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DRIVETRAIN TESTS, INSPECTIONS, AND ADJUSTMENTS
Figure 1. Bracket and Hose.
Figure 2. Bracket, Hose, and Wiring Harness.
Figure 4. Cover Clamp.
Figure 6. Quick Disconnect.
Figure 7. 580 psi Hydraulic Gauge and Pipe Coupling.
Figure 8. Hose Coupling and Pipe Coupling.
Figure 10. Fitting and Dust Cap.
Figure 12. Adjustment Screw.
Figure 13. Test Port Pressure.
Figure 15. Fitting and Dust Cap.
Figure 16. Transmission Test Cover Set Up.
Figure 17. Transmission Test Cover.
Figure 18. Two 580 psi Hydraulic Gauges and Hoses.
Figure 19. Neutral.
Figure 20. First Gear Forward.
Figure 21. Three 580 psi Hydraulic Gauges and Hoses.
Figure 22. Three 580 psi Hydraulic Gauges and Hoses.
Figure 23. Second Gear Forward.
Figure 24. First Gear Reverse.
Figure 26. Transmission Test Cover.
Figure 27. Cover Clamp.
Figure 29. Bracket, Hose, and Wiring Harness.
Figure 30. Bracket and Hose.
PARKING BRAKE TEST
FILL TIME FOR THE TRANSMISSION CLUTCH CALIBRATED
Figure 31. Test Ports.
FILL TIME FOR THE TRANSMISSION CLUTCH CALIBRATED CONTINUED
Figure 32. Calibrations Screen.
Figure 33. Next Button.
Figure 34. Calibration Initializing.
Figure 35. Calibrating Clutch #8.
Figure 36. Calibrating Clutch #7.
Figure 37. Calibrating Clutch #6.
Figure 38. Calibrating Clutch #5.
Figure 39. Calibrating Clutch #4.
Figure 40. Calibrating Clutch #3.
Figure 41. Calibrating Clutch #2.
Figure 42. Calibrating Clutch #1.
Figure 43. Calibration Successful.
Figure 44. Calibration Unsuccessful.
Figure 45. Differential Lock Test Port.
Figure 47. Quick Disconnect.
Figure 48. 580 PSI Hydraulic Gauge and Pipe Coupling.
Figure 49. Hose Coupling and Pipe Coupling.
Figure 51. Hose and Test Port.
Figure 52. Differential Lock Test Port.
Figure 53. Wheel Lean Lock Bolt.
Figure 54. Lift Front Wheels.
Figure 55. Main Menu Display.
Figure 57. All-Wheel Drive Display.
Figure 59. Positive RPM Display.
Figure 61. Lift Front Wheels.
Figure 63. Right Side Panel.
Figure 65. Quick Disconnect.
Figure 66. 580 PSI Hydraulic Gauge and Pipe Coupling.
Figure 68. Hose Coupling and Quick Disconnect.
Figure 69. Pump Test Ports.
Figure 70. Wheel Lean Lock Bolt.
Table 1. AWD Charge Pressure.
Figure 72. Lift Front Wheels.
Figure 73. Wheel Lean Lock Bolt.
Figure 74. Front Cover.
Figure 75. Tube Tee.
Figure 77. Quick Disconnect.
Figure 79. Hose Coupling and Pipe Coupling.
Figure 81. Left Manifold.
Figure 83. Left Manifold Line.
Figure 85. All-Wheel Drive Display.
Figure 86. Diagnostics Display.
Figure 87. 100 Percent Override Display.
Figure 88. 45 Percent Override Display.
Figure 89. Pressure at Test Port (Left).
Figure 90. 45 Percent Override Display.
Figure 91. Diagnostic Display.
Figure 92. 100 Percent Override Display.
Figure 93. Pressure at Test Port (Left).
Figure 94. Hose.
Figure 95. Left Manifold Line.
Figure 97. Left Manifold.
Figure 98. Front Cover.
Figure 99. Right Side Panel.
Figure 100. Hose.
Figure 102. 580 PSI Hydraulic Gauge and Pipe Coupling.
Figure 103. Hose Coupling and Pipe Coupling.
Figure 105. Left Reverse and Forward Test Ports.
Figure 106. Pressure Test Hoses.
Figure 108. Right Reverse and Forward Test Ports.
Figure 109. Hoses and Gauges.
Figure 110. All-Wheel Drive Display.
Figure 111. Diagnostics Display.
Figure 112. Zero Percent Override Display.
Figure 113. 32.5 Percent Display.
Figure 114. Test Port Pressure.
Figure 115. 42.5 Percent Display.
Figure 116. Test Port Pressure.
Figure 117. 82.5 Percent Display.
Figure 118. Test Port Pressure.
Figure 119. 93.5 Percent Display.
Figure 120. Test Port Pressure.
Figure 121. 100 Percent Display.
Figure 122. Test Port Pressure.
Figure 123. Zero Display (New Value).
Figure 124. Zero Percent Override Display.
Figure 125. 32.5 Percent Display.
Figure 126. Test Port Pressure.
Figure 127. 42.5 Percent Display.
Figure 128. 82.5 Percent Display.
Figure 129. Test Port Pressure.
Figure 130. 93.5 Percent Display.
Figure 131. Test Port Pressure.
Figure 132. 100 Percent Display.
Figure 133. Test Port Pressure.
Figure 134. Zero Display (New Value).
Figure 135. Pressure Test Hoses.
Figure 136. Left Reverse and Forward Test Ports.
Figure 137. Right Reverse and Forward Test Ports.
