Cat TH220B & TH330B Telehandler Service Manual – PDF DOWNLOAD
DESCRIPTION:
Cat TH220B & TH330B Telehandler Service Manual – PDF DOWNLOAD
Important Safety Information
- Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions.
- An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
- A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly
- Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.
- Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.
- Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons
- The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
WARNING
- The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.
- The message that appears under the warning explains the hazard and can be either written or pictorially presented.
- Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.
- Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive.
- If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others.
- You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.
- The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time.
- These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar® dealers have the most current information available.
TABLE OF CONTENTS:
Cat TH220B & TH330B Telehandler Service Manual – PDF DOWNLOAD
31200262_TH220B & TH330B Service Manual....................................................................... 1 31200263_Contents of 31200262............................................................................. 1 TORQUE SPECIFICATIONS..................................................................................... 2 31200268_Torque Specifications........................................................................ 2 Table of Contents................................................................................. 4 Specifications Section............................................................................ 6 General Information........................................................................... 6 Introduction to Torque.................................................................... 6 Torque-Turn............................................................................... 6 Torque Sequence........................................................................... 6 Metric (ISO) Fasteners........................................................................ 7 Metric (ISO) Nuts and Bolts............................................................... 7 Metric (ISO) Taperlock Studs.............................................................. 7 Metric (ISO) Machine Screws............................................................... 7 Hex Button Head Screw and Set Screw....................................................... 7 English (SAE) Fasteners....................................................................... 8 English (SAE) Nuts and Bolts.............................................................. 8 English (SAE) Taperlock Studs............................................................. 8 English (SAE) Machine Screws.............................................................. 8 Hex Button Head Screw and Set Screws...................................................... 9 Ground Engaging Tool (G.E.T.) Fasteners....................................................... 9 Installation of Fittings...................................................................... 10 Installation of Split Flange Couplings.................................................... 10 Installation of Adjustable STOR Fittings.................................................. 11 Straight Thread O-Ring Fittings............................................................... 11 Plugs......................................................................................... 13 Straight Thread O-Ring Plugs (Hex Drive).................................................. 13 Straight Thread O-Ring Plugs (Socket Drive)............................................... 14 Drain Plugs with Straight Thread.......................................................... 14 Straight Thread O-Ring Plugs (Mechanical Joint Tube Assemblies)........................... 14 O-Ring Face Seal Fittings..................................................................... 15 Bulkhead Nuts................................................................................. 15 Flare Fittings................................................................................ 16 37 Degree Flare Fitting................................................................... 16 45 Degree Flare and 45 Degree Inverted Flare Fittings..................................... 16 Air Conditioning Fittings..................................................................... 17 Air Brake Fittings............................................................................ 17 Tapered Pipe Thread Fittings.................................................................. 17 Miscellaneous Fittings........................................................................ 18 Hi Duty Tube Fittings (Shear Sleeve)...................................................... 18 SAE Flareless Fittings.................................................................... 18 Flex Fittings............................................................................. 18 Hose Clamps................................................................................... 18 Worm Drive Band Type Clamps............................................................... 18 Constant Torque Hose Clamps............................................................... 19 ENGINE.................................................................................................... 24 31200269_Engine Disassembly-Assembly.................................................................. 24 Table of Contents................................................................................. 4 Disassembly and Assembly Section.................................................................. 28 Battery - Remove and Install.................................................................. 28 Removal Procedure......................................................................... 28 Installation Procedure.................................................................... 29 Alternator - Remove and Install............................................................... 29 Removal Procedure......................................................................... 29 Installation Procedure.................................................................... 30 Electric Starting Motor -Remove and Install................................................... 30 Removal Procedure......................................................................... 30 Installation Procedure.................................................................... 30 Air Cleaner - Remove and Install.............................................................. 31 Removal Procedure......................................................................... 31 Installation Procedure.................................................................... 31 Muffler - Remove and Install.................................................................. 32 Removal Procedure......................................................................... 32 Installation Procedure.................................................................... 33 Expansion Tank - Remove and Install........................................................... 34 Removal Procedure......................................................................... 34 Radiator - Remove............................................................................. 35 Removal Procedure......................................................................... 35 Radiator - Install............................................................................ 39 Installation Procedure.................................................................... 39 Fan Guard - Remove and Install................................................................ 42 Removal Procedure......................................................................... 42 Installation Procedure.................................................................... 42 Fan - Remove and Install...................................................................... 42 Removal Procedure......................................................................... 42 Installation Procedure.................................................................... 43 Engine Mount - Remove and Install............................................................. 43 Removal Procedure......................................................................... 43 Installation Procedure.................................................................... 45 Refrigerant Compressor - Remove and Install................................................... 47 Removal Procedure......................................................................... 47 Installation Procedure.................................................................... 48 Refrigerant Condenser - Remove and Install.................................................... 48 Removal Procedure......................................................................... 48 Installation Procedure.................................................................... 49 Engine Enclosure - Remove and Install......................................................... 50 Removal Procedure......................................................................... 50 Installation Procedure.................................................................... 51 Engine - Remove............................................................................... 52 Removal Procedure......................................................................... 52 Engine - Install.............................................................................. 58 Installation Procedure.................................................................... 58 POWER TRAIN............................................................................................... 70 31200270_Power Train Test-Adjust...................................................................... 70 Table of Contents................................................................................. 4 Systems Operation Section......................................................................... 74 Graphic Color Codes........................................................................... 74 Introduction.................................................................................. 75 General Information........................................................................... 76 Location of Electrical Components............................................................. 77 Transmission Neutralizer Switch........................................................... 78 Parking Brake Switch...................................................................... 78 Service Brake Pressure Switch............................................................. 78 Transmission Direction Control Lever (Power Shuttle Transmission)......................... 79 Transmission Speed Selector (Powersynchro Transmission)................................... 79 Differential Lock Switch (if Equipped..................................................... 79 Transmission Oil Temperature Sensor....................................................... 79 Torque Converter Output Sensor for the Temperature of the Oil............................. 79 Engine Speed Sensor....................................................................... 79 Torque Converter Output Speed Sensor...................................................... 79 Transmission Intermediate Speed Sensors................................................... 80 Transmission Output Speed Sensor.......................................................... 80 Shift Rail Sensors........................................................................ 80 Electronic Control Module................................................................. 80 Modulating Valve for the Synchronizers.................................................... 80 Solenoid Valves........................................................................... 81 Transmission Neutralizer Override Switch.................................................. 81 Location of Hydraulic Components.............................................................. 81 Transmission Charge Pump.................................................................. 82 Torque Converter.......................................................................... 82 Hydraulic Oil Cooler...................................................................... 82 Electrical Input Components................................................................... 83 Sensors................................................................................... 83 Switches.................................................................................. 85 Transmission Control...................................................................... 86 Electronic Control Module..................................................................... 87 Inputs.................................................................................... 87 Outputs................................................................................... 87 Input/Output.............................................................................. 87 Electrical Output Components.................................................................. 91 Synchronizer Solenoids.................................................................... 92 Directional Solenoids..................................................................... 92 Instrument Cluster........................................................................ 92 Data Link..................................................................................... 93 CAT Data Link............................................................................. 93 CAN Data Link............................................................................. 93 Electrical Schematic.......................................................................... 