipping seals. Remove tape from exhaust pipe.

WARNING

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to do so may result in injury or death to personnel. 3. Clean any exposed metal parts coated with rust-preventive compound using Cleaning Compound, Solvent, Type III (WP 0303, Item 6). 4. Inspect equipment for any damage incurred during shipment. Check if equipment has been modified.

0040-1

TM 5-2410-241-23-1

0040

INSPECTION INSTRUCTIONS – CONTINUED 5. Check equipment against packing slip to ensure shipment is complete. Report any discrepancies on SF Form 364, Report of Discrepancy (ROD). 6. Clean all external surfaces as needed. Touch up any paint scratches (see TM 43-0139, Painting Instructions for Army Materiel, and TB 43-0242, CARC Spot Painting). 7. Remove all Basic Issue Items (BII) and Components of End Item (COEI) and stow in accordance with TM 5-2410-241-10. END OF TASK SERVICING INSTRUCTIONS

0040

1.

Service machine in accordance with PMCS instructions in TM 5-2410-241-10 to include machine exercise and PMCS instructions in this manual (WP 0038 and WP 0039). Schedule the next PMCS on DA Form 2404 or DA Form 5988-E, Equipment Inspection and Maintenance Worksheet.

2.

Refer to TM 5-2410-241-10 and perform functional checks of all major machine systems to ensure machine is ready for operation. Remove all warning tags.

END OF TASK END OF WORK PACKAGE

0040-2

4 TM 5-2410-241-23-1

0041

FIELD MAINTENANCE 0 0 4 1

-

HYDRAULIC OIL COOLER CORE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Wrench, Combination, 1-1/8” (S0788) (WP 0302, Item 68) Wrench, Combination, 1-1/4” (S0789) (WP 0302, Item 68) Wrench, Combination, 1-3/8” (S0791) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (4)

0

References WP 0295

0

0

0

Equipment Condition

0

Machine parked (TM 5-2410-241-10) Hydraulic tank drained (WP 0184) Engine enclosure left door guard removed (WP 0202) 0

0

0

0

0

0

0

0

0

0

0041-1

Drawing Required TM 5-2410-241-24P, Figure 3 Estimated Time to Complete 3.0 Hr

0

0

0

0

TM 5-2410-241-23-1

0041

REMOVAL

00041

NOTE Tag hoses, lines and fittings to aid installation. 1. Disconnect upper hose (Figure 1, Item 6) from fitting (Figure 1, Item 5). 2. Remove fitting (Figure 1, Item 5) and plug (Figure 1, Item 4) from cooler (Figure 1, Item 3). 3. Disconnect lower hose (Figure 1, Item 7) from fitting (Figure 1, Item 8). 4. Remove fitting (Figure 1, Item 8) from cooler (Figure 1, Item 3). 5. Remove two bolts (Figure 1, Item 9) and washers (Figure 1, Item 10) from cooler (Figure 1, Item 3). 6. Remove two nuts (Figure 1, Item 2), washers (Figure 1, Item 1) and cooler (Figure 1, Item 3) from machine.

Figure 1. Cooler.

0041-2

0041

TM 5-2410-241-23-1

0041

REMOVAL – CONTINUED 7. Remove O-rings (Figure 2, Items 2 and 6) from fitting (Figure 2, Item 1). Discard O-rings. 8. Remove O-rings (Figure 2, Items 4 and 5) from fitting (Figure 2, Item 3). Discard O-rings.

Figure 2. O-rings.

0041

END OF TASK CLEANING AND INSPECTION

00041

Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

00041

NOTE Install hoses, lines and fittings as tagged during removal. 1. Install two new O-rings (Figure 2, Items 5 and 4) on fitting (Figure 2, Item 3). 2. Install two new O-rings (Figure 2, Items 6 and 2) on fitting (Figure 2, Item 1).

0041-3

TM 5-2410-241-23-1

0041

INSTALLATION – CONTINUED 3. Install cooler (Figure 3, Item 3), two washers (Figure 3, Item 1), and nuts (Figure 3, Item 2) on machine. 4. Install two washers (Figure 3, Item 10), bolts (Figure 3, Item 9) on cooler (Figure 3, Item 3). 5. Install fitting (Figure 3, Item 8) on cooler (Figure 3, Item 3). 6. Connect lower hose (Figure 3, Item 7) on fitting (Figure 3, Item 8). 7. Install fitting (Figure 3, Item 5) and plug (Figure 3, Item 4) on cooler (Figure 3, Item 3). 8. Connect upper hose (Figure 3, Item 6) on fitting (Figure 3, Item 5).

Figure 3. Cooler.

0041

END OF TASK FOLLOW-ON TASKS

00041

1. Fill hydraulic tank (WP 0184). 2. Install engine enclosure left door guard (WP 0202). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0041-4

8 TM 5-2410-241-23-1

0042

FIELD MAINTENANCE 0 0

4 2

-

TRANSMISSION OIL COOLER CORE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Materials/Parts

0

References WP 0295

0

0

0

Equipment Condition 0

0

Machine parked (TM 5-2410-241-10) Engine oil cooler removed (WP 0084) Bottom guard removed (third from front) (WP 0199)

0

Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket O-ring (4) Personnel Required Two

0

0

0

0

0

0

Drawing Required

0

0

TM 5-2410-241-24P, Figure 4, 52

0

0

Estimated Time to Complete

0

0

11.5 Hr

0042-1

0

TM 5-2410-241-23-1

0042

REMOVAL

00042

NOTE Tag hoses, lines and fittings to aid installation. 1. Loosen clamp (Figure 1, Item 6) from hose (Figure 1, Item 7). 2. Remove hose (Figure 1, Item 7) from fitting (Figure 1, Item 8). 3. Remove eight bolts (Figure 1, Item 2), washers (Figure 1, Item 3), clamp (Figure 1, Item 4), and lines (Figure 1, Item 1) from transmission oil cooler (Figure 1, Item 5).

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death to personnel.

NOTE Transmission oil cooler weighs approximately 65 lb (29.5 kg). 4. With assistance, remove two bolts (Figure 1, Item 9), washers (Figure 1, Item 10) and transmission oil cooler (Figure 1, Item 5) from bracket (Figure 1, Item 11). 5. Remove two O-rings (Figure 1, Item 12) from lines (Figure 1, Item 1). Discard O-rings.

Figure 1. Hose and Lines.

0042-2

0042

TM 5-2410-241-23-1

0042

REMOVAL – CONTINUED 6. Remove two bolts (Figure 2, Item 2), washers (Figure 2, Item 3) and bracket (Figure 2, Item 1) from mount (Figure 2, Item 4).

Figure 2. Bracket.

0042-3

0042

TM 5-2410-241-23-1

0042

REMOVAL – CONTINUED 7. Remove four bolts (Figure 3, Item 2), bonnet (Figure 3, Item 1) and gasket (Figure 3, Item 4) from transmission oil cooler (Figure 3, Item 3). Discard gasket. 8. Remove fitting (Figure 3, Item 7) and O-ring (Figure 3, Item 8) from bonnet (Figure 3, Item 1). Discard O-ring. 9. Remove plug (Figure 3, Item 5) and O-ring (Figure 3, Item 6) from bonnet (Figure 3, Item 1). Discard O-ring.

Figure 3. Transmission Oil Cooler Core.

0042

END OF TASK CLEANING AND INSPECTION

00042

Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

00042

NOTE Install hoses, lines and fittings as tagged during removal. 1. Install new O-ring (Figure 3, Item 6) and plug (Figure 3, Item 5) on bonnet (Figure 3, Item 1). 2. Install new O-ring (Figure 3, Item 8) and fitting (Figure 3, Item 7) on bonnet (Figure 3, Item 1). 3. Install new gasket (Figure 3, Item 4), bonnet (Figure 3, Item 1) and four bolts (Figure 3, Item 2) on transmission oil cooler (Figure 3, Item 3).

0042-4

TM 5-2410-241-23-1

0042

INSTALLATION – CONTINUED 4. Install bracket (Figure 4, Item 1), two washers (Figure 4, Item 3) and bolts (Figure 4, Item 2) on mount (Figure 4, Item 4).

Figure 4. Bracket.

0042-5

0042

TM 5-2410-241-23-1

0042

INSTALLATION – CONTINUED 5. Install two new O-rings (Figure 5, Item 12) on lines (Figure 5, Item 1).

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death to personnel.

NOTE Transmission oil cooler weighs approximately 65 lb (29.5 kg). 6. With assistance, install transmission oil cooler (Figure 5, Item 5), two washers (Figure 5, Item 10) and bolts (Figure 5, Item 9) on bracket (Figure 5, Item 11). 7. Install two lines (Figure 5, Item 1), clamp (Figure 5, Item 4), eight washers (Figure 5, Item 3) and bolts (Figure 5, Item 2) on transmission oil cooler (Figure 5, Item 5). 8. Connect hose (Figure 5, Item 7) with clamp (Figure 5, Item 6) to fitting (Figure 5, Item 8). 9. Tighten clamp (Figure 5, Item 6) on hose (Figure 5, Item 7).

Figure 5. Hose and Lines. END OF TASK

0042-6

0042

TM 5-2410-241-23-1

FOLLOW-ON TASKS

0042

00042

1. Install engine oil cooler (WP 0084). 2. Install bottom guard (third from front) (WP 0199). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0042-7/(8 blank)

14 TM 5-2410-241-23-1

0043

FIELD MAINTENANCE

-

UPPER COOLANT TANK REPLACEMENT Removal, Cleaning and Inspection, Installation 0

0 4 3

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Wrench Combination 1-1/2” (S0793) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (6) Personnel Required Two

0

References WP 0295

0

0

0

Equipment Condition Machine parked (TM 5-2410-241-10) Coolant drained (WP 0113) Cooling fan removed (WP 0050) Hood removed (WP 0200)

0

0

0

0

0

0

0

0

0

Drawing Required

0

0

TM 5-2410241-24P, Figure 5

0

0

Estimated Time to Complete

0

0

5.0 Hr

REMOVAL

0

00043

WARNING

Components with metal parts can cause severe burns at operating temperature. Allow components to cool before performing maintenance on them. Wear insulated gloves, long sleeves, and eye protection when working with heated parts. Failure to follow this warning may cause injury or death to personnel. 1. Remove three bolts (Figure 1, Item 2), washers (Figure 1, Item 1), and cover (Figure 1, Item 3) from radiator guard (Figure 1, Item 4).

Figure 1. Upper Cover.

0043-1

0043

TM 5-2410-241-23-1

0043

REMOVAL – CONTINUED 2. Remove eight bolts (Figure 2, Item 2) and washers (Figure 2, Item 3) from door (Figure 2, Item 1). 3. With assistance, open two doors (Figure 2, Item 1) and lift from hinges (Figure 2, Item 4). Place door on flat level surface.

Figure 2. Radiator Guard Doors.

0043-2

0043

TM 5-2410-241-23-1

0043

REMOVAL – CONTINUED

NOTE Tag hoses to aid installation. 4. Loosen four clamps (Figure 3, Item 4) from hoses (Figure 3, Item 5). 5. Remove four hoses (Figure 3, Item 5) from radiator cores (Figure 3, Item 3). 6. Remove four clamps (Figure 3, Item 4) from hoses (Figure 3, Item 5). 7. Remove overflow hose (Figure 3, Item 2) from upper coolant tank (Figure 3, Item 1).

Figure 3. Radiator Core Hoses.

0043-3

0043

TM 5-2410-241-23-1

0043

REMOVAL – CONTINUED 8. Loosen clamp (Figure 4, Item 2) from hose (Figure 4, Item 1). 9. Remove hose (Figure 4, Item 1) from shutoff valve (Figure 4, Item 3). 10. Remove clamp (Figure 4, Item 2) from hose (Figure 4, Item 1). 11. Loosen clamp (Figure 4, Item 5) from hose (Figure 4, Item 4). 12. Remove hose (Figure 4, Item 4) from coolant tank (Figure 4, Item 6). 13. Remove clamp (Figure 4, Item 5) from hose (Figure 4, Item 4).

Figure 4. Radiator Core Lower Mount.

0043-4

0043

TM 5-2410-241-23-1

0043

REMOVAL – CONTINUED 14. Remove four bolts (Figure 5, Item 1) and washers (Figure 5, Item 2) from radiator guard (Figure 5, Item 3).

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death to personnel.

NOTE Upper coolant tank weighs approximately 58 lb (26 kg). 15. With assistance, remove upper coolant tank (Figure 5, Item 4) from machine.

Figure 5. Upper Coolant Tank.

0043-5

0043

TM 5-2410-241-23-1

0043

REMOVAL – CONTINUED 16. Remove sight gauge (Figure 6, Item 1) and O-ring (Figure 6, Item 2) from coolant tank (Figure 6, Item 8). Discard O-ring. 17. Remove plug (Figure 6, Item 7) and O-ring (Figure 6, Item 6) from coolant tank (Figure 6, Item 8). Discard Oring. 18. Remove shutoff valve (Figure 6, Item 5) from fitting (Figure 6, Item 3). 19. Remove fitting (Figure 6, Item 3) and O-ring (Figure 6, Item 4) from coolant tank (Figure 6, Item 8). Discard Oring.

Figure 6. Sight Gauge.

0043-6

0043

TM 5-2410-241-23-1

0043

REMOVAL – CONTINUED

NOTE Tag hoses to aid installation. 20. Loosen three clamps (Figure 7, Item 3) and remove hoses (Figure 7, Item 5) from fittings (Figure 7, Item 1). 21. Remove three clamps (Figure 7, Item 3) from hoses (Figure 7, Item 5). 22. Remove three fittings (Figure 7, Item 1) and O-rings (Figure 7, Item 2) from coolant tank (Figure 7, Item 4). Discard O-rings.

Figure 7. Fittings.

0043-7

0043

TM 5-2410-241-23-1

0043

REMOVAL – CONTINUED 23. Remove four bolts (Figure 8, Item 1), washers (Figure 8, Item 2), two strips (Figure 8, Item 3), and baffles (Figure 8, Item 4) from radiator guard (Figure 8, Item 5).

Figure 8. Baffles.

0043

END OF TASK CLEANING AND INSPECTION

00043

Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

00043

1. Install two strips (Figure 8, Item 3), baffles (Figure 8, Item 4), four washers (Figure 8, Item 2), and bolts (Figure 8, Item 1) on radiator guard (Figure 8, Item 5).

0043-8

TM 5-2410-241-23-1

0043

INSTALLATION – CONTINUED

NOTE Install hoses as tagged during removal. 2. Install three new O-rings (Figure 9, Item 2) and fittings (Figure 9, Item 1) on coolant tank (Figure 9, Item 4). 3. Install three clamps (Figure 9, Item 3) on hoses (Figure 9, Item 5). 4. Install three hoses (Figure 9, Item 5) on fittings (Figure 9, Item 1), tighten three clamps (Figure 9, Item 3).

Figure 9. Fittings.

0043

5. Install new O-ring (Figure 10, Item 4) and fitting (Figure 10, Item 3) on coolant tank (Figure 10, Item 8). 6. Install shutoff valve (Figure 10, Item 5) on fitting (Figure 10, Item 3). 7. Install new O-ring (Figure 10, Item 6) and plug (Figure 10, Item 7) on coolant tank (Figure 10, Item 8). 8. Install new O-ring (Figure 10, Item 2) and sight gauge (Figure 10, Item 1) on coolant tank (Figure 10, Item 8).

Figure 10. Sight Gauge.

0043-9

0043

TM 5-2410-241-23-1

0043

INSTALLATION – CONTINUED

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death to personnel.