93 Transmission Charge Pump...................................................................... 95 Modulating Valve (Transmission)............................................................... 95 Solenoid Valves (Transmission)................................................................ 95 Directional Solenoids..................................................................... 95 Speed or Synchronized Solenoids........................................................... 96 Torque Converter.............................................................................. 97 Transmission.................................................................................. 99 Clutch Operation.......................................................................... 102 Operation of the Synchronizers............................................................ 103 Synchronizer for the Third Speed and Fourth Speed......................................... 106 Limits.................................................................................... 108 Cooler (Hydraulic Oil)........................................................................ 109 Transmission Control (Shift Lever)............................................................ 109 Powersynchro Transmission................................................................. 110 Power Shuttle Transmission................................................................ 110 Transmission Power Flow....................................................................... 111 Examples of Power Flow Through the Transmission........................................... 113 Differential Lock Control (If Equipped)....................................................... 115 Front Axle and Rear Axle...................................................................... 117 Final Drives.............................................................................. 117 Hydraulic Schematic (Power Train System)...................................................... 119 Neutral (Power Shuttle Transmission)...................................................... 119 Neutral (Powersynchro Transmission)....................................................... 120 Neutral into First Gear (Start of shift).................................................. 121 Neutral Into First Gear (End of Shift) (FORWARD).......................................... 122 Configuration Parameters...................................................................... 124 Testing and Adjusting Section..................................................................... 126 Transmission Shift Rail - Calibrate........................................................... 126 Machine Preparation....................................................................... 126 Transmission Fill - Calibrate................................................................. 133 Machine Preparation....................................................................... 133 Torque Converter Stall - Test................................................................. 140 Introduction.............................................................................. 140 Required Tools............................................................................ 140 Test Procedure............................................................................ 140 Measurement of the Stall Speed............................................................ 141 Transmission Pressures - Test and Adjust...................................................... 141 Pressure Test Points for the Powersynchro Transmission.................................... 142 Pressure Test Points for the Power Shuttle Transmission................................... 143 Oil Level Check........................................................................... 143 Torque Converter Inlet Pressure........................................................... 143 Regulated Pump Pressure................................................................... 144 Operating Pressures of Clutches and Synchronizers......................................... 145 Differential Pinion Bearing - Adjust.......................................................... 146 Introduction.............................................................................. 146 Required Tools............................................................................ 146 Procedure................................................................................. 147 Differential Backlash and Bearings - Adjust................................................... 152 Front Axle Differential................................................................... 152 Rear Axle Differential.................................................................... 155 Tooth Contact Pattern..................................................................... 156 Axle Housing and Bearing Preload - Adjust..................................................... 158 Introduction.............................................................................. 158 Adjustment Procedure...................................................................... 159 31200271_Power Train Disassembly-Assembly............................................................. 164 Table of Contents................................................................................. 4 Disassembly and Assembly Section.................................................................. 168 Transmission Control (Select Lever) - Remove and Install...................................... 168 Removal Procedure......................................................................... 168 Installation Procedure.................................................................... 170 Drive Shaft (Front) - Remove and Install...................................................... 171 Removal Procedure......................................................................... 171 Installation Procedure.................................................................... 172 Drive Shaft (Rear) - Remove and Install....................................................... 172 Removal Procedure......................................................................... 172 Installation Procedure.................................................................... 173 Transmission and Torque Converter - Remove.................................................... 173 Removal Procedure......................................................................... 173 Transmission - Disassemble.................................................................... 178 Disassembly Procedure..................................................................... 178 Transmission - Assemble....................................................................... 206 Assembly Procedure........................................................................ 206 Transmission and Torque Converter - Install................................................... 234 Installation Procedure.................................................................... 234 Drive and Steering Axle (Front) - Remove...................................................... 238 Removal procedure......................................................................... 238 Drive and Steering Axle (Front) - Install..................................................... 240 Installation Procedure.................................................................... 240 Drive and Steering Axle (Rear) - Remove....................................................... 241 Removal procedure......................................................................... 241 Drive and Steering Axle (Rear) - Install...................................................... 243 Installation Procedure.................................................................... 243 Tie Rod (Steering) - Remove and Install....................................................... 245 Removal Procedure......................................................................... 245 Installation procedure.................................................................... 246 Steering Cylinder - Remove and Install........................................................ 246 Removal Procedure......................................................................... 246 Installation Procedure.................................................................... 248 Final Drive Planetary - Remove................................................................ 249 Removal Procedure......................................................................... 249 Final Drive Planetary Disassemble............................................................. 249 Disassembly Procedure..................................................................... 249 Final Drive Planetary - Assemble.............................................................. 250 Assembly Procedure........................................................................ 250 Final Drive Planetary - Install............................................................... 250 Installation Procedure.................................................................... 250 Axle Housing and Flange Remove................................................................ 250 Removal Procedure......................................................................... 250 Axle Housing and Flange - Disassemble......................................................... 253 Disassembly Procedure..................................................................... 253 Axle Housing and Flange - Assemble............................................................ 255 Assembly Procedure........................................................................ 255 Axle Housing and Flange Install............................................................... 257 Installation Procedure.................................................................... 257 Axle Shaft - Remove and Install............................................................... 260 Removal Procedure......................................................................... 260 Installation Procedure.................................................................... 261 Axle Housing (Service Brakes, Differential and Bevel Gear) (Front) - Remove................... 262 Removal Procedure............................................................................. 262 Axle Housing (Service Brakes, Differential and Bevel Gear) (Front) - Disassemble.............. 263 Disassembly Procedure..................................................................... 263 Axle Housing (Service Brakes, Differential and Bevel Gear) (Front) - Assemble................. 269 Assembly Procedure........................................................................ 269 Axle Housing (Service Brakes, Differential and Bevel Gear) (Front) - Install.................. 278 Installation Procedure.................................................................... 278 Axle Housing (Differential and Bevel Gear) (Rear) - Remove.................................... 279 Removal Procedure......................................................................... 279 Axle Housing (Differential and Bevel Gear) (Rear) - Assemble.................................. 280 Assembly Procedure........................................................................ 280 Axle Housing (Differential and Bevel Gear) (Rear) - Disassemble............................... 285 Disassembly Procedure..................................................................... 285 Axle Housing (Differential and Bevel Gear) (Rear) - Install................................... 289 Installation Procedure.................................................................... 289 Brake Cylinder (Master) Remove and Install.................................................... 289 Removal Procedure......................................................................... 289 Installation Procedure.................................................................... 291 Parking Brake Control -Remove and Install..................................................... 292 Removal Procedure......................................................................... 292 Installation Procedure.................................................................... 293 Parking Brake - Remove........................................................................ 294 Removal Procedure......................................................................... 294 Parking Brake - Disassemble................................................................... 294 Disassembly Procedure..................................................................... 294 Parking Brake - Assemble...................................................................... 296 Assembly Procedure........................................................................ 296 Parking Brake - Install....................................................................... 298 Installation Procedure.................................................................... 298 Tire and Rim - Remove and Install............................................................. 299 Removal Procedure......................................................................... 299 Installation Procedure.................................................................... 300 VEHICLE SYSTEMS........................................................................................... 306 31200275_Hydraulic System Schematic................................................................... 306 31200272_Hydraulic System Test Adjust................................................................. 308 Table of Contents................................................................................. 4 Systems Operation Section......................................................................... 312 Graphic Color Codes........................................................................... 312 Introduction.................................................................................. 313 General Information........................................................................... 314 Main Control Valve Group (Implement)...................................................... 314 Electronic Pilot Valve Group (Implement).................................................. 315 Machine ECM............................................................................... 316 Electronic Joystick....................................................................... 317 Operator Switches......................................................................... 318 Piston Pump (Implement and Steering)...................................................... 318 Hydraulic Oil Tank........................................................................ 318 Hydraulic Oil Filter...................................................................... 318 System Operation.......................................................................... 319 Load Independent Flow Division (LIFD)..................................................... 320 Location of Electrical Components......................................................... 320 Switch (Lockout Control).................................................................. 320 Joystick Control.......................................................................... 320 Sensor (Boom Raise/Lower)................................................................. 321 Sensor For Boom Extend And Boom Retract Or Boom Tilt Forward And Rackback................. 321 Switch (Continuous Auxiliary Flow)........................................................ 321 Switch For Boom Extend and Boom Retract Or Boom Tilt Forward And Rackback................. 321 Switch (Auxiliary Actuator in the + Direction)............................................ 321 Switch (Auxiliary Actuator in the - Direction)............................................ 321 Switch (Auxiliary Services 1 or 2)........................................................ 321 Switch (Quick Coupler).................................................................... 322 Switch (Frame Level)...................................................................... 322 Switch (Fully Lowered Boom)............................................................... 322 Switch (Critical Angle)................................................................... 323 Switch (Fully Retracted Boom)............................................................. 323 Switch (Reversing Fan (If Equipped))...................................................... 323 Machine (ECM)............................................................................. 323 Main Control Valve (Implement)............................................................ 324 Solenoids (Frame Level)................................................................... 324 Solenoid (Diverter Valve)................................................................. 324 Relay (Frame Level)....................................................................... 325 Relays (Diverter Valve)................................................................... 325 Relays (Quick Coupler).................................................................... 325 Location of Hydraulic Components.............................................................. 326 Hydraulic Tank............................................................................ 326 Piston Pump (Implement and Steering)...................................................... 326 Compensator Valve......................................................................... 327 Main Control Valve Group (Implement)...................................................... 327 Inlet Manifold............................................................................ 327 Outlet Manifold........................................................................... 328 Trailer and Towing Hitch Hydraulic System (Option)........................................ 328 Boom Cylinder............................................................................. 329 Load Control Valve (Boom Cylinder Lock)................................................... 330 Telescoping Cylinder...................................................................... 330 Load Control Valve (Telescoping Cylinder Lock)............................................ 330 Tilt Cylinder............................................................................. 330 Lock for Load Control Valve (Tilt Cylinder)............................................... 331 Compensating Cylinder..................................................................... 331 Load Control Valve (Compensating Cylinder Lock)........................................... 331 Frame Leveling Cylinder................................................................... 331 Lock Valve (Frame Leveling Cylinder)...................................................... 332 Diverter Valve............................................................................ 332 Quick Coupler Cylinder.................................................................... 332 Electrical Input Components................................................................... 333 Switches.................................................................................. 334 Joystick Control.......................................................................... 334 Auxiliary Switches........................................................................ 334 Thumb Slider.............................................................................. 334 Boom Critical Angle Switch................................................................ 334 Frame Leveling Switch..................................................................... 334 Boom Retracted Switch..................................................................... 334 Quick Coupler Switch...................................................................... 335 Continuous Flow Switch.................................................................... 335 Implement Lockout Switch.................................................................. 335 Boom Lowered Switch....................................................................... 335 Electronic Control Module..................................................................... 336 Inputs.................................................................................... 336 Outputs................................................................................... 336 Data Links................................................................................ 336 Input/Output.............................................................................. 336 Electrical Output Components.................................................................. 338 Relays.................................................................................... 339 Solenoids................................................................................. 339 Electrical Function Requirements.............................................................. 340 Transmission Neutralizer.................................................................. 340 Solenoid Outputs.......................................................................... 340 System Voltage............................................................................ 340 Shuttle Shift for the Power Shuttle Transmission.......................................... 340 Shift Lever (Cat Data Link) for Powersynchro Transmission................................. 340 Rear Axle Lock (if equipped).............................................................. 340 Machine Security System................................................................... 340 Parking Brake............................................................................. 340 Service Brake Pressure Switch for the Transmission Neutralizer............................ 340 More Electrical Function Requirements..................................................... 340 Steering.................................................................................. 341 The Neutral Start Is Disabled............................................................. 341 Stabilizer Raise/Lower (if equipped) is Disabled.......................................... 341 Boom Raise/Lower Is Disabled.............................................................. 342 The Boom Extend/Retract Is Disabled....................................................... 342 Disable The Rackback And Dump............................................................. 342 The Frame Level (if equipped) is Disabled................................................. 342 Disable the Quick Coupler................................................................. 343 Miscellaneous............................................................................. 343 Electrical Schematic.......................................................................... 344 Programmable Hydraulic System (PHS)....................................................... 345 Piston Pump (Implement and Steering).......................................................... 346 Piston Pump............................................................................... 346 Compensator Valve......................................................................... 347 Low Pressure Standby...................................................................... 348 Upstroke.................................................................................. 349 Constant Flow............................................................................. 350 Destroke.................................................................................. 351 High Pressure Stall....................................................................... 353 Main Control Valve (Implement)............................................................ 354 Manifold Valve (Inlet).................................................................... 356 Check and Relief Valves....................................................................... 358 Manifold Valve (Outlet)....................................................................... 358 Pilot Hydraulic System........................................................................ 360 Telescoping System............................................................................ 362 Valve for the Telescoping Cylinder in the HOLD Position................................... 362 Valve for the Telescoping Cylinder in the EXTEND Position................................. 364 Valve for the Telescoping Cylinder in the RETRACT Position................................ 366 Hydraulic Fan System.......................................................................... 367 Reversing Fan (If Equipped)............................................................... 367 Auxiliary Hydraulic System.................................................................... 369 Auxiliary Control (Combined Circuit)...................................................... 370 Auxiliary Circuit 1....................................................................... 372 Auxiliary Circuit 2....................................................................... 373 Continuous Flow (Auxiliary Hydraulics).................................................... 374 Quick Coupler............................................................................. 374 Quick Coupler Circuit DISENGAGED.......................................................... 375 Quick Coupler Pins ENGAGED................................................................ 376 Relief Valves and Makeup Valves........................................................... 376 Compensating System........................................................................... 377 Trailer and Towing Hitch Hydraulic System..................................................... 381 Introduction.............................................................................. 381 Towing Hitch Cylinder LOWER............................................................... 383 Towing Hitch Cylinder RAISE............................................................... 385 Trailer DUMP.............................................................................. 388 Trailer LOWER............................................................................. 390 Service Brakes ENGAGED.................................................................... 393 Hydraulic System Schematic.................................................................... 394 Configuration Parameters...................................................................... 397 Testing and Adjusting Section..................................................................... 398 Testing and Adjusting......................................................................... 398 Joystick Control - Calibrate.............................................................. 398 Main Control Valve (Implement) - Calibrate.................................................... 418 Programmable Hydraulic System (PHS) Valve Calibrations.................................... 418 Manual Adjustment After Calibrating The Valves............................................ 427 Hydraulic System Pressure - Release........................................................... 427 Relieving Pressure in the Hydraulic System................................................ 428 Location of the Load Control Valve (Lock)................................................. 428 Relieving Pressure from the Load Control Valves (Lock).................................... 429 Hydraulic System Pressures - Test and Adjust.................................................. 432 Test and Adjustment Procedures............................................................ 432 Pilot Pressure (Pressure Reducing Valve) - Test and Adjust.................................... 432 Pilot Pressure Test....................................................................... 432 Pressure Reducing Valve Adjustment........................................................ 434 Relief Valve (Implement) - Test and Adjust.................................................... 