NOTE Upper coolant tank weighs approximately 58 lb (26 kg). 9. With assistance, install upper coolant tank (Figure 11, Item 4) on machine. 10. Install four washers (Figure 11, Item 2) and bolts (Figure 11, Item 1) on radiator guard (Figure 11, Item 3).

Figure 11. Upper Coolant Tank.

0043-10

0043

TM 5-2410-241-23-1

0043

INSTALLATION – CONTINUED

NOTE Install hoses as tagged during removal. 11. Install clamp (Figure 12, Item 5) on hose (Figure 12, Item 4). 12. Install hose (Figure 12, Item 4) on coolant tank (Figure 12, Item 6) and tighten clamp (Figure 12, Item 5). 13. Install clamp (Figure 12, Item 2) on hose (Figure 12, Item 1). 14. Install hose (Figure 12, Item 1) on shutoff valve (Figure 12, Item 3) and tighten clamp (Figure 12, Item 2).

Figure 12. Radiator Core Lower Mount.

0043-11

0043

TM 5-2410-241-23-1

0043

INSTALLATION – CONTINUED 15. Install overflow hose (Figure 13, Item 2) on upper coolant tank (Figure 13, Item 1). 16. Install four clamps (Figure 13, Item 4) on hoses (Figure 13, Item 5). 17. Install four hoses (Figure 13, Item 5) on radiator cores (Figure 13, Item 3) and tighten clamps (Figure 13, Item 4).

Figure 13. Radiator Core Hoses.

0043

18. With assistance, lift two doors (Figure 14, Item 1) on hinges (Figure 14, Item 4). Close doors. 19. Install eight washers (Figure 14, Item 3) and bolts (Figure 14, Item 2) on doors (Figure 14, Item 1).

Figure 14. Radiator Guard Doors.

0043-12

0043

TM 5-2410-241-23-1

0043

INSTALLATION – CONTINUED 20. Install cover (Figure 15, Item 3), three washers (Figure 15, Item 1), and bolts (Figure 15, Item 2) on radiator guard (Figure 15, Item 4).

Figure 15. Upper Cover.

0043

END OF TASK FOLLOW-ON TASKS

00043

1. Install cooling fan (WP 0050). 2. Fill cooling system (WP 0113). 3. Install hood (WP 0200). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0043-13/(14 blank)

10 TM 5-2410-241-23-1

0044

FIELD MAINTENANCE

-

A/C CONDENSER REPLACEMENT Removal, Cleaning and Inspection, Installation 0 0 4 4

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Tool Kit, Service, Refrigeration, Ordnance (WP 0302, Item 66) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Oil, Lubricating, Refrigerant Compressor (WP 0303, Item 22) Tag, Marker (WP 0303, Item 34) O-ring (2) Personnel Required 91C References WP 0295

0

Equipment Condition

0

Machine parked (TM 5-2410-241-10) Refrigerant recovered from A/C system (WP 0263) Engine enclosure left door guard removed (WP 0202) Engine enclosure right door guard removed (WP 0204) Hydraulic oil cooler core removed (WP 0041) 0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0044-1

Drawing Required TM 5-2410-241-24P, Figure 8 Estimated Time to Complete 8.5 Hr

0

0

0

0

TM 5-2410-241-23-1

REMOVAL

0044

00044

CAUTION Cap all A/C lines and fittings during removal to protect against contamination. Failure to follow this caution may result in equipment damage.

NOTE Tag A/C lines to aid installation. 1. Loosen tube nut (Figure 1, Item 1) and remove line (Figure 1, Item 4) from condenser (Figure 1, Item 2). 2. Remove O-ring (Figure 1, Item 3) from line (Figure 1, Item 4). Discard O-ring.

Figure 1. Lower A/C Line.

0044-2

0044

TM 5-2410-241-23-1

0044

REMOVAL – CONTINUED 3. Loosen tube nut (Figure 2, Item 3) and remove line (Figure 2, Item 4) from condenser (Figure 2, Item 1). 4. Remove O-ring (Figure 2, Item 5) from line (Figure 2, Item 4). Discard O-ring. 5. Remove four bolts (Figure 2, Item 9) and washers (Figure 2, Item 10) from condenser (Figure 2, Item 1). 6. Remove two bolts (Figure 2, Item 8), washers (Figure 2, Item 7), and bracket (Figure 2, Item 2) from condenser (Figure 2, Item 1). 7. Remove two grommets (Figure 2, Item 6) from bracket (Figure 2, Item 2).

Figure 2. Right Side Mount.

0044-3

0044

TM 5-2410-241-23-1

0044

REMOVAL – CONTINUED 8. Remove bolt (Figure 3, Item 1), washer (Figure 3, Item 5), clamp (Figure 3, Item 4) and spacer (Figure 3, Item 6) from bracket (Figure 3, Item 3). Position A/C line (Figure 3, Item 2) aside.

Figure 3. Upper A/C Line Clamp.

0044

9. Remove bolt (Figure 4, Item 3), washer (Figure 4, Item 2), nut (Figure 4, Item 5), washer (Figure 4, Item 6), and angle bracket (Figure 4, Item 4) from bracket (Figure 4, Item 1).

Figure 4. Cooler Angle Bracket.

0044-4

0044

TM 5-2410-241-23-1

0044

REMOVAL – CONTINUED

NOTE Plate will be loose when bolts are removed. 10. Remove two bolts (Figure 5, Item 7) and washers (Figure 5, Item 8) from condenser (Figure 5, Item 6). 11. Remove two bolts (Figure 5, Item 4), washers (Figure 5, Item 5), and slide condenser (Figure 5, Item 6) from right side of machine. 12. Remove plate (Figure 5, Item 2) from bracket (Figure 5, Item 3). 13. Remove two bolts (Figure 5, Item 13), washers (Figure 5, Item 14), and bracket (Figure 5, Item 3) from bracket (Figure 5, Item 1). 14. Remove two bolts (Figure 5, Item 10), washers (Figure 5, Item 11), and bracket (Figure 5, Item 9) from machine. 15. Remove two grommets (Figure 5, Item 12) from bracket (Figure 5, Item 9).

Figure 5. Left Side Mount.

0044

END OF TASK CLEANING AND INSPECTION

00044

Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0044-5

TM 5-2410-241-23-1

0044

INSTALLATION

00044

NOTE Install A/C lines as tagged during removal. 1. Install two grommets (Figure 6, Item 12) on bracket (Figure 6, Item 9). 2. Install bracket (Figure 6, Item 9), two washers (Figure 6, Item 11), and bolts (Figure 6, Item 10) on machine. 3. Install bracket (Figure 6, Item 3), two washers (Figure 6, Item 14), and bolts (Figure 6, Item 13) on bracket (Figure 6, Item 1). 4. Position plate (Figure 6, Item 2) on bracket (Figure 6, Item 3). 5. Through right side of machine install condenser (Figure 6, Item 6), two washers (Figure 6, Item 5), and bolts (Figure 6, Item 4) on machine. 6. Install two washers (Figure 6, Item 8), and bolts (Figure 6, Item 7) on condenser (Figure 6, Item 6).

Figure 6. Left Side Mount.

0044-6

0044

TM 5-2410-241-23-1

0044

INSTALLATION – CONTINUED 7. Install angle bracket (Figure 7, Item 4), washer (Figure 7, Item 6), nut (Figure 7, Item 5), washer (Figure 7, Item 2), and bolt (Figure 7, Item 3) on bracket (Figure 7, Item 1).

Figure 7. Cooler Angle Bracket.

0044

8. Position A/C line (Figure 8, Item 2) on bracket (Figure 8, Item 3). 9. Install spacer (Figure 8, Item 6), clamp (Figure 8, Item 4), washer (Figure 8, Item 5), and bolt (Figure 8, Item 1) on bracket (Figure 8, Item 3).

Figure 8. Upper A/C Line Clamp.

0044-7

0044

TM 5-2410-241-23-1

0044

INSTALLATION – CONTINUED 10. Install two grommets (Figure 9, Item 6) on bracket (Figure 9, Item 2). 11. Install bracket (Figure 9, Item 2), two washers (Figure 9, Item 7), and bolts (Figure 9, Item 8) on condenser (Figure 9, Item 1). 12. Install four washers (Figure 9, Item 10) and bolts (Figure 9, Item 9) on condenser (Figure 9, Item 1). 13. Lubricate and install new O-ring (Figure 9, Item 5) on line (Figure 9, Item 4). 14. Install line (Figure 9, Item 4) and tube nut (Figure 9, Item 3) on condenser (Figure 9, Item 1).

Figure 9. Upper A/C Line.

0044-8

0044

TM 5-2410-241-23-1

0044

INSTALLATION – CONTINUED 15. Lubricate and install new O-ring (Figure 10, Item 3) on line (Figure 10, Item 4). 16. Install line (Figure 10, Item 4) and tube nut (Figure 10, Item 1) on condenser (Figure 10, Item 2).

Figure 10. Lower A/C Line.

0044

END OF TASK FOLLOW-ON TASKS

00044

1. Install hydraulic oil cooler core (WP 0041). 2. Install engine enclosure left door guard (WP 0202). 3. Install engine enclosure right door guard (WP 0204). 4. Charge refrigerant on A/C system (WP 0263). 5. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0044-9/(10 blank)

10 TM 5-2410-241-23-1

0045

FIELD MAINTENANCE

-

MUFFLER ASSEMBLY REPLACEMENT Removal, Cleaning and Inspection, Installation 0 0 4 5

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Socket Wrench, 3/8" Drive, 6 Point, Long, 16 mm (S0554) (WP 0302, Item 68) Materials/Parts

WP 0295

0

0

0

Equipment Condition 0

0

Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) (7)

References

0

0

0

Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 9 Estimated Time to Complete 1.5 Hr

REMOVAL

0

0

0

0

0

0

00045

1. Remove two nuts (Figure 1, Item 2), washers (Figure 1, Item 7), plate (Figure 1, Item 8), four washers (Figure 1, Item 3), two bolts (Figure 1, Item 6), washers (Figure 1, Item 4), and plate (Figure 1, Item 5) from pipe (Figure 1, Item 1).

Figure 1. Hood Support.

0045-1

0045

TM 5-2410-241-23-1

0045

REMOVAL – CONTINUED 2. Loosen two clamps (Figure 2, Item 2) and remove hose (Figure 2, Item 1) from pipe (Figure 2, Item 3) and air cleaner (Figure 2, Item 4). 3. Loosen nut (Figure 2, Item 6) and clamp (Figure 2, Item 5) from pipe (Figure 2, Item 3). 4. Remove pipe (Figure 2, Item 3) from muffler (Figure 2, Item 7). 5. Remove clamp (Figure 2, Item 5) from pipe (Figure 2, Item 3).

Figure 2. Tailpipe.

0045-2

0045

TM 5-2410-241-23-1

0045

REMOVAL – CONTINUED

NOTE •

Tag and mark electrical connectors to aid installation.

•

Note wiring harness routing to aid installation.

•

Note location of tiedown straps to aid installation.

6. Remove tiedown straps (Figure 3, Item 2) from alternator wiring harness (Figure 3, Item 1). Discard tiedown straps. 7. Disconnect terminal (Figure 3, Item 3) from alternator (Figure 3, Item 4).

Figure 3. A/C Compressor Clutch Wiring Harness.

0045-3

0045

TM 5-2410-241-23-1

0045

REMOVAL – CONTINUED 8. Loosen nut (Figure 4, Item 3) and clamp (Figure 4, Item 2) on muffler (Figure 4, Item 1).

Figure 4. Muffler.

0045-4

0045

TM 5-2410-241-23-1

0045

REMOVAL – CONTINUED 9. Remove two bolts (Figure 5, Item 5), washers (Figure 5, Item 4), and muffler (Figure 5, Item 6) from muffler bracket (Figure 5, Item 1). 10. Remove tiedown straps (Figure 5, Item 8) from harness bracket (Figure 5, Item 7). Discard tiedown straps. 11. Remove two bolts (Figure 5, Item 10), washers (Figure 5, Item 11), and harness bracket (Figure 5, Item 7) from muffler bracket (Figure 5, Item 1). 12. Disconnect harness (Figure 5, Item 9) from engine temperature sensor (Figure 5, Item 13). 13. Move wiring harness (Figure 5, Item 9) to the side. 14. Remove bolt (Figure 5, Item 3) and washer (Figure 5, Item 2) from muffler bracket (Figure 5, Item 1). 15. Remove bolts (Figure 5, Item 10), washers (Figure 5, Item 11), and muffler bracket (Figure 5, Item 1) from hood (Figure 5, Item 12).

Figure 5. Muffler Bracket.

0045

END OF TASK CLEANING AND INSPECTION

00045

Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0045-5

TM 5-2410-241-23-1

0045

INSTALLATION

00045

1. Install muffler bracket (Figure 6, Item 1), two washers (Figure 6, Item 11), and bolts (Figure 6, Item 10) on hood (Figure 6, Item 12). 2. Install washer (Figure 6, Item 2) and bolt (Figure 6, Item 3) on muffler bracket (Figure 6, Item 1). 3. Install harness bracket (Figure 6, Item 7), two washers (Figure 6, Item 11), and bolts (Figure 6, Item 10) on muffler bracket (Figure 6, Item 1). 4. Place wiring harness (Figure 6, Item 9) on harness bracket (Figure 6, Item 7). 5. Connect harness (Figure 6, Item 9) to engine temperature sensor (Figure 6, Item 13). 6. Install new tiedown straps (Figure 6, Item 8) on harness bracket (Figure 6, Item 7). 7. Install muffler (Figure 6, Item 6), two washers (Figure 6, Item 4), and bolts (Figure 6, Item 5) on muffler bracket (Figure 6, Item 1).

Figure 6. Muffler Bracket.

0045-6

0045

TM 5-2410-241-23-1

0045

INSTALLATION – CONTINUED 8. Install clamp (Figure 7, Item 2) on muffler (Figure 7, Item 1). 9. Tighten nut (Figure 7, Item 3) on clamp (Figure 7, Item 2).

Figure 7. Muffler.

0045-7

0045

TM 5-2410-241-23-1

0045

INSTALLATION – CONTINUED 10. Connect terminal (Figure 8, Item 3) to alternator (Figure 8, Item 4). 11. Install new tiedown straps (Figure 8, Item 2) on alternator wiring harness (Figure 8, Item 1).

Figure 8. A/C Compressor Clutch Wire.

0045-8

0045

TM 5-2410-241-23-1

0045

INSTALLATION – CONTINUED 12. Install clamp (Figure 9, Item 5) on pipe (Figure 9, Item 3). 13. Install pipe (Figure 9, Item 3) on muffler (Figure 9, Item 7). 14. Tighten clamp (Figure 9, Item 5) and nut (Figure 9, Item 6) on pipe (Figure 9, Item 3). 15. Install hose (Figure 9, Item 1) and two clamps (Figure 9, Item 2) on air cleaner (Figure 9, Item 4) and pipe (Figure 9, Item 3).

Figure 9. Tailpipe.

0045

16. Install plate (Figure 10, Item 5), two washers (Figure 10, Item 4), bolts (Figure 10, Item 6), four washers (Figure 10, Item 3), plate (Figure 10, Item 8), two washers (Figure 10, Item 7), and nuts (Figure 10, Item 2) on pipe (Figure 10, Item 1).