434 Auxiliary Pressure Test (Port A and Port B)............................................... 434 Auxiliary Relief Valve Adjustments........................................................ 436 Hydraulic Oil Contamination - Test............................................................ 436 Hydraulic Oil Contamination............................................................... 436 Flushing the Sampling Valve............................................................... 436 Obtaining the Sample...................................................................... 437 General Information Table..................................................................... 438 31200273_Steering System Test-Adjust.................................................................. 444 Table of Contents................................................................................. 4 Systems Operation Section......................................................................... 448 Graphic Color Codes........................................................................... 448 General Information........................................................................... 449 Steering Arrangement...................................................................... 449 Introduction.................................................................................. 451 Location of Electrical Components............................................................. 452 Selector Switch for the Steering Mode..................................................... 452 Position Sensors.......................................................................... 452 Electronic Control Module................................................................. 453 Solenoid for Crab Steer................................................................... 453 Solenoid for Circle Steer................................................................. 453 Relay (Crab Steer)........................................................................ 453 Relay (Circle Steer)...................................................................... 454 Location of Hydraulic Components.............................................................. 454 Steering Wheel............................................................................ 454 Metering Pump............................................................................. 455 Piston Pump............................................................................... 455 Line for the Signal Limiter Valve for the Steering........................................ 455 Priority Valve............................................................................ 455 Control Valve (Steering).................................................................. 456 Steering Cylinders........................................................................ 334 Hydraulic Tank............................................................................ 456 Hydraulic Tank Breather................................................................... 456 Hydraulic Oil Level Indicator............................................................. 457 Hydraulic Oil Drain Plugs................................................................. 457 Electrical Input Components................................................................... 457 Steering Mode Switch...................................................................... 457 Position Sensor........................................................................... 458 Electronic Control Module..................................................................... 458 Electrical Output Components.................................................................. 459 Relays.................................................................................... 459 Instrument Cluster........................................................................ 459 Data Link..................................................................................... 459 CAT Data Link............................................................................. 459 CAN Data Link............................................................................. 460 Electrical Schematic.......................................................................... 460 Inlet Manifold................................................................................ 460 Steering Priority Valve................................................................... 461 Screens (75 and 100 Micron)............................................................... 461 Flow Control Valve (Dump valve for the load sensing oil).................................. 461 Relief Valve (Load sensing oil)........................................................... 461 Check Valve............................................................................... 461 Steering Not Activated.................................................................... 462 Steering Activated........................................................................ 463 Steering System............................................................................... 464 Steering Control System................................................................... 464 Steering in Neutral....................................................................... 465 Right Turn in Two-Wheel Steer Mode........................................................ 467 Left Turn in Circle Steer Mode............................................................ 469 Left Turn in Crab Steer Mode.............................................................. 471 Hydraulic Schematic (Steering System)......................................................... 473 Piston Pump (Implement and Steering).......................................................... 474 Piston Pump............................................................................... 474 Compensator Valve......................................................................... 475 Low Pressure Standby...................................................................... 476 Upstroke.................................................................................. 477 Constant Flow............................................................................. 478 Destroke.................................................................................. 479 High Pressure Stall....................................................................... 481 Solenoid Valve (Steering Mode Selector)....................................................... 482 Solenoid Valve............................................................................ 482 Metering Pump (Steering)...................................................................... 482 Hold...................................................................................... 484 Right Turn................................................................................ 485 Position Sensor (Steering).................................................................... 487 Configuration Parameters...................................................................... 488 Testing and Adjusting Section..................................................................... 490 Hydraulic Oil Contamination - Test............................................................ 490 Hydraulic Oil Contamination............................................................... 490 Flushing the Sampling Valve............................................................... 490 Obtaining the Sample...................................................................... 490 Pump Flow - Test.............................................................................. 491 Pump Flow................................................................................. 491 Test On The Machine....................................................................... 491 Test On The Bench......................................................................... 492 Steering System Pressures - Test and Adjust................................................... 492 Steering System Pressure Tests and Adjustments............................................ 492 Steering Pressure Test.................................................................... 493 Steering Pressure Adjustment.............................................................. 493 Margin Pressure Test...................................................................... 494 Margin Pressure Adjustment................................................................ 495 Test for the Relief Valve (Load Sensing Oil).............................................. 495 Adjustment of the Relief Valve (Load Sensing Oil)......................................... 496 Test for Pressure Compensator............................................................. 496 Pressure Compensator Adjustment........................................................... 497 Low Pressure Standby Test................................................................. 497 Low Pressure Standby Adjustment........................................................... 498 Steering System - Purge....................................................................... 499 Purging the Steering System............................................................... 499 Solenoid Valve (Steering Mode Selector) - Test................................................ 499 The Solenoid's for the Steering Modes..................................................... 499 Position Sensor (Steering) - Adjust........................................................... 500 Position Sensor........................................................................... 500 Wheel Alignment - Check and Adjust............................................................ 502 Checking the Wheel Alignment With Wheels In Place......................................... 503 Adjusting the Wheel Alignment............................................................. 503 Adjusting the Steering Angle.............................................................. 504 General Information Table..................................................................... 505 31200274_Braking System Test-Adjust................................................................... 510 Table of Contents................................................................................. 4 Systems Operation Section......................................................................... 168 Graphic Color Codes........................................................................... 514 Introduction.................................................................................. 515 General Information........................................................................... 516 Brake Packs............................................................................... 516 Brake Pedal............................................................................... 516 Brake Cylinder............................................................................ 516 Service Brake Pressure Switch............................................................. 517 Parking Brake Lever....................................................................... 517 Location of Electrical Components............................................................. 517 Parking Brake Switch...................................................................... 517 Service Brake Pressure Switch............................................................. 517 Stoplight Switch.......................................................................... 517 Location of Components (Braking).............................................................. 518 Parking Brake Lever....................................................................... 518 Parking Brake Actuator.................................................................... 518 Service Brake Pedal....................................................................... 518 Brake Cylinder............................................................................ 519 Service Brake Discs....................................................................... 519 Service Brake................................................................................. 519 Service Brake............................................................................. 519 The Service Brake System with the Brakes Disengaged....................................... 521 The Service Brake System with the Brakes Engaged.......................................... 522 Parking Brake................................................................................. 523 Engaging the Parking Brake................................................................ 523 Disengaging the Parking Brake............................................................. 524 Brake Cylinder (Master)....................................................................... 525 Brake Cylinder with the Brakes Disengaged................................................. 526 Brake Cylinder with the Brakes Engaged.................................................... 528 Hydraulic Schematic (Braking System).......................................................... 530 Configuration Parameters...................................................................... 531 Electrical Function Requirements.............................................................. 532 Transmission Neutralizer.................................................................. 532 System Voltage............................................................................ 532 Shuttle Shift for the Power Shuttle Transmission.......................................... 532 Shift Lever (Cat Data Link) for Powersynchro Transmission................................. 532 Rear Axle Lock (if equipped).............................................................. 448 Machine Security System................................................................... 448 Parking Brake............................................................................. 532 Service Brake Pressure Switch for the Transmission Neutralizer............................ 533 More Electrical Function Requirements......................................................... 533 Steering.................................................................................. 533 The Neutral Start Is Disabled............................................................. 449 Stabilizer Raise/Lower (if equipped) is Disabled.......................................... 534 Boom Raise/Lower Is Disabled.............................................................. 534 The Boom Extend/Retract Is Disabled....................................................... 534 Disable The Rackback And Dump............................................................. 534 The Frame Level (if equipped) is Disabled................................................. 535 Disable the Quick Coupler................................................................. 535 Miscellaneous............................................................................. 535 Testing and Adjusting Section..................................................................... 536 Testing and Adjusting Service Brake - Test.................................................... 536 Holding Ability Test for the Service Brakes............................................... 536 Stopping Performance Test for the Service Brakes.......................................... 398 Service Brake Control - Check and Adjust...................................................... 536 Adjusting the Brake Pedal Linkage......................................................... 536 Service Brake Discs - Check................................................................... 538 Checking the Wear on the Service Brake Discs.............................................. 538 Procedure for Checking the Wear........................................................... 538 Service Brake Air - Purge..................................................................... 539 Purging Air from the Braking System....................................................... 539 Parking Brake - Test.......................................................................... 540 Holding Ability Test for the Parking Brake................................................ 540 Parking Brake Control - Check and Adjust...................................................... 541 Adjusting the Parking Brake Control Cable................................................. 541 31200276_Machine Components Specifications............................................................ 548 Table of Contents................................................................................. 4 Specifications Section............................................................................ 552 Hydraulic Tank................................................................................ 552 Piston Pump (Implement and Steering).......................................................... 553 Solenoid Valve (Pilot Selector)............................................................... 554 Frame......................................................................................... 557 Boom.......................................................................................... 558 Boom Cylinder................................................................................. 173 Boom Cylinder................................................................................. 560 Boom Cylinder................................................................................. 561 Load Control Valve (Boom Cylinder) (Lock)..................................................... 533 Compensating Cylinder......................................................................... 563 Compensating Cylinder......................................................................... 564 Telescoping Cylinder.......................................................................... 565 Telescoping Cylinder.......................................................................... 566 Load Control Valve (Telescoping Cylinder) (Lock).............................................. 567 Tilt Cylinder................................................................................. 568 Tilt Cylinder................................................................................. 569 Load Control Valve (Tilt Cylinder) (Lock)..................................................... 570 Diverter Valve................................................................................ 570 Diverter Valve................................................................................ 571 Towing Hitch.................................................................................. 572 Towing Hitch.................................................................................. 572 Towing Hitch.................................................................................. 459 Towing Hitch.................................................................................. 572 Towing Hitch.................................................................................. 460 Towing Hitch.................................................................................. 460 Piston Pump (Hydraulic Fan)................................................................... 574 Piston Pump Gp............................................................................ 574 Relief Valve.............................................................................. 574 Elbow..................................................................................... 574 Solenoid Valve Gp......................................................................... 574 Fan Drive Mounting Group...................................................................... 575 Metering Pump (Steering)...................................................................... 576 Solenoid Valve (Steering Mode Selector)....................................................... 576 Position Sensor (Steering).................................................................... 576 Flexible Coupling Drive....................................................................... 340 Transmission.................................................................................. 578 Transmission.................................................................................. 580 Position Sensor (Transmission)................................................................ 581 Oil Filter.................................................................................... 582 Hydraulic Oil Cooler.......................................................................... 584 Drive Shaft................................................................................... 585 Drive Shaft................................................................................... 585 Drive and Steering Axle (Front)............................................................... 586 168-7440 Drive and Steering Axle Gp....................................................... 586 271 -6424 Drive and Steering Axle Gp...................................................... 587 Drive and Steering Axle (Rear)................................................................ 589 168-7441 Drive and Steering Axle Gp....................................................... 589 Differential and Bevel Gear Group............................................................. 590 Axle Housing and Flange Group................................................................. 517 Axle Housing and Flange Group................................................................. 369 Final Drive Planetary Group................................................................... 592 Axle Housing Group (Differential and Brake Cylinder).......................................... 593 238-5225 Axle Housing Gp with a Locking Differential...................................... 593 231 -0737 Axle Housing Gp without a Locking Differential.................................. 594 Brake Cylinder (Master)....................................................................... 596 Parking Brake Control......................................................................... 597 Parking Brake................................................................................. 598 Fender........................................................................................ 598 Wheel (Tire and Rim).......................................................................... 599 Fuel Tank (Auxiliary)......................................................................... 600 Fuel Tank..................................................................................... 601 Engine Enclosure.............................................................................. 602 Engine and Transmission Mounting.............................................................. 604 Air Cleaner................................................................................... 605 Engine Oil Drain.............................................................................. 607 Muffler....................................................................................... 608 Suction Fan................................................................................... 609 Battery....................................................................................... 610 Coolant Lines Group........................................................................... 611 Coolant Recovery Group........................................................................ 612 Cab........................................................................................... 613 Latch Adjustment.......................................................................... 614 Cab Mounting.................................................................................. 615 Cab Door...................................................................................... 616 Access Door................................................................................... 618 Joystick Control.............................................................................. 619 Steering Wheel and Column..................................................................... 620 Window Wiper and Wiper Motor.................................................................. 621 Window Washer Tank............................................................................ 622 Rear View Mirror.............................................................................. 623 Work Tool Linkage............................................................................. 623 Carriage Cylinder (Rotate).................................................................... 624 Carriage Cylinder (Sideshift)................................................................. 624 Hydraulic Cylinder (Multipurpose Bucket)...................................................... 625 Grapple Cylinder.............................................................................. 626 31200277_Machine Systems Disassembly-Assembly......................................................... 632 Table of Contents................................................................................. 4 Disassembly and Assembly Section.................................................................. 636 Hydraulic System Pressure - Release........................................................... 168 Release Procedure......................................................................... 636 Bottom Guard - Remove and Install............................................................. 636 Removal Procedure......................................................................... 636 Installation Procedure.................................................................... 637 Hydraulic Tank - Remove....................................................................... 637 Removal Procedure......................................................................... 637 Hydraulic Tank - Install...................................................................... 639 Installation Procedure.................................................................... 639 Piston Pump (Implement and Steering) - Remove................................................. 640 Removal Procedure......................................................................... 640 Piston Pump (Implement and Steering) - Disassemble............................................ 641 Disassembly Procedure..................................................................... 641 Piston Pump (Implement and Steering) - Assemble............................................... 646 Assembly Procedure........................................................................ 531 Piston Pump (Implement and Steering) - Install................................................ 651 Installation Procedure.................................................................... 651 Main Control Valve (Implement) - Remove....................................................... 652 Removal Procedure......................................................................... 652 Electronic Pilot Valve - Remove and Install................................................... 655 Removal Procedure......................................................................... 655 Installation Procedure.................................................................... 656 Bank Valve (Implement) - Disassemble.......................................................... 657 Disassembly Procedure..................................................................... 657 Bank Valve (Implement) - Assemble............................................................. 345 Assembly Procedure........................................................................ 664 Main Control Valve (Implement) - Install...................................................... 670 Installation Procedure.................................................................... 670 Tilt Cylinder - Remove and Install............................................................ 672 Removal Procedure......................................................................... 