Figure 10. Hood Support. END OF TASK

0045-9

0045

TM 5-2410-241-23-1

FOLLOW-ON TASKS

0045

00045

Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0045-10

4 TM 5-2410-241-23-1

0046

FIELD MAINTENANCE

-

ENGINE MOUNTS REPLACEMENT Removal, Cleaning and Inspection, Installation 0

0 4 6

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Wrench, Combination, 1-1/8” (S0788) (WP 0302, Item 68)

Drawing Required

0

0

0

0

0

0

0

Rag, Wiping (WP 0303, Item 24)

WP 0295

Machine parked (TM 5-2410-241-10) Engine removed (WP 0057)

TM 5-2410-241-24P, Figure 12

Materials/Parts

References

0

Equipment Condition

Estimated Time to Complete

0

0

36.5 Hr

0

0

0

REMOVAL

00046

NOTE Procedure shows left side engine mounts. Follow same procedure for right side engine mounts. Remove six bolts (Figure 1, Item 3), washers (Figure 1, Item 2) and engine mount (Figure 1, Item 4) from flywheel assembly (Figure 1, Item 1).

Figure 1. Engine Mount. END OF TASK

0046-1

0046

TM 5-2410-241-23-1

0046

CLEANING AND INSPECTION

00046

1. Clean all parts IAW Mechanical General Maintenance Instructions (WP 0295). 2. Inspect bolt holes (Figure 2, Item 1) for elongation, cracks or breaks. Replace engine mount. 3. Inspect engine mount (Figure 2, Item 2) for cracks, breaks or damage. Replace engine mount. 4. Inspect mount (Figure 2, Item 3) for deformity or damage. Replace engine mount if deformed or damaged.

Figure 2. Engine Mount Inspection. END OF TASK

0046-2

0046

TM 5-2410-241-23-1

0046

INSTALLATION

00046

NOTE Procedure shows left side engine mounts. Follow same procedure for right side engine mounts. Install engine mount (Figure 3, Item 4), six washers (Figure 3, Item 2), and bolts (Figure 3, Item 3) on flywheel assembly (Figure 3, Item 1).

Figure 3. Engine Mount.

0046

END OF TASK FOLLOW-ON TASKS

00046

1. Install engine (WP 0057). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0046-3/(4 blank)

8 TM 5-2410-241-23-1

0047

FIELD MAINTENANCE

-

ENGINE SUPPORT REPLACEMENT Removal, Cleaning and Inspection, Installation 0

0 4 7

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Extension, 3/4” Drive, 7” Long (S0377) (WP 0302, Item 68) Handle, Ratchet, 3/4” Drive, 17” Long (S0374) (WP 0302, Item 68) Socket, Socket wrench, 3/4” Drive, 1-1/2”, 12 Point (S0390) (WP 0302, Item 68) Lifting Device, 5,000-lb Capacity Materials/Parts

Personnel Required Two

0

0

0

References 0

WP 0295 Equipment Condition

0

0

0

0

0

0

Machine parked (TM 5-2410-241-10) Crankshaft damper, pulley and removed (WP 0080) Engine coolant drained (WP 0113)

0

spacer 0

0

0

Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Lifting device (5,000-lb capacity)

Drawing Required

0

0

TM 5-2410-241-24P, Figure 12

0

0

0

Estimated Time to Complete

0

10.0 Hr REMOVAL

0

00047

1. Remove three bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and two brackets (Figure 1, Items 3 and 6) from engine support (Figure 1, Item 5). 2. Position two brackets (Figure 1, Items 3 and 6) and hose (Figure 1, Item 4) aside.

Figure 1. Brackets and Hose.

0047-1

0047

TM 5-2410-241-23-1

0047

REMOVAL – CONTINUED

NOTE Tag hoses to aid installation. 3. Remove clamp (Figure 2, Item 2) and hose (Figure 2, Item 1) from line (Figure 2, Item 3). 4. Loosen two clamps (Figure 2, Item 5) and remove line (Figure 2, Item 4) from two hoses (Figure 2, Item 6).

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death to personnel.

NOTE •

Engine weighs approximately 3,750 lb (1,700 Kg)

•

Engine must be properly supported before removing bolts.

5. Install suitable lifting device on front of engine. 6. Remove two bolts (Figure 2, Item 7) and washers (Figure 2, Item 8) from engine support (Figure 2, Item 9).

Figure 2. Engine Support to Frame.

0047-2

0047

TM 5-2410-241-23-1

0047

REMOVAL – CONTINUED 7. Using suitable lifting device, lift engine off frame. 8. Remove five bolts (Figure 3, Item 1), washers (Figure 3, Item 2), and engine support (Figure 3, Item 3) from engine.

Figure 3. Engine Support to Engine. END OF TASK

0047-3

0047

TM 5-2410-241-23-1

0047

CLEANING AND INSPECTION

00047

1. Clean all parts IAW Mechanical General Maintenance Instructions (WP 0295). 2. Inspect bolt holes (Figure 4, Item 2) for elongation, cracks, or damage. Replace engine support. 3. Inspect central bearing opening (Figure 4, Item 3) for cracks, breaks, elongation or damage. Replace engine support, if damaged. 4. Inspect mounting bolt sleeves (Figure 4, Item 4) for bending, cracks, missing pieces or damage. Replace engine support, if damaged. 5. Inspect engine support (Figure 4, Item 1) for deformity, cracks or damage. Replace engine support, if damaged.

Figure 4. Engine Support Inspection. END OF TASK

0047-4

0047

TM 5-2410-241-23-1

INSTALLATION

0047

00047

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death to personnel.

NOTE Engine weighs approximately 3,750 lb (1,700 Kg). 1. Install suitable lifting device on front of engine. 2. Install engine support (Figure 5, Item 3), five washers (Figure 5, Item 2), and bolts (Figure 5, Item 1) on engine.

Figure 5. Engine Support to Engine.

0047-5

0047

TM 5-2410-241-23-1

0047

INSTALLATION – CONTINUED 3. Using suitable lifting device, lower engine on frame. 4. Install two washers (Figure 6, Item 8) and bolts (Figure 6, Item 7) on engine support (Figure 6, Item 9).

NOTE Install hoses as tagged during removal. 5. Install two clamps (Figure 6, Item 5) on two hoses (Figure 6, Item 6). 6. Install line (Figure 6, Item 4) on two hoses (Figure 6, Item 6) and tighten two clamps (Figure 6, Item 5). 7. Install clamp (Figure 6, Item 2) on hose (Figure 6, Item 1). 8. Install hose (Figure 6, Item 1) on line (Figure 6, Item 3) and tighten clamp (Figure 6, Item 2). 9. Remove lifting device from engine.

Figure 6. Engine Support to Frame.

0047-6

0047

TM 5-2410-241-23-1

0047

INSTALLATION – CONTINUED 10. Position two brackets (Figure 7, Items 3 and 6) and hose (Figure 7, Item 4) on engine support (Figure 7, Item 5). 11. Install two brackets (Figure 7, Items 3 and 6), three washers (Figure 7, Item 2), and bolts (Figure 7, Item 1) on engine support (Figure 7, Item 5).

Figure 7. Brackets and Hose.

0047

END OF TASK FOLLOW-ON TASKS

00047

1. Install crankshaft damper, pulley, and spacer (WP 0080). 2. Fill engine with coolant (WP 0113). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0047-7/(8 blank)

4 TM 5-2410-241-23-1

0048

FIELD MAINTENANCE

-

TRUNNION ASSEMBLY REPLACEMENT Removal, Cleaning and Inspection, Installation 0 0 4 8

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) References WP 0295

0

Equipment Condition Machine parked (TM 5-2410-241-10) Fan hub pulley removed (WP 0095) Front engine support removed (WP 0047)

0

0

0

0

0

0

0

Drawing Required TM 5-2410-241-24P, Figure 12

0

0

0

0

Estimated Time to Complete

0

4.5 Hr REMOVAL

0

00048

1. Remove eight bolts (Figure 1, Item 3), washers (Figure 1, Item 4), and trunnion (Figure 1, Item 2) from engine (Figure 1, Item 1).

Figure 1. Trunnion. END OF TASK

0048-1

0048

TM 5-2410-241-23-1

0048

CLEANING AND INSPECTION

00048

1. Clean all parts IAW Mechanical General Maintenance Instructions WP 0295. 2. Inspect bolt holes (Figure 2, Item 1) on trunnion bracket (Figure 2, Item 2) for elongation, cracks, or damage. Replace trunnion, if damaged. 3. Inspect vibration dampers (Figure 2, Item 5) on trunnion bracket (Figure 2, Item 2) for deterioration, flaking, splits, or missing pieces. Replace trunnion, if damaged. 4. Inspect bolt holes (Figure 2, Item 4) on trunnion (Figure 2, Item 3) for elongation, cracks, or damage. Replace trunnion, if damaged. 5. Inspect trunnion (Figure 2, Item 3) for deformation, cracks, dents, or damage. Replace trunnion, if damaged.

Figure 2. Trunnion Inspection. INSTALLATION

0048

00048

1. Install trunnion (Figure 3, Item 2), eight washers (Figure 3, Item 4), and bolts (Figure 3, Item 3) on engine (Figure 3, Item 1).

Figure 3. Trunnion. END OF TASK

0048-2

0048

TM 5-2410-241-23-1

FOLLOW-ON TASKS

0048

00048

1. Install front engine support (WP 0047). 2. Install fan hub pulley (WP 0095). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0048-3/(4 blank)

10 TM 5-2410-241-23-1

0049

FIELD MAINTENANCE

-

WATER LINES REPLACEMENT Removal, Cleaning and Inspection, Installation 0 0 4 9

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Materials/Parts

0

Equipment Condition

0

Machine parked (TM 5-2410-241-10) Coolant drained (WP 0113) Engine enclosure left door guard removed (WP 0202) 0

0

0

0

0

Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring References WP 0295 REMOVAL

0

0

0

0

0

Drawing Required TM 5-2410-241-24P, Figure 29 Estimated Time to Complete

0

0

0

6.0 Hr

0

9

1. Remove bolt (Figure 1, Item 4), washer (Figure 1, Item 2), clamp (Figure 1, Item 3), spacer (Figure 1, Item 5), and receiver/dryer (Figure 1, Item 1) from plate (Figure 1, Item 6). Place receiver/dryer aside.

Figure 1. Receiver/Dryer.

0049-1

0049

TM 5-2410-241-23-1

0049

REMOVAL – CONTINUED 2. Remove two bolts (Figure 2, Item 4), washers (Figure 2, Item 5), clamp (Figure 2, Item 6), and plate (Figure 2, Item 2) from engine (Figure 2, Item 1). Place plate and wiring harness assembly (Figure 2, Item 3) aside.

Figure 2. Mounting Plate.

0049-2

0049

TM 5-2410-241-23-1

0049

REMOVAL – CONTINUED 3. Remove two bolts (Figure 3, Item 6), washers (Figure 3, Item 5), and clip (Figure 3, Item 1) from bracket (Figure 3, Item 4).

NOTE Bracket will be held in place by pipe. Remove bracket with pipe. 4. Remove four bolts (Figure 3, Item 2), washers (Figure 3, Item 3), and bracket (Figure 3, Item 4) from engine.

Figure 3. Cooling Pipe Mount.

0049-3

0049

TM 5-2410-241-23-1

0049

REMOVAL – CONTINUED

NOTE Tag hoses to aid installation. 5. Loosen four clamps (Figure 4, Item 2) on two hoses (Figure 4, Item 1). 6. Remove water pipe (Figure 4, Item 3) and two hoses (Figure 4, Item 1) from engine (Figure 4, Item 4). 7. Remove bracket (Figure 4, Item 5) from machine. 8. Remove four clamps (Figure 4, Item 2) and two hoses (Figure 4, Item 1) from water pipe (Figure 4, Item 3).

Figure 4. Lower Cooling Pipe.

0049-4

0049

TM 5-2410-241-23-1

0049

REMOVAL – CONTINUED 9. Remove plug (Figure 5, Item 7) from pipe (Figure 5, Item 1). 10. Remove bolt (Figure 5, Item 5), washer (Figure 5, Item 6), and clamp (Figure 5, Item 4) from engine (Figure 5, Item 8). 11. Remove four bolts (Figure 5, Item 3), washers (Figure 5, Item 2), and pipe (Figure 5, Item 1) from engine (Figure 5, Item 8). 12. Remove O-ring (Figure 5, Item 9) from pipe (Figure 5, Item 1). Discard O-ring.

Figure 5. Upper Cooling Pipe.

0049

END OF TASK CLEANING AND INSPECTION

00049

Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0049-5

TM 5-2410-241-23-1

0049

INSTALLATION

00049

1. Install new O-ring (Figure 6, Item 9) on pipe (Figure 6, Item 1). 2. Install pipe (Figure 6, Item 1), four washers (Figure 6, Item 2), and bolts (Figure 6, Item 3), on engine (Figure 6, Item 8). 3. Install bolt (Figure 6, Item 5), washer (Figure 6, Item 6), and clamp (Figure 6, Item 4) on engine (Figure 6, Item 8). 4. Install plug (Figure 6, Item 7) on pipe (Figure 6, Item 1).

Figure 6. Upper Cooling Pipe.

0049-6

0049

TM 5-2410-241-23-1

0049

INSTALLATION – CONTINUED

NOTE Install hoses as tagged during removal. 5. Install two hoses (Figure 7, Item 1) and four clamps (Figure 7, Item 2) on water pipe (Figure 7, Item 3). 6. Position bracket (Figure 7, Item 5) on machine. 7. Install two hoses (Figure 7, Item 1) and water pipe (Figure 7, Item 3) on engine (Figure 7, Item 4). 8. Tighten four clamps (Figure 7, Item 2) on two hoses (Figure 7, Item 1).

Figure 7. Lower Cooling Pipe.

0049

9. Install bracket (Figure 8, Item 4), four washers (Figure 8, Item 3) and bolts (Figure 8, Item 2) on engine. 10. Install two clips (Figure 8, Item 1), washers (Figure 8, Item 5) and bolts (Figure 8, Item 6) on bracket (Figure 8, Item 4).

Figure 8. Cooling Pipe Mount.

0049-7

0049

TM 5-2410-241-23-1

0049

INSTALLATION – CONTINUED 11. Position plate (Figure 9, Item 2) and wiring harness assembly (Figure 9, Item 3) on engine (Figure 9, Item 1). 12. Install clamp (Figure 9, Item 6), two washers (Figure 9, Item 5) and bolts (Figure 9, Item 4) on engine (Figure 9, Item 1).

Figure 9. Mounting Plate.

0049-8

0049

TM 5-2410-241-23-1

0049

INSTALLATION – CONTINUED 13. Position receiver/dryer (Figure 10, Item 1) and install spacer (Figure 10, Item 5), clamp (Figure 10, Item 3), washer (Figure 10, Item 2) and bolt (Figure 10, Item 4) on plate (Figure 10, Item 6).

Figure 10. Receiver/Dryer.

0049

END OF TASK FOLLOW-ON TASKS

00049

1. Fill cooling system (WP 0113). 2. Install engine enclosure left door guard (WP 0202). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0049-9/(10 blank)

16 TM 5-2410-241-23-1

0050

FIELD MAINTENANCE

-

COOLING FAN REPLACEMENT Removal, Cleaning and Inspection, Installation 0

0 5 0

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) O-ring Personnel Required Two References WP 0295

0

0

0

Equipment Condition Machine parked (TM 5-2410-241-10) V-belt (A/C compressor) removed (WP 0096) V-belt set (Alternator) removed (WP 0098) A/C condenser removed (WP 0044)

0

0

0

0

0

0

0

Drawing Required TM 5-2410-241-24P, Figure 6, 8

0

0

0

0

0

0

0050-1

Estimated Time to Complete 3.0 Hr

0

0

TM 5-2410-241-23-1

0050

REMOVAL

00050

NOTE The following procedure is for the left lower bracket removal. Use same procedure for right lower bracket removal. 1. Remove two bolts (Figure 1, Item 5) and washers (Figure 1, Item 4) from lower bracket (Figure 1, Item 6). 2. Remove two bolts (Figure 1, Item 1), washers (Figure 1, Item 2), clip (Figure 1, Item 3), and lower bracket (Figure 1, Item 6) from machine. Position clip aside.