672 Installation Procedure.................................................................... 674 Control Valve (Compensating Cylinder) - Remove and Install.................................... 675 Removal Procedure......................................................................... 675 Installation Procedure.................................................................... 676 Compensating Cylinder Remove and Install...................................................... 677 Removal Procedure......................................................................... 677 Installation Procedure.................................................................... 679 Load Control Valve (Telescoping Cylinder) Remove and Install.................................. 681 Removal Procedure......................................................................... 681 Installation Procedure.................................................................... 683 Telescoping Cylinder - Remove and Install..................................................... 685 Removal Procedure......................................................................... 685 Installation Procedure.................................................................... 689 Diverter Valve (Boom Head) - Remove and Install............................................... 693 Removal Procedure......................................................................... 693 Installation Procedure.................................................................... 694 Load Control Valve (Boom Cylinder) - Remove and Install....................................... 30 Removal Procedure......................................................................... 695 Installation Procedure.................................................................... 696 Boom Cylinder - Remove and Install............................................................ 698 Removal Procedure......................................................................... 698 Installation Procedure.................................................................... 701 Coupler Cylinder - Remove and Install......................................................... 703 Removal Procedure......................................................................... 703 Installation Procedure.................................................................... 705 Quick Coupler (Hydraulic) - Remove and Install................................................ 707 Removal Procedure......................................................................... 707 Installation Procedure.................................................................... 709 Work Tool Linkage - Remove and Install........................................................ 710 Removal Procedure......................................................................... 710 Installation Procedure.................................................................... 711 Boom - Remove................................................................................. 712 Removal Procedure......................................................................... 712 Boom - Disassemble............................................................................ 716 Disassembly Procedure..................................................................... 716 Boom -Assemble................................................................................ 721 Assembly Procedure........................................................................ 721 Boom - Install................................................................................ 725 Installation Procedure.................................................................... 725 Hydraulic Oil Cooler (Transmission and Hydraulic System) - Remove and Install................. 728 Removal Procedure......................................................................... 728 Installation Procedure.................................................................... 729 Transmission Oil Cooler................................................................... 730 Hitch Cylinder - Remove and Install........................................................... 730 Removal Procedure......................................................................... 730 Installation Procedure.................................................................... 731 Towing Hitch (Hydraulic) - Remove and Install................................................. 732 Removal Procedure......................................................................... 732 Installation Procedure.................................................................... 733 Control Valve (Trailer and Towing Hitch) - Remove............................................. 734 Removal Procedure......................................................................... 734 Control Valve (Trailer and Towing Hitch) - Disassemble........................................ 735 Disassembly Procedure..................................................................... 735 Control Valve (Trailer and Towing Hitch) - Assemble........................................... 738 Assembly Procedure........................................................................ 738 Control Valve (Trailer and Towing Hitch) - Install............................................ 741 Installation Procedure.................................................................... 741 Fuel Tank - Remove............................................................................ 742 Removal Procedure......................................................................... 742 Fuel Tank - Install........................................................................... 743 Installation Procedure.................................................................... 743 Steering Wheel - Remove and Install........................................................... 745 Removal Procedure......................................................................... 745 Installation Procedure.................................................................... 746 Steering Column - Remove...................................................................... 746 Removal Procedure......................................................................... 746 Steering Column - Install..................................................................... 749 Installation Procedure.................................................................... 749 Solenoid Valve (Steering Mode Selector) - Remove and Install.................................. 752 Removal Procedure......................................................................... 752 Installation Procedure.................................................................... 753 Metering Pump (Steering) - Remove............................................................. 754 Removal Procedure......................................................................... 754 Metering Pump (Steering) - Install............................................................ 757 Installation Procedure.................................................................... 757 Window Wiper and Wiper Motor (Front) - Remove and Install..................................... 759 Removal Procedure......................................................................... 759 Installation Procedure.................................................................... 760 Window Wiper and Wiper Motor (Rear) - Remove and Install...................................... 761 Removal Procedure......................................................................... 761 Installation Procedure.................................................................... 762 Window Wiper and Wiper Motor (Roof) - Remove and Install...................................... 764 Removal Procedure......................................................................... 764 Installation procedure.................................................................... 765 Joystick Control - Remove and Install......................................................... 766 Removal Procedure......................................................................... 766 Installation Procedure.................................................................... 767 Seat - Remove and Install..................................................................... 767 Removal Procedure......................................................................... 767 Installation Procedure.................................................................... 768 Cab Heater - Remove........................................................................... 769 Removal Procedure......................................................................... 769 Cab Heater - Install.......................................................................... 771 Installation Procedure.................................................................... 771 Heater Core - Remove and Install.............................................................. 774 Removal Procedure......................................................................... 774 Installation Procedure.................................................................... 774 Air Conditioner - Remove...................................................................... 775 Removal Procedure......................................................................... 775 Air Conditioner - Install..................................................................... 780 Installation Procedure.................................................................... 780 Evaporator Coil - Remove and Install.......................................................... 786 Removal Procedure......................................................................... 786 Installation procedure.................................................................... 786 Blower Motor (Air Conditioner and Heater) - Remove and Install................................ 787 Removal Procedure......................................................................... 787 Installation procedure.................................................................... 790 Cab - Remove.................................................................................. 793 Removal Procedure......................................................................... 793 Cab - Install................................................................................. 799 Installation Procedure.................................................................... 799 Fender - Remove and Install................................................................... 804 Removal Procedure......................................................................... 804 Installation Procedure.................................................................... 804 ELECTRICAL SYSTEMS........................................................................................ 810 31200278_Electrical System Schematic.................................................................. 810 31200279_Electronic Control System, Hydrostatic Transmission Troubleshooting Test-Adjust.............. 814 Table of Contents................................................................................. 816 Introduction...................................................................................... 820 General Information........................................................................... 820 Service Tools................................................................................. 820 Connector Locations........................................................................... 821 Connector Contact Numbers................................................................. 821 Diagnostic Capabilities....................................................................... 822 Monitoring System/Instrument Cluster...................................................... 822 The Caterpillar Electronic Technician (ET)................................................ 823 Logged Event Codes........................................................................ 824 Status Groups For The Electronic Technician............................................... 825 Machine Preparation for Troubleshooting....................................................... 825 General Troubleshooting Information........................................................... 826 Visual Inspection............................................................................. 826 Operational Checks............................................................................ 826 Operational Checks (Braking System)....................................................... 826 Operational Checks (Steering System)...................................................... 827 Operational Checks (Power Train).......................................................... 827 Operational Checks (Hydraulic System)..................................................... 827 Event Code List............................................................................... 829 Warning Levels............................................................................ 829 Indications and System Response........................................................... 829 Troubleshooting........................................................................... 830 Telehandler Event Code List............................................................... 830 Symptom Procedures................................................................................ 832 Steering System............................................................................... 832 Troubleshooting The Steering System....................................................... 832 Brake System.................................................................................. 833 Troubleshooting The Brake System.......................................................... 833 Troubleshooting The Parking Brake......................................................... 834 Transmission.................................................................................. 834 Troubleshooting The Transmission System................................................... 834 Hydraulic System.............................................................................. 836 Troubleshooting The Hydraulic System...................................................... 836 Torque Converter.............................................................................. 838 Troubleshooting The Torque Converter...................................................... 838 Differential and Final Drive.................................................................. 839 The Differential And The Final Drive Troubleshooting...................................... 839 Diagnostic Code Procedures........................................................................ 842 Diagnostic Code List.......................................................................... 842 Module Identifier (MID)................................................................... 842 Component Identifier (CID)................................................................ 842 Failure Mode Identifier (FMI)............................................................. 844 Using the Operator Monitor to Determine Diagnostic Codes...................................... 846 Using Caterpillar Electronic Technician to Determine Diagnostic Codes......................... 846 Active Diagnostic Codes................................................................... 847 Logged Diagnostic Codes................................................................... 848 MID 039 - CID 0041 - FMI 03................................................................... 849 MID 039 - CID 0041 - FMI 04................................................................... 850 MID 039 - CID 0070 - FMI 03................................................................... 851 MID 039 - CID 0070 - FMI 04................................................................... 853 MID 039 - CID 0096 - FMI 03................................................................... 854 MID 039 - CID 0096 - FMI 04................................................................... 855 MID 039 - CID0 110 - FMI 03................................................................... 856 MID 039 - CID 0110 - FMI 04................................................................... 857 MID 039 - CID 0177 - FMI 03................................................................... 858 MID 039 - CID 0177 - FMI 04................................................................... 860 MID 039 - CID 0191 - FMI 02................................................................... 860 MID 039 - CID 0246 - FMI 12................................................................... 862 MID 039 - CID 0262 - FMI 03................................................................... 863 MID 039 - CID 0262 - FMI 04................................................................... 864 MID 039 - CID 0271 - FMI 03................................................................... 865 MID 039 - CID 0271 - FMI 04................................................................... 866 MID 039 - CID 0271 - FMI 05................................................................... 867 MID 039 - CID 0368 - FMI 03................................................................... 869 MID 039 - CID 0368 - FMI 04................................................................... 870 MID 039 - CID 0444 - FMI 03................................................................... 871 MID 039 - CID 0444 - FMI 04................................................................... 872 MID 039 - CID 0444 - FMI 05................................................................... 873 MID 039 - CID 0489 - FMI 02................................................................... 875 MID 039 - CID 0489 - FMI 04................................................................... 877 MID 039 - CID 0490 - FMI 02................................................................... 879 MID 039 - CID 0590 - FMI 02................................................................... 882 MID 039 - CID 0590 - FMI 09................................................................... 884 MID 039 - CID 0590 - FMI 12................................................................... 886 MID 039 - CID 0629 - FMI 04................................................................... 888 MID 039 - CID 0668 - FMI 02................................................................... 889 MID 039 - CID 0668 - FMI 09................................................................... 891 MID 039 - CID 0668 - FMI 12................................................................... 893 MID 039 - CID 0672 - FMI 02................................................................... 895 MID 039 - CID 0702 - FMI 02................................................................... 896 MID 039 - CID 0750 - FMI 02................................................................... 899 MID 039 - CID 0811 - FMI 09................................................................... 900 MID 039 - CID 0817 - FMI 04................................................................... 902 MID 039 - CID 0826 - FMI 03................................................................... 903 MID 039 - CID 0882 - FMI 05................................................................... 905 MID 039 - CID 0882 - FMI 06................................................................... 906 MID 039 - CID 1127 - FMI 00................................................................... 907 MID 039 - CID 1127 - FMI 01................................................................... 910 MID 039 - CID 1127 - FMI 02................................................................... 913 MID 039 - CID 1127 - FMI 08................................................................... 915 MID 039 - CID 1128 - FMI 00................................................................... 918 MID 039 - CID 1128 - FMI 01................................................................... 921 MID 039 - CID 1128 - FMI 02................................................................... 924 MID 039 - CID 1128 - FMI 08................................................................... 927 MID 039 - CID 1138 - FMI 05................................................................... 930 MID 039 - CID 1138 - FMI 06................................................................... 932 MID 039 - CID 1187 - FMI 04................................................................... 933 MID 039 - CID 1189 - FMI 00................................................................... 934 MID 039 - CID 1189 - FMI 01................................................................... 937 MID 039 - CID 1189 - FMI 02................................................................... 939 MID 039 - CID 1189 - FMI 08................................................................... 942 MID 039 - CID 1193 - FMI 05................................................................... 945 MID 039 - CID 1193 - FMI 06................................................................... 947 MID 039 - CID 1251 - FMI 08................................................................... 948 MID 039 - CID 1326 - FMI 02................................................................... 949 MID 039 - CID 1401 - FMI 03................................................................... 950 MID 039 - CID 1401 - FMI 05................................................................... 951 MID 039 - CID 1401 - FMI 06................................................................... 952 MID 039 - CID 1402 - FMI 03................................................................... 953 MID 039 - CID 1402 - FMI 06................................................................... 956 MID 039 - CID 1403 - FMI 03................................................................... 957 MID 039 - CID 1403 - FMI 05................................................................... 958 MID 039 - CID 1403 - FMI 06................................................................... 959 MID 039 - CID 1404 - FMI 03................................................................... 960 MID 039 - CID 1404 - FMI 05................................................................... 961 MID 039 - CID 1404 - FMI 06................................................................... 962 MID 039 - CID 1405 - FMI 03................................................................... 964 MID 039 - CID 1405 - FMI 05................................................................... 965 MID 039 - CID 1405 - FMI 06................................................................... 966 MID 039 - CID 1406 - FMI 03................................................................... 967 MID 039 - CID 1406 - FMI 05................................................................... 968 MID 039 - CID 1406 - FMI 06................................................................... 970 MID 039 - CID 1407 - FMI 03................................................................... 971 MID 039 - CID 1407 - FMI 05................................................................... 972 MID 039 - CID 1407 - FMI 06................................................................... 973 MID 039 - CID 1410 - FMI 05................................................................... 975 MID 039 - CID 1410 - FMI 06................................................................... 977 MID 039 - CID 1482 - FMI 03................................................................... 979 MID 039 - CID 1482 - FMI 04................................................................... 981 MID 039 - CID 1529 - FMI 02................................................................... 982 MID 039 - CID 1603 - FMI 09................................................................... 984 MID 039 - CID 1639 - FMI 02................................................................... 986 MID 039 - CID 1639 - FMI 09................................................................... 988 MID 039 - CID 1658 - FMI 00................................................................... 990 MID 039 - CID 1658 - FMI 01................................................................... 993 MID 039 - CID 1658 - FMI 02................................................................... 996 MID 039 - CID 1658 - FMI 08................................................................... 998 MID 039 - CID 1718 - FMI 02...................................................................1001 MID 039 - CID 1740 - FMI 03...................................................................1003 MID 039 - CID 1740 - FMI 04...................................................................1004 MID 039 - CID 1740 - FMI 05...................................................................1005 MID 039 - CID 1741 - FMI 03...................................................................1007 MID 039 - CID 1741 - FMI 04...................................................................1008 MID 039 - CID 1741 - FMI 05...................................................................1009 MID 039 - CID 1763 - FMI 02...................................................................1011 MID 039 - CID 1788 - FMI 02...................................................................1013 MID 039 - CID 1789 - FMI 02...................................................................1014 MID 039 - CID 1820 - FMI 05...................................................................1016 MID 039 - CID 1820 - FMI 06...................................................................1017 MID 039 - CID 1823 - FMI 03...................................................................1018 MID 039 - CID 1823 - FMI 04...................................................................1020 MID 039 - CID 1823 - FMI 08...................................................................1023 MID 039 - CID 1824 - FMI 03...................................................................1025 MID 039 - CID 1824 - FMI 04...................................................................1027 MID 039 - CID 1824 - FMI 08...................................................................1029 MID 039 - CID 1825 - FMI 03...................................................................1031 MID 039 - CID 1825 - FMI 04...................................................................1033 MID 039 - CID 1825 - FMI 08...................................................................1035 MID 039 - CID 1826 - FMI 00...................................................................1037 MID 039 - CID 1826 - FMI 01...................................................................1039 MID 039 - CID 1826 - FMI 02...................................................................1042 MID 039 - CID 1826 - FMI 08...................................................................1044 MID 039 - CID 1827 - FMI 13...................................................................1045 MID 039 - CID 1828 - FMI 02...................................................................1046 MID 039 - CID 1829 - FMI 02...................................................................1047 MID 039 - CID 1830 - FMI 02...................................................................1049 MID 039 - CID 1831 - FMI 05...................................................................1051 MID 039 - CID 1831 - FMI 06...................................................................1053 MID 039 - CID 1832 - FMI 02...................................................................1054 MID 039 - CID 1833 - FMI 02...................................................................1055 MID 039 - CID 1834 - FMI 03...................................................................1056 MID 039 - CID 1845 - FMI 02...................................................................1058 MID 039 - CID 1845 - FMI 05...................................................................1060 MID 039 - CID 1845 - FMI 06...................................................................1062 MID 039 - CID 1845 - FMI 09...................................................................1064 MID 039 - CID 1846 - FMI 