Figure 1. Lower Brackets.

0050-2

0050

TM 5-2410-241-23-1

0050

REMOVAL – CONTINUED 3. Remove bolt (Figure 2, Item 3), washer (Figure 2, Item 2), and clip (Figure 2, Item 4) from fan guard (Figure 2, Item 1). Position clip aside. 4. Remove two nuts (Figure 2, Item 5) from fan guard (Figure 2, Item 1).

Figure 2. Top of Fan Guard.

0050-3

0050

TM 5-2410-241-23-1

0050

REMOVAL – CONTINUED 5. Remove three bolts (Figure 3, Item 4), washers (Figure 3, Item 3), clip (Figure 3, Item 2) and bracket (Figure 3, Item 1) from machine. Position clip aside.

Figure 3. Upper Left Bracket.

0050

6. Remove bolt (Figure 4, Item 1), washer (Figure 4, Item 2), and hose clamp (Figure 4, Item 3) from hose (Figure 4, Item 4) and fan guard (Figure 4, Item 5).

Figure 4. Hose Clamp.

0050-4

0050

TM 5-2410-241-23-1

0050

REMOVAL – CONTINUED 7. Remove bolt (Figure 5, Item 4) and washer (Figure 5, Item 5) from hose with bracket (Figure 5, Item 7). 8. Move hose with bracket (Figure 5, Item 7) to the side. 9. Remove three bolts (Figure 5, Item 3), washers (Figure 5, Item 2) and bracket (Figure 5, Item 1) from machine. 10. Remove bracket (Figure 5, Item 8) from fan guard (Figure 5, Item 6).

Figure 5. Upper Right Bracket.

0050-5

0050

TM 5-2410-241-23-1

0050

REMOVAL – CONTINUED 11. Remove bolt (Figure 6, Item 5) and washer (Figure 6, Item 6) from two fan guard sections (Figure 6, Items 1 and 4). 12. Remove six bolts (Figure 6, Item 3), washers (Figure 6, Item 2) and two fan guard sections (Figure 6, Items 1 and 4) from machine.

Figure 6. Fan Guard.

0050-6

0050

TM 5-2410-241-23-1

0050

REMOVAL – CONTINUED

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death to personnel.

NOTE Fan spider weighs approximately 75 lb (34 kg). 13. With assistance, remove eight bolts (Figure 7, Item 1) and washers (Figure 7, Item 2) from fan spider (Figure 7, Item 3). 14. Slide fan spider (Figure 7, Item 3) forward.

Figure 7. Fan Spider.

0050-7

0050

TM 5-2410-241-23-1

0050

REMOVAL – CONTINUED 15. Remove six bolts (Figure 8, Item 1), O-ring (Figure 8, Item 2) and fan spider adapter (Figure 8, Item 4) from fan clutch hub (Figure 8, Item 5). Discard O-ring. 16. With assistance, remove fan spider assembly (Figure 8, Item 3) from machine.

Figure 8. Fan Spider Adapter.

0050

END OF TASK CLEANING AND INSPECTION

00050

1. Clean all parts IAW Mechanical General Maintenance Instructions (WP 0295). 2. Inspect fan shroud (Figure 9, Item 1) for cracks, deformity, or broken structural members. Replace fan shroud. 3. Inspect fan shroud (Figure 9, Item 1) for elongation or breaks in mounting tabs (Figure 9, Item 4). Replace fan shroud. 4. Inspect fan spider (Figure 9, Item 2) for cracks, breaks, missing pieces or other damage to the fan spider blades. Replace fan spider.

0050-8

TM 5-2410-241-23-1

0050

CLEANING AND INSPECTION – CONTINUED 5. Inspect fan spider (Figure 9, Item 2) for elongation or cracks around mounting holes (Figure 9, Item 3). Replace fan spider.

Figure 9. Fan Spider Inspection.

0050

6. Inspect fan spider adapter (Figure 10, Item 1) for elongated mounting holes (Figure 10, Item 2), cracks, breaks or deformities. Replace fan spider adapter.

Figure 10. Fan Spider Adapter Inspection. END OF TASK

0050-9

0050

TM 5-2410-241-23-1

INSTALLATION

0050

00050

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or death to personnel.

NOTE Fan spider weighs approximately 75 lb (34 kg). 1. With assistance, place fan spider assembly (Figure 11, Item 3) on machine in location shown. 2. Install fan spider adapter (Figure 11, Item 4), new O-ring (Figure 11, Item 2), six bolts (Figure 11, Item 1) on fan clutch hub (Figure 11, Item 5).

Figure 11. Fan Spider Adapter.

0050-10

0050

TM 5-2410-241-23-1

0050

INSTALLATION – CONTINUED 3. Slide fan spider (Figure 12, Item 3) rearward. 4. Install eight washers (Figure 12, Item 2) and bolts (Figure 12, Item 1) on fan spider (Figure 12, Item 3).

Figure 12. Fan Spider.

0050-11

0050

TM 5-2410-241-23-1

0050

INSTALLATION – CONTINUED 5. Install two fan guard sections (Figure 13, Items 1 and 4), six washers (Figure 13, Item 2) and bolts (Figure 13, Item 3) on machine. 6. Install washer (Figure 13, Item 6) and bolt (Figure 13, Item 5) on two fan guard sections (Figure 13, Items 1 and 4).

Figure 13. Fan Guard.

0050-12

0050

TM 5-2410-241-23-1

0050

INSTALLATION – CONTINUED 7. Install bracket (Figure 14, Item 8) on fan guard (Figure 14, Item 6). 8. Install bracket (Figure 14, Item 1), three washers (Figure 14, Item 2) and bolts (Figure 14, Item 3) on machine. 9. Move hose with bracket (Figure 14, Item 7) to bracket (Figure 14, Item 1). 10. Install washer (Figure 14, Item 5) and bolt (Figure 14, Item 4) on bracket (Figure 14, Item 7).

Figure 14. Upper Right Bracket.

0050-13

0050

TM 5-2410-241-23-1

0050

INSTALLATION – CONTINUED 11. Install hose clamp (Figure 15, Item 3), washer (Figure 15, Item 2) and bolt (Figure 15, Item 1) on hose (Figure 15, Item 4) and fan guard (Figure 15, Item 5).

Figure 15. Hose Clamp.

0050

12. Install bracket (Figure 16, Item 1), clip (Figure 16, Item 2), three washers (Figure 16, Item 3) and bolts (Figure 16, Item 4) on machine.

Figure 16. Upper Left Bracket.

0050-14

0050

TM 5-2410-241-23-1

0050

INSTALLATION – CONTINUED 13. Install two nuts (Figure 17, Item 5) on fan guard (Figure 17, Item 1). 14. Install clip (Figure 17, Item 4), washer (Figure 17, Item 2) and bolt (Figure 17, Item 3) on fan guard (Figure 17, Item 1).

Figure 17. Top of Fan Guard.

0050-15

0050

TM 5-2410-241-23-1

0050

INSTALLATION – CONTINUED

NOTE The following procedure is for the left lower bracket installation. Use this same procedure for the right lower bracket installation. 15. Install lower bracket (Figure 18, Item 6), clip (Figure 18, Item 3), two washers (Figure 18, Item 2) and bolts (Figure 18, Item 1) on machine. 16. Install two washers (Figure 18, Item 4) and bolts (Figure 18, Item 5) on lower bracket (Figure 18, Item 6).

Figure 18. Lower Brackets.

0050

END OF TASK FOLLOW-ON TASKS

00050

1. Install A/C condenser (WP 0044). 2. Install V-belt set (Alternator) (WP 0098). 3. Install V-belt (A/C compressor) (WP 0096). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0050-16

22 TM 5-2410-241-23-1

0051

FIELD MAINTENANCE

-

RADIATOR COOLING LINES REPLACEMENT Aftercooler Pump Inlet Hoses and Pipe Removal, Water Temperature Regulator Outlet Hose and Pipe Removal, Water Pump Inlet Hose Removal, Water Tank Outlet Hose Removal, Vent Line Removal, Cleaning and Inspection, Vent Line Installation, Water Tank Outlet Hose Installation, Water Pump Inlet Hose Installation, Water Temperature Regulator Outlet Hose and Pipe Installation, Aftercooler Pump Inlet Hoses and Pipe Installation 0 0 5 1

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring References WP 0202 WP 0295

0

0

0

Equipment Condition Machine parked (TM 5-2410-241-10) Coolant drained (WP 0113) Front engine bottom guards removed (WP 0199)

0

0

0

0

0

0

0

0

0

0

0

0051-1

Drawing Required TM 5-2410-241-24P, Figure 1 Estimated Time to Complete 7.0 Hr

0

0

0

0

TM 5-2410-241-23-1

AFTERCOOLER PUMP INLET HOSES AND PIPE REMOVAL

0051

00051

CAUTION Plug all lines, hoses, and tubes to prevent contamination and leaks.

NOTE Tag lines and hoses to aid installation. 1. Remove engine enclosure left door guard (WP 0202). 2. Loosen clamp (Figure 1, Item 1) and clamp (Figure 1, Item 5) from hose (Figure 1, Item 3). 3. Remove hose (Figure 1, Item 3) from aftercooler pump (Figure 1, Item 2) and pipe (Figure 1, Item 4). 4. Remove clamp (Figure 1, Item 1) and clamp (Figure 1, Item 5) from hose (Figure 1, Item 3).

Figure 1. Aftercooler Pump Hose.

0051-2

0051

TM 5-2410-241-23-1

0051

AFTERCOOLER PUMP INLET HOSES AND PIPE REMOVAL – CONTINUED 5. Loosen clamp (Figure 2, Item 3), and clamp (Figure 2, Item 5) from hose (Figure 2, Item 4). 6. Remove hose (Figure 2, Item 4), from radiator (Figure 2, Item 2) and pipe (Figure 2, Item 1). 7. Remove clamp (Figure 2, Item 3), and clamp (Figure 2, Item 5) from hose (Figure 2, Item 4).

Figure 2. Hose at Radiator. END OF TASK

0051-3

0051

TM 5-2410-241-23-1

WATER TEMPERATURE REGULATOR OUTLET HOSE AND PIPE REMOVAL

0051

00051

1. Remove engine enclosure left door guard (WP 0202). 2. Loosen clamp (Figure 3, Item 2) from hose (Figure 3, Item 1). 3. Remove hose (Figure 3, Item 1) from radiator (Figure 3, Item 3). 4. Remove clamp (Figure 3, Item 2) from hose (Figure 3, Item 1).

Figure 3. Water Temperature Regulator Hose at Radiator.

0051-4

0051

TM 5-2410-241-23-1

0051

WATER TEMPERATURE REGULATOR OUTLET HOSE AND PIPE REMOVAL – CONTINUED 5. Loosen clamp (Figure 4, Item 6) from hose (Figure 4, Item 7). 6. Remove hose (Figure 4, Item 7) from pipe (Figure 4, Item 1). 7. Remove clamp (Figure 4, Item 6) from hose (Figure 4, Item 7). 8. Remove nut (Figure 4, Item 5), washer (Figure 4, Item 2), bolt (Figure 4, Item 4) and washer (Figure 4, Item 2), from engine (Figure 4, Item 3) and pipe (Figure 4, Item 1).

Figure 4. Water Temperature Regulator Pipe.

0051-5

0051

TM 5-2410-241-23-1

0051

WATER TEMPERATURE REGULATOR OUTLET HOSE AND PIPE REMOVAL – CONTINUED 9. Loosen clamp (Figure 5, Item 3) and clamp (Figure 5, Item 8) from hose (Figure 5, Item 6). 10. Remove hose (Figure 5, Item 6) from pipe (Figure 5, Item 4) and water temperature regulator housing (Figure 5, Item 7). 11. Remove clamp (Figure 5, Item 3) and clamp (Figure 5, Item 8) from hose (Figure 5, Item 6). 12. Loosen clamp (Figure 5, Item 5) and clamp (Figure 5, Item 10) from hose (Figure 5, Item 9). 13. Remove hose (Figure 5, Item 9) from pipe (Figure 5, Item 4) and aftercooler (Figure 5, Item 11). 14. Remove clamp (Figure 5, Item 5) and clamp (Figure 5, Item 10) from hose (Figure 5, Item 9). 15. Loosen clamp (Figure 5, Item 2) from hose (Figure 5, Item 1). 16. Remove hose (Figure 5, Item 1) from fitting (Figure 5, Item 14). 17. Remove clamp (Figure 5, Item 2) from hose (Figure 5, Item 1). 18. Loosen clamp (Figure 5, Item 13) from hose (Figure 5, Item 12). 19. Remove hose (Figure 5, Item 12) from fitting (Figure 5, Item 14). 20. Remove clamp (Figure 5, Item 13) from hose (Figure 5, Item 12).

Figure 5. Hose to Water Temperature Regulator.

0051-6

0051

TM 5-2410-241-23-1

0051

WATER TEMPERATURE REGULATOR OUTLET HOSE AND PIPE REMOVAL – CONTINUED 21. Remove bolt (Figure 6, Item 8) and washer (Figure 6, Item 9) from machine. 22. Remove nut (Figure 6, Item 5), bolt (Figure 6, Item 1), two washers (Figure 6, Item 4), and adjuster (Figure 6, Item 3) from A/C compressor bracket (Figure 6, Item 2). 23. Remove bolt (Figure 6, Item 7), two washers (Figure 6, Item 6) and adjuster (Figure 6, Item 3) from bracket. (Figure 6, Item 15). 24. Remove nut (Figure 6, Item 11) and hose (Figure 6, Item 10) from fitting (Figure 6, Item 12). 25. Remove pipe (Figure 6, Item 13) from machine. 26. Remove fitting (Figure 6, Item 14) from pipe (Figure 6, Item 13).

Figure 6. Adjuster. END OF TASK

0051-7

0051

TM 5-2410-241-23-1

0051

WATER PUMP INLET HOSE REMOVAL

00051

1. Remove three bolts (Figure 7, Item 2), washers (Figure 7, Item 1) and door (Figure 7, Item 3) from machine. 2. Loosen clamp (Figure 7, Item 5) from hose (Figure 7, Item 6). 3. Remove hose (Figure 7, Item 6) from water pump (Figure 7, Item 4). 4. Remove clamp (Figure 7, Item 5) from hose (Figure 7, Item 6).

Figure 7. Water Pump Inlet Hose.

0051-8

0051

TM 5-2410-241-23-1

0051

WATER PUMP INLET HOSE REMOVAL – CONTINUED 5. Loosen clamp (Figure 8, Item 3) from hose (Figure 8, Item 1). 6. Remove hose (Figure 8, Item 1) from radiator (Figure 8, Item 2). 7. Remove clamp (Figure 8, Item 3) from hose (Figure 8, Item 1).

Figure 8. Water Pump Inlet Hose at Radiator. END OF TASK

0051-9

0051

TM 5-2410-241-23-1

0051

WATER TANK OUTLET HOSE REMOVAL

00051

1. Remove clamp (Figure 9, Item 1) and hose (Figure 9, Item 2) from upper coolant tank (Figure 9, Item 3). 2. Remove three bolts (Figure 9, Item 5), washers (Figure 9, Item 6), and clips (Figure 9, Item 4) from radiator (Figure 9, Item 7). 3. Remove clamp (Figure 9, Item 8) and hose (Figure 9, Item 2) from water pump (Figure 9, Item 9).

Figure 9. Water Pump Inlet Line. END OF TASK

0051-10

0051

TM 5-2410-241-23-1

VENT LINE REMOVAL

0051

00051

1. Remove clamp (Figure 10, Item 2) and hose (Figure 10, Item 1) from valve (Figure 10, Item 3). 2. Remove bolt (Figure 10, Item 12), washer (Figure 10, Item 13), clip (Figure 10, Item 11) and hose (Figure 10, Item 1) from bracket (Figure 10, Item 14). 3. Remove clamp (Figure 10, Item 8) and hose (Figure 10, Item 1) from fitting (Figure 10, Item 9). 4. Remove clamp (Figure 10, Item 10) and hose (Figure 10, Item 4) from fitting (Figure 10, Item 9). 5. Remove clamp (Figure 10, Item 5) and hose (Figure 10, Item 4) from fitting (Figure 10, Item 6) on water temperature regulator (Figure 10, Item 7).

Figure 10. Vent Lines.

0051

END OF TASK CLEANING AND INSPECTION

00051

Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0051-11

TM 5-2410-241-23-1

0051

VENT LINE INSTALLATION

00051

NOTE Install hoses as tagged during removal. 1. Install clamp (Figure 11, Item 2) and hose (Figure 11, Item 1) on valve (Figure 11, Item 3). 2. Install bolt (Figure 11, Item 12), washer (Figure 11, Item 13), clip (Figure 11, Item 11) and hose (Figure 11, Item 1) on bracket (Figure 11, Item 14). 3. Install clamp (Figure 11, Item 8) and hose (Figure 11, Item 1) on fitting (Figure 11, Item 9). 4. Install clamp (Figure 11, Item 10) and hose (Figure 11, Item 4) on fitting (Figure 11, Item 9). 5. Install clamp (Figure 11, Item 5) and hose (Figure 11, Item 4) on fitting (Figure 11, Item 6) on water temperature regulator (Figure 11, Item 7).

Figure 11. Vent Lines. END OF TASK

0051-12

0051

TM 5-2410-241-23-1

0051

WATER TANK OUTLET HOSE INSTALLATION

00051

1. Install clamp (Figure 12, Item 1) and hose (Figure 12, Item 2) on upper coolant tank (Figure 12, Item 3). 2. Install three bolts (Figure 12, Item 5), washers (Figure 12, Item 6), and clips (Figure 12, Item 4) on radiator (Figure 12, Item 7). 3. Install clamp (Figure 12, Item 8) and hose (Figure 12, Item 2) on water pump (Figure 12, Item 9).

Figure 12. Water Pump Input Line. END OF TASK

0051-13

0051

TM 5-2410-241-23-1

WATER PUMP INLET HOSE INSTALLATION

0051

00051

1. Install clamp (Figure 13, Item 3) on hose (Figure 13, Item 1). 2. Install hose (Figure 13, Item 1) on radiator (Figure 13, Item 2). 3. Tighten clamp (Figure 13, Item 3) on hose (Figure 13, Item 1).

Figure 13. Water Pump Inlet Hose at Radiator.

0051-14

0051

TM 5-2410-241-23-1

0051

WATER PUMP INLET HOSE INSTALLATION – CONTINUED

00051

4. Install clamp (Figure 14, Item 5) on hose (Figure 14, Item 6). 5. Install hose (Figure 14, Item 6) on water pump (Figure 14, Item 4). 6. Tighten clamp (Figure 14, Item 5) on hose (Figure 14, Item 6). 7. Install door (Figure 14, Item 3), three washers (Figure 14, Item 1) and bolts (Figure 14, Item 2) on machine.

Figure 14. Water Pump Inlet Hose. END OF TASK

0051-15

0051

TM 5-2410-241-23-1

0051

WATER TEMPERATURE REGULATOR OUTLET HOSE AND PIPE INSTALLATION

00051

1. Install fitting (Figure 15, Item 14) on pipe (Figure 15, Item 13). 2. Install pipe (Figure 15, Item 13) on machine. 3. Install hose (Figure 15, Item 10) and nut (Figure 15, Item 11) on fitting (Figure 15, Item 12). 4. Install adjuster (Figure 15, Item 3), two washers (Figure 15, Item 6) and bolt (Figure 15, Item 7) on bracket (Figure 15, Item 15). 5. Install adjuster (Figure 15, Item 3), two washers (Figure 15, Item 4), bolt (Figure 15, Item 1), and nut (Figure 15, Item 5) on A/C compressor bracket (Figure 15, Item 2). 6. Install washer (Figure 15, Item 9) and bolt (Figure 15, Item 8) on machine.

Figure 15. Adjuster.

0051-16

0051

TM 5-2410-241-23-1

0051

WATER TEMPERATURE REGULATOR OUTLET HOSE AND PIPE INSTALLATION – CONTINUED 7. Install clamp (Figure 16, Item 13) on hose (Figure 16, Item 12). 8. Install hose (Figure 16, Item 12) on fitting (Figure 16, Item 14). 9. Tighten clamp (Figure 16, Item 13) on hose (Figure 16, Item 12). 10. Install clamp (Figure 16, Item 2) on hose (Figure 16, Item 1). 11. Install hose (Figure 16, Item 1) on fitting (Figure 16, Item 14). 12. Tighten clamp (Figure 16, Item 2) on hose (Figure 16, Item 1). 13. Install clamp (Figure 16, Item 10) and clamp (Figure 16, Item 5) on hose (Figure 16, Item 9). 14. Install hose (Figure 16, Item 9) on aftercooler (Figure 16, Item 11) and pipe (Figure 16, Item 4). 15. Tighten clamp (Figure 16, Item 10) and clamp (Figure 16, Item 5) on hose (Figure 16, Item 9). 16. Install clamp (Figure 16, Item 8) and clamp (Figure 16, Item 3) on hose (Figure 16, Item 6). 17. Install hose (Figure 16, Item 6) on water temperature regulator housing (Figure 16, Item 7) and pipe (Figure 16, Item 4). 18. Tighten clamp (Figure 16, Item 8) and clamp (Figure 16, Item 3) on hose (Figure 16, Item 6).

Figure 16. Hose to Water Temperature Regulator.

0051-17

0051

TM 5-2410-241-23-1

0051

WATER TEMPERATURE REGULATOR OUTLET HOSE AND PIPE INSTALLATION – CONTINUED 19. Install washer (Figure 17, Item 2), bolt (Figure 17, Item 4), washer (Figure 17, Item 2) and nut (Figure 17, Item 5) on pipe (Figure 17, Item 1) and engine (Figure 17, Item 3). 20. Install clamp (Figure 17, Item 6) on hose (Figure 17, Item 7). 21. Install hose (Figure 17, Item 7) on pipe (Figure 17, Item 1). 22. Tighten clamp (Figure 17, Item 6) on hose (Figure 17, Item 7).

Figure 17. Water Temperature Regulator Pipe.

0051-18

0051

TM 5-2410-241-23-1

0051

WATER TEMPERATURE REGULATOR OUTLET HOSE AND PIPE INSTALLATION – CONTINUED 23. Install clamp (Figure 18, Item 2) on hose (Figure 18, Item 1). 24. Install hose (Figure 18, Item 1) on radiator (Figure 18, Item 3). 25. Tighten clamp (Figure 18, Item 2) on hose (Figure 18, Item 1). 26. Install engine enclosure left door guard (WP 0202).

Figure 18. Water Temperature Regulator Hose at Radiator. END OF TASK

0051-19

0051

TM 5-2410-241-23-1

AFTERCOOLER PUMP INLET HOSES AND PIPE INSTALLATION

0051

00051

1. Install pipe (Figure 19, Item 4) on machine. 2. Install clamp (Figure 19, Item 5) and clamp (Figure 19, Item 3) on hose (Figure 19, Item 4). 3. Install hose (Figure 19, Item 4) on pipe (Figure 19, Item 1) and radiator (Figure 19, Item 2). 4. Tighten clamp (Figure 19, Item 5) and clamp (Figure 19, Item 3) on hose (Figure 19, Item 4).

Figure 19. Hose at Radiator.

0051-20

0051

TM 5-2410-241-23-1

0051

AFTERCOOLER PUMP INLET HOSES AND PIPE INSTALLATION – CONTINUED 5. Install clamp (Figure 20, Item 5) and clamp (Figure 20, Item 1) on hose (Figure 20, Item 3). 6. Install hose (Figure 20, Item 3) on pipe (Figure 20, Item 4) and aftercooler pump (Figure 20, Item 2). 7. Tighten clamp (Figure 20, Item 5) and clamp (Figure 20, Item 1) on hose (Figure 20, Item 3). 8. Install engine enclosure left door guard (WP 0202).

Figure 20. Aftercooler Pump Hose.

0051

END OF TASK FOLLOW-ON TASKS

00051

1. Fill cooling system (WP 0113). 2. Install front engine bottom guards (WP 0199). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0051-21/(22 blank)

8 TM 5-2410-241-23-1

0052

FIELD MAINTENANCE

-

RADIATOR DRAIN LINES REPLACEMENT Removal, Cleaning and Inspection, Installation 0 0 5 2

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Materials/Parts

Equipment Condition

0

Machine parked (TM 5-2410-241-10) Coolant drained (WP 0113) Front and middle bottom guards removed (WP 0199)

0

0

0

0

0

Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (8) References WP 0295

0

0

Drawing Required TM 5-2410-241-24P, Figure 1

0

0

Estimated Time to Complete

0

5.0 Hr

REMOVAL

0

0

0

0

00052

NOTE Tag hoses to aid installation. 1. Loosen clamp (Figure 1, Item 3) from hose (Figure 1, Item 4). 2. Remove hose (Figure 1, Item 4) from fitting (Figure 1, Item 1). 3. Remove clamp (Figure 1, Item 3) from hose (Figure 1, Item 4). 4. Remove fitting (Figure 1, Item 1) from radiator (Figure 1, Item 5). 5. Remove O-ring (Figure 1, Item 2) from fitting (Figure 1, Item 1). Discard O-ring.

Figure 1. Radiator Drain Hose and Fitting.

0052-1

0052

TM 5-2410-241-23-1

0052

REMOVAL – CONTINUED 6. Loosen clamp (Figure 2, Item 5) from hose (Figure 2, Item 4). 7. Remove hose (Figure 2, Item 4) from fitting (Figure 2, Item 1). 8. Remove clamp (Figure 2, Item 5) from hose (Figure 2, Item 4). 9. Remove fitting (Figure 2, Item 1) from transmission cooler (Figure 2, Item 3). 10. Remove O-ring (Figure 2, Item 2) from fitting (Figure 2, Item 1). Discard O-ring.

Figure 2. Transmission Cooler Drain Hose and Fitting.

0052-2

0052

TM 5-2410-241-23-1

0052

REMOVAL – CONTINUED 11. Remove three bolts (Figure 3, Item 10), washers (Figure 3, Item 11) and clamps (Figure 3, Item 9) from hose (Figure 3, Item 8). 12. Remove three bolts (Figure 3, Item 14), washers (Figure 3, Item 13) and brackets (Figure 3, Item 12) from engine (Figure 3, Item 15). 13. Loosen clamp (Figure 3, Item 7) from hose (Figure 3, Item 8). 14. Remove hose (Figure 3, Item 8) from coupling assembly (Figure 3, Item 4). 15. Remove clamp (Figure 3, Item 7) from hose (Figure 3, Item 8). 16. Loosen clamp (Figure 3, Item 2) from hose (Figure 3, Item 1). 17. Remove hose (Figure 3, Item 1) from fitting (Figure 3, Item 3). 18. Remove clamp (Figure 3, Item 2) from hose (Figure 3, Item 1). 19. Loosen clamp (Figure 3, Item 5) from hose (Figure 3, Item 6). 20. Remove hose (Figure 3, Item 6) from coupling assembly (Figure 3, Item 4). 21. Remove clamp (Figure 3, Item 5) from hose (Figure 3, Item 6). 22. Remove two bolts (Figure 3, Item 17), washers (Figure 3, Item 16) and coupling assembly (Figure 3, Item 4) from engine (Figure 3, Item 15).

Figure 3. Drain Hoses.

0052-3

0052

TM 5-2410-241-23-1

0052

REMOVAL – CONTINUED 23. Remove fitting (Figure 4, Item 1) and O-ring (Figure 4, Item 2) from valve (Figure 4, Item 3). Discard O-ring. 24. Remove valve (Figure 4, Item 3) and O-ring (Figure 4, Item 13) from coupling (Figure 4, Item 4). Discard Oring. 25. Remove fitting (Figure 4, Item 6) and O-ring (Figure 4, Item 7) from valve (Figure 4, Item 8). Discard O-ring. 26. Remove valve (Figure 4, Item 8) and O-ring (Figure 4, Item 5) from tee (Figure 4, Item 11). Discard O-ring. 27. Remove fitting (Figure 4, Item 9) and O-ring (Figure 4, Item 10) from tee (Figure 4, Item 11). Discard O-ring. 28. Remove tee (Figure 4, Item 11) and O-ring (Figure 4, Item 12) from coupling (Figure 4, Item 4). Discard O-ring.

Figure 4. Drain Line Valves.

0052

END OF TASK CLEANING AND INSPECTION

00052

Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

00052

1. Install new O-ring (Figure 4, Item 12) and tee (Figure 4, Item 11) on coupling (Figure 4, Item 4). 2. Install new O-ring (Figure 4, Item 10) and fitting (Figure 4, Item 9) on tee (Figure 4, Item 11). 3. Install new O-ring (Figure 4, Item 5) and valve (Figure 4, Item 8) on tee (Figure 4, Item 11). 4. Install new O-ring (Figure 4, Item 7) and fitting (Figure 4, Item 6) on valve (Figure 4, Item 8). 5. Install new O-ring (Figure 4, Item 13) and valve (Figure 4, Item 3) and from coupling (Figure 4, Item 4). 6. Install new O-ring (Figure 4, Item 2) and fitting (Figure 4, Item 1) on valve (Figure 4, Item 3).

0052-4

TM 5-2410-241-23-1

0052

INSTALLATION – CONTINUED

NOTE Install hoses as tagged during removal. 7. Install coupling assembly (Figure 5, Item 4), two washers (Figure 5, Item 16), and bolts (Figure 5, Item 17) on engine (Figure 5, Item 15). 8. Install clamp (Figure 5, Item 5) on hose (Figure 5, Item 6). 9. Install hose (Figure 5, Item 6) on coupling assembly (Figure 5, Item 4). 10. Tighten clamp (Figure 5, Item 5) on hose (Figure 5, Item 6). 11. Install clamp (Figure 5, Item 2) on hose (Figure 5, Item 1). 12. Install hose (Figure 5, Item 1) on fitting (Figure 5, Item 3). 13. Tighten clamp (Figure 5, Item 2) on hose (Figure 5, Item 1). 14. Install clamp (Figure 5, Item 7) on hose (Figure 5, Item 8). 15. Install hose (Figure 5, Item 8) on coupling assembly (Figure 5, Item 4). 16. Tighten clamp (Figure 5, Item 7) on hose (Figure 5, Item 8). 17. Install three brackets (Figure 5, Item 12), washers (Figure 5, Item 13) and bolts (Figure 5, Item 14) on engine (Figure 5, Item 15). 18. Install three clamps (Figure 5, Item 9), washers (Figure 5, Item 11) and bolts (Figure 5, Item 10) on hose (Figure 5, Item 8).

Figure 5. Drain Hoses.