02...................................................................1067 MID 039 - CID 1846 - FMI 05...................................................................1069 MID 039 - CID 1846 - FMI 06...................................................................1071 MID 039 - CID 1846 - FMI 09...................................................................1073 MID 039 - CID 1847 - FMI 02...................................................................1076 MID 039 - CID 1847 - FMI 05...................................................................1078 MID 039 - CID 1847 - FMI 06...................................................................1080 MID 039 - CID 1847 - FMI 09...................................................................1082 MID 039 - CID 1930 - FMI 05...................................................................1085 MID 039 - CID 1930 - FMI 06...................................................................1086 MID 039 - CID 1935 - FMI 03...................................................................1088 MID 039 - CID 1935 - FMI 04...................................................................1090 MID 039 - CID 1960 - FMI 09...................................................................1093 MID 039 - CID 2101 - FMI 08...................................................................1095 MID 039 - CID 2197 - FMI 02...................................................................1097 MID 039 - CID 2240 - FMI 05...................................................................1099 MID 039 - CID 2240 - FMI 06...................................................................1101 MID 039 - CID 2241 - FMI 05...................................................................1102 MID 039 - CID 2241 - FMI 06...................................................................1104 MID 039 - CID 2242 - FMI 05...................................................................1105 MID 039 - CID 2242 - FMI 06...................................................................1107 MID 039 - CID 2243 - FMI 05...................................................................1108 MID 039 - CID 2243 - FMI 06...................................................................1110 MID 039 - CID 2281 - FMI 05...................................................................1111 MID 039 - CID 2281 - FMI 06...................................................................1113 MID 039 - CID 2282 - FMI 05...................................................................1114 MID 039 - CID 2282 - FMI 06...................................................................1115 MID 039 - CID 2287 - FMI 05...................................................................1117 MID 039 - CID 2287 - FMI 06...................................................................1118 MID 039 - CID 2288 - FMI 05...................................................................1120 MID 039 - CID 2288 - FMI 06...................................................................1122 MID 039 - CID 2289 - FMI 05...................................................................1124 MID 039 - CID 2289 - FMI 06...................................................................1126 MID 039 - CID 2290 - FMI 05...................................................................1127 MID 039 - CID 2525 - FMI 03...................................................................1131 MID 039 - CID 2525 - FMI 05...................................................................1132 MID 039 - CID 2525 - FMI 06...................................................................1133 MID 039 - CID 2670 - FMI 03...................................................................1134 MID 039 - CID 2670 - FMI 05...................................................................1135 MID 039 - CID 2670 - FMI 06...................................................................1136 MID 039 - CID 2722 - FMI 02...................................................................1138 MID 082 - CID 0271 - FMI 04...................................................................1140 MID 082 - CID 0271 - FMI 05...................................................................1141 MID 082 - CID 0324 - FMI 03...................................................................1143 MID 082 - CID 0324 - FMI 04...................................................................1144 MID 082 - CID 0324 - FMI 05...................................................................1145 MID 082 - CID 1125 - FMI 03...................................................................1146 MID 082 - CID 1125 - FMI 04...................................................................1148 MID 082 - CID 1125 - FMI 08...................................................................1150 MID 082 - CID 1763 - FMI 02...................................................................1152 MID 082 - CID 1763 - FMI 03...................................................................1154 MID 082 - CID 1763 - FMI 04...................................................................1157 MID 082 - CID 1763 - FMI 05...................................................................1159 MID 082 - CID 1879 - FMI 03...................................................................1162 MID 082 - CID 1879 - FMI 04...................................................................1164 MID 082 - CID 1879 - FMI 08...................................................................1165 MID 117 - CID 0168 - FMI 00...................................................................1167 MID 117 - CID 0168 - FMI 01...................................................................1168 MID 117 - CID 0668 - FMI 12...................................................................1169 Testing and Adjusting Section.....................................................................1172 Testing and Adjusting.........................................................................1172 General Information.......................................................................1172 Electrical Connector - Inspect............................................................1172 Wiring Harness (Open Circuit) -Test.......................................................1176 Wiring Harness (Short Circuit) -Test......................................................1176 Electronic Control Module (ECM) - Flash Program...........................................1177 Electronic Control Module (ECM) - Configure...............................................1177 Electronic Control Module (ECM) - Replace.................................................1183 Connector Contact Description.............................................................1184 Glossary of Electrical Terms..............................................................1186 System Schematic..........................................................................1188 31200280_LSI System Operation & Maintenance...........................................................1202 Table of Contents................................................................................. 4 Systems Operation Section......................................................................... 168 Introduction.................................................................................. 168 General Information...........................................................................1207 Operational Modes.........................................................................1207 Location of Electrical Components.............................................................1207 Electrical Control Module................................................................. 485 Instrument Cluster........................................................................1207 Sensor....................................................................................1208 Electrical Input Components...................................................................1208 Sensor....................................................................................1208 Electronic Control Module.....................................................................1208 Electrical Output Components..................................................................1208 Testing and Adjusting Section.....................................................................1210 Testing and Adjusting Sensor - Test...........................................................1210 Test On The Vehicle.......................................................................1210 Removal And Installation of the Sensor for the Longitudinal Stability Indicator System.... 539 General Instructions......................................................................1211 Removal Instructions......................................................................1211 Surface Preparation.......................................................................1211 Application of the Adhesive...............................................................1211 Sensor Installation.......................................................................1211 Coverage of the Mounting Pads.............................................................1212 Calibration of the Sensor.................................................................1212 Electrical Information....................................................................1212 Display Module - Replace......................................................................1212 Calibration...................................................................................1213 Longitudinal Stability Indicator (LSI) Calibration........................................1213 31200281_Monitor System Test-Adjust...................................................................1224 Table of Contents................................................................................. 4 Systems Operation Section......................................................................... 168 Introduction.................................................................................. 168 Operation.................................................................................1228 Power Up..................................................................................1228 Power Down................................................................................1228 Diagnostics...............................................................................1228 Failure Modes.............................................................................1228 Software.................................................................................. 636 Features......................................................................................1228 Instrument Cluster........................................................................1228 Status Indicators.........................................................................1229 Gauge Indicators.......................................................................... 518 Location of Electrical Components.............................................................1231 Instrument Cluster........................................................................1231 Electronic Control Module.................................................................1231 Turn Signal...............................................................................1231 High Beam Switch..........................................................................1232 Starting Aid Switch.......................................................................1232 Hydraulic Oil Filter Bypass Pressure Switch...............................................1232 Engine Oil Pressure Switch................................................................ 320 Air Filter Restriction Indicator..........................................................1233 Fuel Level Sensor.........................................................................1233 Transmission Oil Temperature Sensor.......................................................1233 Engine Speed Sensor.......................................................................1233 Engine Coolant Temperature Sensor.........................................................1234 Component Description.........................................................................1235 Switches..................................................................................1235 Sensors...................................................................................1236 Additional Circuits.......................................................................1236 Data Link.................................................................................1236 CAT Data Link.............................................................................1236 CAN Data Link.............................................................................1237 Warning Operation.............................................................................1237 Diagnostic Operation..........................................................................1237 Troubleshooting Procedures................................................................1237 Module Identifier (MID)...................................................................1238 Component Identifier (CID)................................................................1238 Failure Mode Identifier (FMI).............................................................1238 Testing and Adjusting Section.....................................................................1240 Testing and Adjusting.........................................................................1240 Self Test.....................................................................................1240 Self Test.................................................................................1240 Module - Replace.............................................................................. 490 Connector Contact Description.................................................................1241 System Schematic..............................................................................1242
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