0052-5

0052

TM 5-2410-241-23-1

0052

INSTALLATION – CONTINUED 19. Install new O-ring (Figure 6, Item 2) on fitting (Figure 6, Item 1). 20. Install fitting (Figure 6, Item 1) on transmission cooler (Figure 6, Item 3). 21. Install clamp (Figure 6, Item 5) on hose (Figure 6, Item 4). 22. Install hose (Figure 6, Item 4) on fitting (Figure 6, Item 1). 23. Tighten clamp (Figure 6, Item 5) on hose (Figure 6, Item 4).

Figure 6. Transmission Cooler Drain Hose and Fitting.

0052

24. Install new O-ring (Figure 7, Item 2) on fitting (Figure 7, Item 1). 25. Install fitting (Figure 7, Item 1) on radiator (Figure 7, Item 5). 26. Install clamp (Figure 7, Item 3) on hose (Figure 7, Item 4). 27. Install hose (Figure 7, Item 4) on fitting (Figure 7, Item 1). 28. Tighten clamp (Figure 7, Item 3) on hose (Figure 7, Item 4).

Figure 7. Radiator Drain Hose and Fitting. END OF TASK

0052-6

0052

TM 5-2410-241-23-1

FOLLOW-ON TASKS

0052

00052

1. Fill cooling system (WP 0113). 2. Install front and middle bottom guards (WP 0199). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0052-7/(8 blank)

10 TM 5-2410-241-23-1

0053

FIELD MAINTENANCE

-

NATO SLAVE AND CABLES REPLACEMENT NATO Slave Removal, NATO Slave Cable Removal, Cleaning and Inspection, NATO Slave Cable Installation, NATO Slave Installation 0 0

5 3

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Inner gasket Lockwasher (2) Outer gasket References WP 0199 WP 0295

0

Equipment Condition

0

Machine parked (TM 5-2410-241-10) Engine enclosure left door guard removed (WP 0202) 0

0

0

0

0

0

0

0

0

0

0

0

0053-1

Drawing Required TM 5-2410-241-24P, Figure 10 Estimated Time to Complete 2.0 Hr

0

0

0

0

TM 5-2410-241-23-1

0053

WARNING

Make sure master battery switch is in OFF position before replacing NATO slave and cables. Failure to follow this warning may result in injury or death to personnel or damage to equipment. NATO SLAVE REMOVAL

00053

1. Remove screw (Figure 1, Item 4), washer (Figure 1, Item 3) and tether (Figure 1, Item 5) from NATO slave cap (Figure 1, Item 2). Place tether aside. 2. Remove NATO slave cap (Figure 1, Item 2) from NATO slave (Figure 1, Item 1).

Figure 1. NATO Slave Cap.

0053-2

0053

TM 5-2410-241-23-1

0053

NATO SLAVE REMOVAL – CONTINUED

00053

NOTE •

Negative cable attaches to right side of NATO slave. Right side of NATO slave faces rear of machine. Positive cable attaches to left side of NATO slave. Left side of NATO slave faces front of machine.

•

Tag and mark electrical connectors and note cable routing to aid installation.

3. Position boot (Figure 2, Item 1) aside and remove bolt (Figure 2, Item 2), lockwasher (Figure 2, Item 3), and cable (Figure 2, Item 4) from NATO slave (Figure 2, Item 5). Discard lockwasher. 4. Remove bolt (Figure 2, Item 8), lockwasher (Figure 2, Item 7), and cable (Figure 2, Item 6) from NATO slave (Figure 2, Item 5). Discard lockwasher. 5. Remove two bolts (Figure 2, Item 14), washers (Figure 2, Item 11), clamp (Figure 2, Item 12) and wiring harness (Figure 2, Item 13) from bracket assembly (Figure 2, Item 9). 6. Remove bracket assembly (Figure 2, Item 9) from engine (Figure 2, Item 10).

Figure 2. NATO Slave Cables.

0053-3

0053

TM 5-2410-241-23-1

0053

NATO SLAVE REMOVAL – CONTINUED

00053

NOTE Note orientation of gasket to aid installation. 7. Remove four nuts (Figure 3, Item 8), washers (Figure 3, Item 7) and inner gasket (Figure 3, Item 6) from bracket (Figure 3, Item 5). Discard inner gasket.

NOTE •

Note position of tether to aid installation.

•

Note orientation of gasket to aid installation.

8. Remove four bolts (Figure 3, Item 1), washers (Figure 3, Item 2), tether (Figure 3, Item 9), NATO slave (Figure 3, Item 3) and outer gasket (Figure 3, Item 4) from bracket (Figure 3, Item 5). Discard outer gasket.

Figure 3. NATO Slave and Bracket. END OF TASK

0053-4

0053

TM 5-2410-241-23-1

0053

NATO SLAVE CABLE REMOVAL

00053

NOTE •

Negative cable attaches to right side of NATO slave. Right side of NATO slave faces rear of machine. Positive cable attaches to left side of NATO slave. Left side of NATO slave faces front of machine.

•

Tag and mark electrical connectors and note cable routing to aid installation.

1. Position boot (Figure 4, Item 2) aside and remove bolt (Figure 4, Item 3), lockwasher (Figure 4, Item 4), and cable (Figure 4, Item 5) from NATO slave (Figure 4, Item 1). Discard lockwasher. 2. Remove bolt (Figure 4, Item 8), lockwasher (Figure 4, Item 7), and cable (Figure 4, Item 6) from NATO slave (Figure 4, Item 1). Discard lockwasher. 3. Remove bolt (Figure 4, Item 10), washer (Figure 4, Item 9) and clamp (Figure 4, Item 11) from engine (Figure 4, Item 13). 4. Remove clamp (Figure 4, Item 11) from two cables (Figure 4, Item 12).

Figure 4. NATO Slave Cables and Clamp.

0053-5

0053

TM 5-2410-241-23-1

0053

NATO SLAVE CABLE REMOVAL – CONTINUED

NOTE Note routing cables and tag electrical connectors to aid installation. 5. Remove front engine bottom guard (WP 0199). 6. Remove nut (Figure 5, Item 2) and positive cable (Figure 5, Item 1) from starter (Figure 5, Item 5). 7. Remove nut (Figure 5, Item 3) and negative cable (Figure 5, Item 4) from starter (Figure 5, Item 5). 8. Remove positive cable (Figure 5, Item 1) and negative cable (Figure 5, Item 4) from machine.

Figure 5. Starter Cable Connections.

0053

END OF TASK CLEANING AND INSPECTION

00053

Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0053-6

TM 5-2410-241-23-1

0053

NATO SLAVE CABLE INSTALLATION

00053

NOTE Route cables and install electrical connectors as noted during removal. 1. Position negative cable (Figure 5, Item 4) and positive cable (Figure 5, Item 1) on machine. 2. Install negative cable (Figure 5, Item 4) and nut (Figure 5, Item 3) on starter (Figure 5, Item 5). 3. Install positive cable (Figure 5, Item 1) and nut (Figure 5, Item 2) on starter (Figure 5, Item 5).

NOTE •

Negative cable attaches to right side of NATO slave. Right side of NATO slave faces rear of machine. Positive cable attaches to left side of NATO slave. Left side of NATO slave faces front of machine.

•

Tag and mark electrical connectors and note cable routing to aid installation.

4. Install clamp (Figure 6, Item 11) on two cables (Figure 6, Item 12). 5. Install clamp (Figure 6, Item 11), washer (Figure 6, Item 9) and bolt (Figure 6, Item 10) on engine (Figure 6, Item 13). 6. Install cable (Figure 6, Item 6), new lockwasher (Figure 6, Item 7), and bolt (Figure 6, Item 8) on NATO slave (Figure 6, Item 1). 7. Install cable (Figure 6, Item 5), new lockwasher (Figure 6, Item 4), and bolt (Figure 6, Item 3) on NATO slave (Figure 6, Item 1). Position boot (Figure 6, Item 2) on bolt.

Figure 6. NATO Slave Cables and Clamp. END OF TASK

0053-7

0053

TM 5-2410-241-23-1

NATO SLAVE INSTALLATION

0053

00053

NOTE •

Install gasket as noted during removal.

•

Install tether as noted during removal.

1. Install new outer gasket (Figure 7, Item 4), NATO slave (Figure 7, Item 3), tether (Figure 7, Item 9), four washers (Figure 7, Item 2), and bolts (Figure 7, Item 1) on bracket (Figure 7, Item 5).

CAUTION Seat raised lip on inner gasket in hole on bracket before tightening retaining hardware. Failure to follow this caution may result in damage to inner gasket.

NOTE Install gasket as noted during removal. 2. Install new inner gasket (Figure 7, Item 6), four washers (Figure 7, Item 7), and nuts (Figure 7, Item 8) on bracket (Figure 7, Item 5).

Figure 7. NATO Slave and Bracket.

0053-8

0053

TM 5-2410-241-23-1

0053

NATO SLAVE INSTALLATION – CONTINUED

NOTE •

Negative cable attaches to right side of NATO slave. Right side of NATO slave faces rear of machine. Positive cable attaches to left side of NATO slave. Left side of NATO slave faces front of machine.

•

Route cables and install electrical connectors as noted during removal.

3. Install bracket assembly (Figure 8, Item 9) on engine (Figure 8, Item 10). 4. Install wiring harness (Figure 8, Item 13), clamp (Figure 8, Item 12), two washers (Figure 8, Item 11), and bolts (Figure 8, Item 14) on bracket assembly (Figure 8, Item 9).

WARNING

Plus and minus symbols are stamped in NATO slave near battery cable terminal connectors. Install NATO slave on bracket so positive terminal connector faces front of machine and negative terminal connector faces rear of machine. Failure to follow this warning may result in injury or death to personnel or damage to equipment. 5. Install cable (Figure 8, Item 6), new lockwasher (Figure 8, Item 7) and bolt (Figure 8, Item 8) on NATO slave (Figure 8, Item 5). 6. Install cable (Figure 8, Item 4), new lockwasher (Figure 8, Item 3) and bolt (Figure 8, Item 2) on NATO slave (Figure 8, Item 5). Position boot (Figure 8, Item 1) on bolt.

Figure 8. NATO Slave Cables.

0053-9

0053

TM 5-2410-241-23-1

0053

NATO SLAVE INSTALLATION – CONTINUED 7. Install NATO slave cap (Figure 9, Item 2) on NATO slave (Figure 9, Item 1). 8. Install tether (Figure 9, Item 5), washer (Figure 9, Item 3) and screw (Figure 9, Item 4) on NATO slave cap (Figure 9, Item 2).

Figure 9. NATO Slave Cap.

0053

END OF TASK FOLLOW-ON TASKS

00053

1. Install engine enclosure left door guard (WP 0202). 2. Verify correct operation of machine (TM 5-2410-240-10). END OF TASK END OF WORK PACKAGE

0053-10

2 TM 5-2410-241-23-1

0054

FIELD MAINTENANCE 0 0 5

4

-

AIR INLET TEMPERATURE SENSOR HARNESS REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65) Materials/Parts

Machine parked (TM 5-2410-241-10)

References

0

0

0

Drawing Required 0

Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36)

Equipment Condition

TM 5-2410-24P, Figure 15

0

0

0

Estimated Time to Complete

0

0

0.5 Hr

0

0

0

WP 0295

0

REMOVAL

00054

NOTE •

Note harness routing to aid installation.

•

Tag and mark all electrical connections to aid installation.

1. Disconnect connector (Figure 1, Item 3) from air inlet temperature sensor (Figure 1, Item 2). 2. Remove tiedown straps (Figure 1, Item 1) from air inlet temperature sensor harness (Figure 1, Item 4). Discard tiedown strap. 3. Disconnect connector (Figure 1, Item 6) from connector (Figure 1, Item 5). 4. Remove air inlet temperature sensor harness (Figure 1, Item 4) from machine.

Figure 1. Fuel Temperature Sensor Harness. END OF TASK

0054-1

0054

TM 5-2410-241-23-1

CLEANING AND INSPECTION

0054

00054

Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

00054

NOTE Install electrical connections and harness routing as noted during removal. 1. Install air inlet temperature sensor harness (Figure 2, Item 4) on machine. 2. Connect connector (Figure 2, Item 6) on connector (Figure 2, Item 5). 3. Install new tiedown strap (Figure 2, Item 1) on air inlet temperature sensor harness (Figure 2, Item 4). 4. Connect connector (Figure 2, Item 3) on air inlet temperature sensor (Figure 2, Item 2).

Figure 2. Fuel Temperature Sensor Harness.

0054

END OF TASK FOLLOW-ON TASKS

00054

Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0054-2

22 TM 5-2410-241-23-1

0055

FIELD MAINTENANCE 0 0 5 5

-

ENGINE MAIN WIRING HARNESS ASSEMBLY REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanic’s (WP 0302, Item 65) Materials/Parts

0

Equipment Condition

0

Machine parked (TM 5-2410-241-10) Engine enclosure left door guard removed (WP 0202) Front floor plate removed (WP 0230) Middle bottom guard removed (WP 0199) 0

0

0

0

0

Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) References WP 0295

0

0

0

0

Drawing Required TM 5-2410-241-24P, Figure 11

0

0

0

0

Estimated Time to Complete 5.0 Hr

0055-1

0

0

TM 5-2410-241-23-1

REMOVAL

0055

00055

NOTE •

Note harness routing to aid installation.

•

Tag and mark all electrical connections to aid installation.

•

Note number and location of tiedown straps to aid installation.

1. Disconnect engine main harness connector (Figure 1, Item 2) from front lighting harness connector (Figure 1, Item 1). 2. Remove tiedown straps (Figure 1, Item 3) from engine main harness (Figure 1, Item 2). Discard tiedown straps.

Figure 1. Radiator Harness Connector.

0055

NOTE •

Note harness routing to aid installation.

•

Tag and mark all electrical connections to aid installation.

3. Remove nut (Figure 2, Item 5), ground strap (Figure 2, Item 4), two ground cables (Figure 2, Item 3) and connectors (Figure 2, Item 2) from starter (Figure 2, Item 1).

Figure 2. Starter Ground Connections.

0055-2

0055

TM 5-2410-241-23-1

0055

REMOVAL – CONTINUED

NOTE •

Note harness routing to aid installation.

•

Tag and mark all electrical connections to aid installation.

•

Note number and location of tiedown straps to aid installation.

4. Remove nut (Figure 3, Item 1) and wire (Figure 3, Item 3) from starter solenoid (Figure 3, Item 2). 5. Remove tiedown straps (Figure 3, Item 4) from engine main harness (Figure 3, Item 5). Discard tiedown straps.

Figure 3. Starter Solenoid Connection.

0055-3

0055

TM 5-2410-241-23-1

0055

REMOVAL – CONTINUED 6. Loosen bolt (Figure 4, Item 2) and disconnect engine main harness connector (Figure 4, Item 1) from ECM (Figure 4, Item 3).

Figure 4. ECM Connections.

0055-4

0055

TM 5-2410-241-23-1

0055

REMOVAL – CONTINUED

NOTE •

Note harness routing to aid installation.

•

Tag and mark all electrical connections to aid installation.

•

Note number and location of tiedown straps to aid installation.

7. Disconnect engine main harness connector (Figure 5, Item 3) from underhood work light switch connector (Figure 5, Item 2). 8. Position connector (Figure 5, Item 1) aside. 9. Remove tiedown straps (Figure 5, Item 4) from engine main harness (Figure 5, Item 5). Discard tiedown straps. 10. Disconnect engine main harness connector (Figure 5, Item 6) from light (Figure 5, Item 7). 11. Position engine main harness (Figure 5, Item 5) aside.

Figure 5. Underhood Work Light Connection.

0055-5

0055

TM 5-2410-241-23-1

0055

REMOVAL – CONTINUED

NOTE •

Note harness routing to aid installation.

•

Tag and mark all electrical connections to aid installation.

•

Note number and location of tiedown straps to aid installation.

12. Disconnect engine main harness connector (Figure 6, Item 5) from ether aid relay (Figure 6, Item 3). 13. Remove tiedown straps (Figure 6, Item 9) from platform connectors (Figure 6, Items 1 and 7). Discard tiedown straps. 14. Disconnect engine main harness connector (Figure 6, Item 8) from platform connector (Figure 6, Item 7). 15. Remove engine main harness connector (Figure 6, Item 6) and platform connector (Figure 6, Item 1) from bracket (Figure 6, Item 2). 16. Loosen bolt (Figure 6, Item 4) and disconnect engine main harness connector (Figure 6, Item 6) from platform connector (Figure 6, Item 1).

Figure 6. Platform Harness Connections.

0055-6

0055

TM 5-2410-241-23-1

0055

REMOVAL – CONTINUED

NOTE •

Note harness routing to aid installation.

•

Tag and mark all electrical connections to aid installation.

•

Note number and location of tiedown straps to aid installation.

17. Disconnect engine main harness connector (Figure 7, Item 4) from ether aid solenoid connector (Figure 7, Item 3). 18. Disconnect engine main harness connector (Figure 7, Item 2) from turbo inlet pressure sensor connector (Figure 7, Item 1). 19. Disconnect engine main harness connector (Figure 7, Item 6) from crank without injection harness connector (Figure 7, Item 5). 20. Remove tiedown straps (Figure 7, Item 7) from engine main harness (Figure 7, Item 8). Discard tiedown straps.

Figure 7. Ether Aid Solenoid Connection.

0055-7

0055

TM 5-2410-241-23-1

0055

REMOVAL – CONTINUED

NOTE •

Note harness routing to aid installation.

•

Tag and mark all electrical connections to aid installation.

21. Disconnect engine main harness connector (Figure 8, Item 2) from A/C compressor connector (Figure 8, Item 1). 22. Remove tiedown straps (Figure 8, Item 4) from engine main harness connector (Figure 8, Item 3). Discard tiedown straps.

Figure 8. A/C Compressor Connection.

0055-8

0055

TM 5-2410-241-23-1

0055

REMOVAL – CONTINUED

NOTE •

Note harness routing to aid installation.

•

Tag and mark all electrical connections to aid installation.

•

Note number and location of tiedown straps to aid installation.

23. Remove engine main harness connector (Figure 9, Item 1) from alternator (Figure 9, Item 2). 24. Remove tiedown straps (Figure 9, Item 3) from engine main harness (Figure 9, Item 4). Discard tiedown straps.

Figure 9. Alternator Connection.

0055-9

0055

TM 5-2410-241-23-1

0055

REMOVAL – CONTINUED

NOTE •

Note harness routing to aid installation.

•

Tag and mark all electrical connections to aid installation.

25. Disconnect engine main harness connector (Figure 10, Item 2) from transmission temperature sensor connector (Figure 10, Item 1). 26. Remove tiedown straps (Figure 10, Item 3) from engine main harness (Figure 10, Item 4). Discard tiedown straps.

Figure 10. Transmission Temperature Connections.

0055-10

0055

TM 5-2410-241-23-1

0055

REMOVAL – CONTINUED

NOTE •

Note harness routing to aid installation.

•

Tag and mark all electrical connections to aid installation.

•

Note number and location of tiedown straps to aid installation.

•

Hydraulic lines and drive shaft removed in picture below for clarity.

27. Remove tiedown straps (Figure 11, Item 4) from engine main harness (Figure 11, Item 3). Discard tiedown straps. 28. Disconnect engine main harness connector (Figure 11, Item 5) from torque converter oil temperature sender connector (Figure 11, Item 6). 29. Disconnect engine main harness connector (Figure 11, Item 1) from torque converter output speed sensor connector (Figure 11, Item 2). 30. Remove engine main harness (Figure 11, Item 3) from machine.

Figure 11. Torque Converter Connections.

0055

END OF TASK CLEANING AND INSPECTION

00055

Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0055-11

TM 5-2410-241-23-1

INSTALLATION

0055

00055

NOTE •

Install harness as noted during removal.

•

Connect connectors as tagged and marked during removal.

•

Install tiedown straps as noted during removal.

1. Install engine main harness (Figure 12, Item 3) on machine. 2. Connect engine main harness connector (Figure 12, Item 1) on torque converter output speed sensor connector (Figure 12, Item 2). 3. Connect engine main harness connector (Figure 12, Item 5) on torque converter oil temperature sender connector (Figure 12, Item 6). 4. Install new tiedown straps (Figure 12, Item 4) on engine main harness (Figure 12, Item 3).

Figure 12. Torque Converter Connections.

0055-12

0055

TM 5-2410-241-23-1

0055

INSTALLATION – CONTINUED

NOTE •

Install harness as noted during removal.

•

Connect connectors as tagged and marked during removal.

5. Install new tiedown straps (Figure 13, Item 3) on engine main harness (Figure 13, Item 4). 6. Connect engine main harness connector (Figure 13, Item 2) on transmission temperature sensor connector (Figure 13, Item 1).

Figure 13. Transmission Temperature Connections.

0055-13

0055

TM 5-2410-241-23-1

0055

INSTALLATION – CONTINUED

NOTE •

Install harness as noted during removal.

•

Connect connectors as tagged and marked during removal.

•

Install tiedown straps as noted during removal.

7. Install new tiedown straps (Figure 14, Item 3) on engine main harness (Figure 14, Item 4). 8. Install engine main harness connector (Figure 14, Item 1) on alternator (Figure 14, Item 2).

Figure 14. Alternator Connection.

0055-14

0055

TM 5-2410-241-23-1

0055

INSTALLATION – CONTINUED

NOTE •

Install harness as noted during removal.

•

Connect connectors as tagged and marked during removal.

9. Install new tiedown straps (Figure 15, Item 4) on engine main harness (Figure 15, Item 3). 10. Connect engine main harness connector (Figure 15, Item 2) on A/C compressor connector (Figure 15, Item 1).

Figure 15. A/C Compressor Connection.

0055-15

0055

TM 5-2410-241-23-1

0055

INSTALLATION – CONTINUED

NOTE •

Install harness as noted during removal.

•

Connect connectors as tagged and marked during removal.

•

Install tiedown straps as noted during removal.

11. Connect engine main harness connector (Figure 16, Item 6) to crank without injection harness connector (Figure 16, Item 5). 12. Connect engine main harness connector (Figure 16, Item 2) to turbo inlet pressure sensor connector (Figure 16, Item 1). 13. Connect engine main harness connector (Figure 16, Item 4) to ether aid solenoid connector (Figure 16, Item 3). 14. Install tiedown straps (Figure 16, Item 7) on engine main harness (Figure 16, Item 8).

Figure 16. Ether Aid Solenoid Connection.

0055-16

0055

TM 5-2410-241-23-1

0055

INSTALLATION – CONTINUED

NOTE •

Install harness as noted during removal.

•

Connect connectors as tagged and marked during removal.

•

Install tiedown straps as noted during removal.

15. Connect engine main harness connector (Figure 17, Item 6) and tighten bolt (Figure 17, Item 4) on platform connector (Figure 17, Item 1). 16. Install platform connector (Figure 17, Item 1) and engine main harness connector (Figure 17, Item 6) on bracket (Figure 17, Item 2). 17. Connect engine main harness connector (Figure 17, Item 8) on platform connector (Figure 17, Item 7). 18. Install new tiedown straps (Figure 17, Item 9) on platform connectors (Figure 17, Items 1 and 7). 19. Connect engine main harness connector (Figure 17, Item 5) on ether aid relay (Figure 17, Item 3).

Figure 17. Platform Harness Connections.

0055-17

0055

TM 5-2410-241-23-1

0055

INSTALLATION – CONTINUED

NOTE •

Install harness as noted during removal.

•

Connect connectors as tagged and marked during removal.

•

Install tiedown straps as noted during removal.

20. Position engine main harness (Figure 18, Item 5) on machine. 21. Connect engine main harness connector (Figure 18, Item 6) on light (Figure 18, Item 7). 22. Install new tiedown straps (Figure 18, Item 4) on engine main harness (Figure 18, Item 5). 23. Position connector (Figure 18, Item 1) on machine. 24. Connect engine main harness connector (Figure 18, Item 3) on underhood work light switch connector (Figure 18, Item 2).

Figure 18. Underhood Work Light Connection.

0055-18

0055

TM 5-2410-241-23-1

0055

INSTALLATION – CONTINUED

NOTE •

Install harness as noted during removal.

•

Connect connectors as tagged and marked during removal.

25. Connect engine main harness connector (Figure 19, Item 1) to ECM (Figure 19, Item 3) and tighten bolt (Figure 19, Item 2).

Figure 19. ECM Connections.

0055-19

0055

TM 5-2410-241-23-1

0055

INSTALLATION – CONTINUED

NOTE •

Install harness as noted during removal.

•

Connect connectors as tagged and marked during removal.

•

Install tiedown straps as noted during removal.

26. Install wire (Figure 20, Item 3) and nut (Figure 20, Item 1) on starter solenoid (Figure 20, Item 2). 27. Install tiedown straps (Figure 20, Item 4) on engine main harness (Figure 20, Item 5).

Figure 20. Starter Solenoid Connection.

0055-20

0055

TM 5-2410-241-23-1

0055

INSTALLATION – CONTINUED

NOTE •

Install harness as noted during removal.

•

Connect connectors as tagged and marked during removal.

28. Install two connectors (Figure 21, Item 2), ground cables (Figure 21, Item 3), ground strap (Figure 21, Item 4), and nut (Figure 21, Item 5) on starter (Figure 21, Item 1).

Figure 21. Starter Ground Connections.

0055

NOTE •

Install harness as noted during removal.

•

Connect connectors as tagged and marked during removal.

•

Install tiedown straps as noted during removal.

29. Connect engine main harness connector (Figure 22, Item 2) to front lighting harness connector (Figure 22, Item 1). 30. Install tiedown straps (Figure 22, Item 3) on engine main harness (Figure 22, Item 2).

Figure 22. Radiator Harness Connector. END OF TASK

0055-21

0055

TM 5-2410-241-23-1

FOLLOW-ON TASKS

0055

00055

1. Install middle bottom guard (WP 0199). 2. Install front floor plate (WP 0230). 3. Install engine enclosure left door guard (WP 0202). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0055-22

2 TM 5-2410-241-23-1

0056

FIELD MAINTENANCE 0 0 5 6

-

CRANK WITHOUT INJECTION WIRING HARNESS ASSEMBLY REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools

0

Tool Kit, General Mechanic’s (WP 0302, Item 65)

Equipment Condition Machine parked (TM 5-2410-241-10)

0

0

0

Drawing Required

Materials/Parts

0

Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36)

TM 5-2410-241-24P, Figure 11

0

0

0

Estimated Time to Complete

0

0

0.5 Hr

0

0

References

0

WP 0295

0

REMOVAL

00056

NOTE •

Note harness routing to aid installation.

•

Tag and mark all electrical connections to aid installation.

1. Disconnect plug (Figure 1, Item 6) from connector (Figure 1, Item 5). 2. Remove tiedown strap (Figure 1, Item 1) from wiring harness (Figure 1, Item 2). Discard tiedown strap. 3. Remove two tiedown straps (Figure 1, Item 3) from wiring harness (Figure 1, Item 2) and connector (Figure 1, Item 4). Discard tiedown straps. 4. Disconnect connector (Figure 1, Item 4) from wiring harness (Figure 1, Item 2). 5. Remove harness (Figure 1, Item 2) from machine.

Figure 1. Fuel Temperature Sensor Harness. END OF TASK 0056-1

0056

TM 5-2410-241-23-1

CLEANING AND INSPECTION

0056

00056

Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

00056

NOTE Install electrical connections and wiring harness routing as noted during removal. 1. Install wiring harness (Figure 2, Item 2) on machine. 2. Connect connector (Figure 2, Item 4) to wiring harness (Figure 2, Item 2). 3. Install two new tiedown straps (Figure 2, Item 3) on connector (Figure 2, Item 4) and wiring harness (Figure 2, Item 2). 4. Install new tiedown strap (Figure 2, Item 1) on wiring harness (Figure 2, Item 2). 5. Connect plug (Figure 2, Item 6) on connector (Figure 2, Item 5).

Figure 2. Fuel Temperature Sensor Harness.

0056

END OF TASK FOLLOW-ON TASKS

00056

Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0056-2

Index

10 TM 5-2410-241-23-1

Index Subject

WP Sequence No.-Page No.

A A/C and Heating Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/C Compressor V-Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/C Condenser Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accumulator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accumulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adapter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aftercooler Housing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aftercooler Water Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioner Evaporator Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning High Pressure Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Low Pressure Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Inlet and Exhaust Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Inlet Manifold Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Inlet Temperature Sensor Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Inlet Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator and Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator and Charging System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arctic Batteries Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arctic Battery Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arctic Battery Cables Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arctic Kit Batteries Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoses and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch and Heater Harness Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arctic Kit Battery Cables and Junction Block Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . Arctic Kit Fuel Metering Pump, Hose, and Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arctic Kit Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Atmospheric Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0036-1 WP 0097-1 WP 0096-1 WP 0044-1 WP 0126-1 WP 0239-1 WP 0115-1 WP 0068-1 WP 0078-1 WP 0111-1 WP 0220-1 WP 0241-1 WP 0261-1 WP 0242-1 WP 0263-1 WP 0027-1 WP 0092-1 WP 0054-1 WP 0063-1 WP 0099-1 WP 0028-1 WP 0163-1 WP 0288-1 WP 0289-1 WP 0287-1 WP 0288-1 WP 0291-1 WP 0285-1 WP 0292-1 WP 0290-1 WP 0283-1 WP 0286-1 WP 0284-1 WP 0287-1 WP 0293-1 WP 0286-1 WP 0090-1 WP 0116-1

B Backup Alarm Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0168-1 Backup Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0183-1 Battery

Index-1

TM 5-2410-241-23-1

Index - Continued Subject

WP Sequence No.-Page No.

Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cables and Alternator Cables Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cables and Alternator Cables Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crossover Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnect Switch, Receptacle and Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ground Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tests and Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blade Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pitch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blade Cutting Edge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Fan Case Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom Guards Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake and Differential Drive Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake and Planetary Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0156-1 WP 0029-1 WP 0029-1 WP 0161-1 WP 0162-1 WP 0160-1 WP 0159-1 WP 0155-1 WP 0030-1 WP 0268-1 WP 0271-1 WP 0270-1 WP 0269-1 WP 0219-1 WP 0199-1 WP 0139-1 WP 0138-1

C Cab Flood Lamp and Bracket Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Interior Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Timing Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging System Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chassis Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Implement Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connector End Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Manifold Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Valve (Steering and Brake) Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterbalance Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coupling Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank Without Injection Wiring Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Rear Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Damper, Pulley and Adapter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Flood Lamp and Bracket Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Head Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift (Bulldozer) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index-2

WP 0252-1 WP 0233-1 WP 0245-1 WP 0022-1 WP 0254-1 WP 0245-1 WP 0093-1 WP 0028-1 WP 0172-1 WP 0021-1 WP 0018-1 WP 0216-1 WP 0147-1 WP 0064-1 WP 0050-1 WP 0075-1 WP 0113-1 WP 0026-1 WP 0217-1 WP 0120-1 WP 0056-1 WP 0102-1 WP 0080-1 WP 0210-1 WP 0108-1 WP 0276-1 WP 0266-1

TM 5-2410-241-23-1

Index - Continued Subject

WP Sequence No.-Page No.

Lift Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ripper Lift Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ripper Tilt Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0197-1 WP 0277-1 WP 0278-1 WP 0198-1

D Dipstick Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiper Motor, Wiper Arm and Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Washer Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double Flange Track Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Belt and Tensioner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0087-1 WP 0249-1 WP 0250-1 WP 0228-1 WP 0132-1 WP 0096-1

E ECM (Powertrain) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Module (ECM) Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Position Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECM Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosure Left Door Guard Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flood Lamp and Bracket Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Wiring Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter, Base and Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Transfer of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Enclosure Left Door Guard Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Door Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Door Guard Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Door Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Mechanical Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equalizer Bar Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ether Bottle, Valve, Bracket, and Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0175-1 WP 0017-1 WP 0057-1 WP 0094-1 WP 0101-1 WP 0202-1 WP 0253-1 WP 0058-1 WP 0024-1 WP 0055-1 WP 0046-1 WP 0084-1 WP 0083-1 WP 0091-1 WP 0114-1 WP 0059-1 WP 0047-1 WP 0019-1 WP 0202-1 WP 0201-1 WP 0204-1 WP 0203-1 WP 0023-1 WP 0125-1 WP 0002-1 WP 0060-1 WP 0067-1 WP 0303-1

F Fan Hub Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0095-1

Index-3

TM 5-2410-241-23-1

Index - Continued Subject

WP Sequence No.-Page No.

Final Drive Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Drive Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire Extinguisher and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flange (Flywheel Housing) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flood Lamp Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floor Plate Replacement Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flange Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Housing Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Crankshaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Floor Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Housing Cover Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Lighting Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Washer Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wiper Motor, Wiper Arm, Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter, Base and Bracket Replacement, Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter, Base and Hose, Secondary Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0136-1 WP 0149-1 WP 0255-1 WP 0104-1 WP 0154-1 WP 0230-1 WP 0231-1 WP 0100-1 WP 0104-1 WP 0103-1 WP 0079-1 WP 0230-1 WP 0081-1 WP 0167-1 WP 0226-1 WP 0222-1 WP 0071-1 WP 0072-1 WP 0069-1 WP 0157-1 WP 0070-1 WP 0025-1 WP 0170-1 WP 0171-1 WP 0065-1 WP 0073-1 WP 0176-1

G Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Maintenance Instructions Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor and Brake Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0141-1 WP 0001-1 WP 0296-1 WP 0258-1

H Harness Assembly (ECM) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headliner and Interior Trim Panels Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headliner Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How To Use Cat Mil ET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How To Use Electronic Technician (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Use On Board Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Counterbalance Valve Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index-4

WP 0105-1 WP 0229-1 WP 0232-1 WP 0221-1 WP 0243-1 WP 0200-1 WP 0182-1 WP 0016-1 WP 0016-1 WP 0015-1 WP 0196-1

TM 5-2410-241-23-1

Index - Continued Subject

WP Sequence No.-Page No.

Oil Cooler Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Cooler Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Motor/Tank Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suction Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Pressure Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Implement Pump Main Control Valve Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Pilot Accumulator Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Steering Motor Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Tank Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Tank Enclosure Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic Drive Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0041-1 WP 0189-1 WP 0185-1 WP 0184-1 WP 0181-1 WP 0195-1 WP 0190-1 WP 0186-1 WP 0187-1 WP 0193-1 WP 0194-1 WP 0192-1 WP 0191-1 WP 0188-1 WP 0140-1

I Idler Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Implement Cylinder Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Implement Pump Discharge Tests and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Implement Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0135-1 WP 0032-1 WP 0033-1 WP 0112-1 WP 0260-1 WP 0262-1

J Junction Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0165-1 Junction Block Replacement (With Arctic Kit Heater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0166-1

L Left Platform Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Cylinder (Bulldozer) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Cylinder Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Cylinder Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List Expendable and Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Radiator Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lowering Equipment with Engine Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Tests, Inspections, and Adjustments Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0207-1 WP 0266-1 WP 0265-1 WP 0197-1 WP 0303-1 WP 0110-1 WP 0218-1 WP 0024-1

M Main Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Allocation Chart (MAC) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Messenger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index-5

WP 0117-1 WP 0301-1 WP 0302-1 WP 0295-1 WP 0236-1

TM 5-2410-241-23-1

Index - Continued Subject

WP Sequence No.-Page No.

Muffler Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0045-1

N NATO Slave and Cables Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0053-1

O Oil Filler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter Engine Base Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside Cab Door Latch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0086-1 WP 0082-1 WP 0089-1 WP 0088-1 WP 0251-1

P Pilot Pressure Tests and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Valve Bulldozer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Valve Service With Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Valve Service With Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pivot Shaft Lubrication Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Platform Access Panels Service, Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Platform Access Panels, Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Platform Enclosure Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Platform Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powertrain Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powertrain Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparation for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Maintenance Checks and Services (PMCS) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primary Fuel Filter, Base and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0034-1 WP 0259-1 WP 0256-1 WP 0257-1 WP 0158-1 WP 0208-1 WP 0207-1 WP 0206-1 WP 0209-1 WP 0177-1 WP 0118-1 WP 0119-1 WP 0020-1 WP 0297-1 WP 0038-1 WP 0039-1 WP 0071-1

Q Quick Drop Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0215-1

R Radiator Cooling Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Core Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drain Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Crankshaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Floor Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Gear Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Washer Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wiper Motor, Wiper Arm, Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rearview Mirror Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receiver Dryer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index-6

WP 0051-1 WP 0109-1 WP 0052-1 WP 0110-1 WP 0205-1 WP 0102-1 WP 0231-1 WP 0085-1 WP 0227-1 WP 0223-1 WP 0235-1 WP 0240-1

TM 5-2410-241-23-1

Index - Continued Subject

WP Sequence No.-Page No.

Recoil Spring Compartment Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Cab Switch Panel Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Platform Access Panels Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ripper Carriage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tooth Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ripper Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROPS Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0150-1 WP 0300-1 WP 0179-1 WP 0208-1 WP 0282-1 WP 0279-1 WP 0281-1 WP 0280-1 WP 0213-1 WP 0107-1 WP 0225-1

S Schematics Work Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Secondary Fuel Filter, Base and Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor Camshaft Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Brake Pedal Limit Switch Tests and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Flange Track Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Fabricated Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sprocket Segment Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Control Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Hydraulic Circuit Tests and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering, Transmission Control and Parking Brake Switch Replacement . . . . . . . . . . . . . . . . . . . . . . Strip Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch and Harness Assembly (Service Brake) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0299-1 WP 0247-1 WP 0248-1 WP 0072-1 WP 0093-1 WP 0037-1 WP 0040-1 WP 0040-1 WP 0040-2 WP 0133-1 WP 0304-1 WP 0137-1 WP 0164-1 WP 0061-1 WP 0031-1 WP 0238-1 WP 0035-1 WP 0237-1 WP 0131-1 WP 0174-1

T Temperature Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tests, Inspections, and Adjustments A/C and Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Inlet and Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theory of Operation Air Conditioning and Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Inlet and Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index-7

WP 0074-1 WP 0036-1 WP 0027-1 WP 0026-1 WP 0025-1 WP 0012-1 WP 0005-1 WP 0007-1

TM 5-2410-241-23-1

Index - Continued Subject

WP Sequence No.-Page No.

Engine and Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Drive and Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Implement and Steering Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primary Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Cylinder (Bulldozer) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Cylinder Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter Output Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter Relief Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter Relief Valve Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Track Adjuster and Recoil Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shoe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermediate Speed Sensor One Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermediate Speed Sensor Two Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Cooler Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission System Oil Filter Base Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arctic Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedures Arctic Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trunnion Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trunnion Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger Inlet Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0004-1 WP 0010-1 WP 0011-1 WP 0003-1 WP 0006-1 WP 0009-1 WP 0267-1 WP 0198-1 WP 0122-1 WP 0123-1 WP 0124-1 WP 0148-1 WP 0298-1 WP 0134-1 WP 0129-1 WP 0127-1 WP 0128-1 WP 0142-1 WP 0145-1 WP 0169-1 WP 0143-1 WP 0144-1 WP 0121-1 WP 0042-1 WP 0173-1 WP 0153-1 WP 0152-1 WP 0151-1 WP 0146-1 WP 0013-1 WP 0014-1 WP 0283-1 WP 0286-1 WP 0022-1 WP 0019-1 WP 0020-1 WP 0048-1 WP 0130-1 WP 0066-1 WP 0062-1

U Upper Coolant Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0043-1 Using Jack Stands to Support Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0294-1

Index-8

TM 5-2410-241-23-1

Index - Continued Subject

WP Sequence No.-Page No.

V Valve Bank 5 Service with Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Bank GP - Test 4 Service with Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Bank GP - Test 5 Service with Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Mechanism Cover, Base, and Injector Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . V-Belt (A/C Compressor) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-Belt Set (Alternator) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0211-1 WP 0212-1 WP 0211-1 WP 0106-1 WP 0096-1 WP 0098-1

W Washer Bottle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump Elbow Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Valve and Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Winch Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Winch Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiper Control Plate and Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiper Motor, Wiper Arm, Wiper Blade Replacement, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiper Motor, Wiper Arm, Wiper Blade Replacement, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness Assembly (Steering Control) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0224-1 WP 0049-1 WP 0076-1 WP 0077-1 WP 0244-1 WP 0272-1 WP 0275-1 WP 0273-1 WP 0274-1 WP 0180-1 WP 0214-1 WP 0246-1 WP 0234-1 WP 0222-1 WP 0223-1 WP 0178-1

Y Yoke Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0264-1

Index-9 /(Index-10 Blank)

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA.

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE Date you filled out this form.

TO (Forward to proponent of publication or form) (Include ZIP Code)

FROM (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command

Your mailing address

ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER

TM Number ITEM

PAGE

PARAGRAPH

LINE

FIGURE TABLE NO.

DATE

TITLE

Date of the TM

Title of the TM

RECOMMENDED CHANGES AND REASON (Exact wording of recommended change must be given)

0007-3

Figure 2, Item 9 should show a lockwasher. Currently shows a flat washer.

0018-2

Cleaning and inspection, Step 6, reference to governor support pin (14) is wrong reference. Reference should be change to (12).

SAMPLE

TYPED NAME, GRADE OR TITLE

Your Name DA FORM 2028, FEB 74

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

Your Phone Number

SIGNATURE

Your Signature

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication)

FROM (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

Date you filled out

Your Address

this form

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER

DATE

Date of the TM

TM Number PAGE NO.

COLM NO.

LINE NO.

NATIONAL STOCK NUMBER

TITLE

Title of the TM

TOTAL NO. REFERENCE FIGURE ITEM OF MAJOR NO. NO. NO. ITEMS SUPPORTED

RECOMMENDED ACTION

SAMPLE PART III – REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

Your Name

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

Your Phone Number

Your Signature APD V4.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA

TO (Forward to proponent of publication or form) (Include ZIP Code)

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

FROM (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER

DATE

TM 5-2410-241-23-1 ITEM

PAGE

PARAGRAPH

TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

29 February 2012 LINE

FIGURE TABLE NO.

TITLE Field Maintenance Manual D7R Series II Dozer Type I with Winch, Type II with Ripper

RECOMMENDED CHANGES AND REASON

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication)

FROM (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION/FORM NUMBER

TM 5-2410-241-23-1 PAGE NO.

COLM NO.

LINE NO.

DATE 29 February 2012

NATIONAL STOCK NUMBER

REFERENCE FIGURE ITEM NO. NO. NO.

TITLE Field Maintenance Manual D7R Series II Dozer Type I with Winch, Type II with Ripper TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III – REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

APD V4.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA

TO (Forward to proponent of publication or form) (Include ZIP Code)

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

FROM (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER

DATE

TM 5-2410-241-23-1 ITEM

PAGE

PARAGRAPH

TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

29 February 2012 LINE

FIGURE TABLE NO.

TITLE Field Maintenance Manual D7R Series II Dozer Type I with Winch, Type II with Ripper

RECOMMENDED CHANGES AND REASON

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication)

FROM (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION/FORM NUMBER

TM 5-2410-241-23-1 PAGE NO.

COLM NO.

LINE NO.

DATE 29 February 2012

NATIONAL STOCK NUMBER

REFERENCE FIGURE ITEM NO. NO. NO.

TITLE Field Maintenance Manual D7R Series II Dozer Type I with Winch, Type II with Ripper TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III – REMARKS (Any general remark, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

APD V4.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA

TO (Forward to proponent of publication or form) (Include ZIP Code)

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

FROM (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER

DATE

TM 5-2410-241-23-1 ITEM

PAGE

PARAGRAPH

TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

29 February 2012 LINE

FIGURE TABLE NO.

TITLE Field Maintenance Manual D7R Series II Dozer Type I with Winch, Type II with Ripper

RECOMMENDED CHANGES AND REASON

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication)

FROM (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION/FORM NUMBER

TM 5-2410-241-23-1 PAGE NO.

COLM NO.

LINE NO.

DATE 29 February 2012

NATIONAL STOCK NUMBER

REFERENCE FIGURE ITEM NO. NO. NO.

TITLE Field Maintenance Manual D7R Series II Dozer Type I with Winch, Type II with Ripper TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III – REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

APD V4.00

By Order of the Secretary of the Army: RAYMOND T. ODIERNO General, United States Army Chief of Staff

Official: JOYCE E. MORROW Administrative Assistant to the Secretary of the Army 1201201

Distribution: To be distributed in accordance with the initial distribution number (IDN) 257897 requirements for TM 5-2410-241-23-1.

2

Back Cover

THE METRIC SYSTEM AND EQUIVALENTS Linear Measure

Square Measure

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Kilometer = 1000 Meters = 0.621 Miles

1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles

Weights

Cubic Measure

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.2 Pounds 1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons

1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet Temperature

Liquid Measure 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33.82 Fluid Ounces

5/9 (°F - 32) = °C 212° Fahrenheit is equivalent to 100° Celsius 90° Fahrenheit is equivalent to 32.2° Celsius 32° Fahrenheit is equivalent to 0° Celsius 9/5 C° +32 = F°

APPROXIMATE CONVERSION FACTORS To Change

To

Multiply By

To Change

To

Multiply By

Inches

Centimeters

2.540

Centimeters

Inches

0.394

Feet

Meters

0.305

Meters

Feet

3.280

Yards

Meters

0.914

Meters

Yards

1.094

Miles

Kilometers

1.609

Kilometers

Miles

0.621

Sq Inches

Sq Centimeters

6.451

Sq Centimeters

Sq Inches

0.155

Sq Feet

Sq Meters

0.093

Sq Meters

Sq Feet

10.764

Sq Yards

Sq Meters

0.836

Sq Meters

Sq Yards

1.196

Sq Miles

Sq Kilometers

2.590

Sq Kilometers

Sq Miles

0.386

Acres

Sq Hectometers

0.405

Sq Hectometers

Acres

2.471

Cubic Feet

Cubic Meters

0.028

Cubic Meters

Cubic Feet

35.315

Cubic Yards

Cubic Meters

0.765

Cubic Meters

Cubic Yards

1.308

Fluid Ounces

Milliliters

29.573

Milliliters

Fluid Ounces

0.034

Pints

Liters

0.473

Liters

Pints

2.113

Quarts

Liters

0.946

Liters

Quarts

1.057

Gallons

Liters

3.785

Liters

Gallons

0.264

Ounces

Grams

28.349

Grams

Ounces

0.035

Pounds

Kilograms

0.454

Kilograms

Pounds

2.205

Short Tons

Metric Tons

0.907

Metric Tons

Short Tons

1.102

Pound-Feet

Newton-Meters

1.356

Newton-Meters

Pound-Feet

0.738

Pounds per Sq Inch

Kilopascals

6.895

Kilopascals

Pounds per Sq Inch

0.145

Miles per Gallon

Kilometers per Liter

0.425

Kilometers per Liter

Miles per Gallon

2.354

Miles per Hour

Kilometers per Hour

1.609

Kilometers per Hour

Miles per Hour

0.621

PIN: 086457-000