CHASSIS TESTS, INSPECTIONS, AND ADJUSTMENTS
Hydraulic System Pressure Test Hose and Gauge
Figure 1. Fan Guard.
Figure 2. Inlet Line.
Figure 4. Hose.
Figure 6. Hydraulic Gauge and Pipe Coupling.
Figure 8. Hose Coupling and Quick Disconnect.
Figure 10. Hose and Pressure Gauge Assembly.
Figure 11. Cooling Fan and Brake Pump Adjustment.
Figure 12. Hose and Pressure Gauge Assembly.
Figure 14. Plug and Cap.
Figure 16. Fan Guard.
Figure 17. Clamp and Lines.
Figure 18. Tube Tee.
Figure 20. Quick Disconnect.
Figure 22. Brake Manifold Test Port.
Figure 24. Differential Gauge.
Figure 25. Diagnostic Tests Display.
Figure 26. Engine Display.
Figure 27. Differential Pressure Gauge.
Figure 28. Margin Pressure Adjustment.
Figure 29. Differential Gauge.
Figure 31. Brake Manifold Test Port.
Figure 33. Clamp and Lines.
Figure 34. Hose.
Figure 35. Quick Disconnect.
Figure 36. Hose Coupling and Pipe Coupling.
Figure 37. Hose Coupling and Quick Disconnect.
Figure 39. Clamp.
Figure 41. Test Hoses and Tees.
Figure 42. Cut-In Pressure Adjustment.
Figure 43. Cut-Out Pressure Adjustment.
Figure 44. Test Hoses and Tees.
Figure 45. Clamp.
Lowering the Piston in Brake Accumulators
Figure 47. Accumulator.
Figure 49. Nitrogen Charging Kit Assembly.
Figure 50. Accumulator and Valve Assembly.
Figure 51. Valve and Pressure Gauge.
Figure 52. Nitrogen Cylinder and Cap.
Figure 53. Regulator and Nitrogen Bottle.
Figure 55. Nitrogen Bottle Venting.
Figure 57. Right Accumulator and Valve.
Figure 59. Regulator and Nitrogen Bottle.
Figure 61. Nitrogen Bottle Venting.
Figure 62. Right Accumulator and Valve.
Figure 64. Nitrogen Charge Group.
Figure 65. Cap.
Figure 66. Service Brake.
Figure 67. Air Purge Screw and Drain Hose.
Figure 68. Service Brake.
Figure 69. Hose.
Figure 70. Quick Disconnect.
Figure 71. 1,450 PSI Pressure Gauge.
Figure 74. Hose Coupling and Test Port.
Figure 75. Test Hose.
Figure 76. Hose Coupling and Test Port.
SERVICE BRAKES TEST
Figure 78. Compensator.
Figure 79. Hose.
Figure 80. Quick Disconnect.
Figure 81. 1450 PSI Pressure Gauge.
Figure 83. Hose Coupling and O-ring.
Figure 85. Test Hose.
Figure 87. Left Service Brake Test Port.
Figure 88. Hose.
Figure 90. Dust Cover and Test Port.
Figure 92. Differential Pressure Gauge (High Side).
Figure 94. Test Hose and Low Side Port.
Figure 96. Adjustment Locknut and Screw.
Figure 97. Test Hose and Low Side Port.
Figure 99. Test Hose and High Side Port.
Figure 101. Hose.
Figure 103. Dust Cover and Test Port.
Figure 104. Test Hose and High Side Port.
Figure 106. Pressure Gauge Assembly and Hose.
Figure 107. Dust Cover.
Figure 109. Pressure Gauge.
Figure 110. Test Ports.
Figure 111. Signal Adjustments.
Figure 113. Dust Cover.
Figure 115. Test Port.
Figure 116. Hose.
Figure 118. Pressure Gauge Assembly.
Figure 120. Dust Cover and Test Port.
Figure 122. Pressure Gauge.
Figure 124. Test Hose and High Side Port.
Figure 126. Mark Cylinder Position.
MAGNETIC SWITCH (SECONDARY STEERING RELAY) TEST
Figure 127. Hose.
Figure 129. Pressure Gauge Assembly.
Figure 131. Tee Body Assembly.
Figure 133. Secondary Steering Pump.
Figure 134. Tee Body Assembly.
CONTROL MANIFOLD (STEERING BACKUP) TEST
Figure 136. Vehicle Support Stands.
Figure 138. Measure Distance.
CAB TESTS AND ADJUSTMENTS
REFRIGERANT RECOVERY MACHINE CONNECT
Figure 1. Air Conditioner Pressure Ports.
A/C SYSTEM PERFORMANCE TEST
Table 1. Pressure Range Table.
Figure 2. Air Conditioner Pressure Ports.
CHAPTER 3. PMCS MAINTENANCE INSTRUCTIONS
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL PMCS PROCEDURES
GENERAL PMCS PROCEDURES - Continued
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 1. Preventive Maintenance Checks and Services (PMCS).
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Figure 1. Conditioner Cover.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
GENERAL LUBRICATION INSTRUCTIONS
GENERAL LUBRICATION INSTRUCTIONS CONTINUED
Table 3. 120M Motor Grader PMCS Mandatory Replacement Parts List.
CHAPTER 4. MAINTENANCE INSTRUCTIONS
SERVICE UPON RECEIPT
SERVICING INSTRUCTIONS
COOLING MODULE REPAIR
Figure 1. Coolant Tube Band.
Figure 3. A/C Condenser Core Hoses.
Figure 5. Left-Side Hydraulic Hose to Cooler.
Figure 6. Hydraulic Fan Motor Hoses.
Figure 7. Drain Line Clamps and Electrical Connector.
Figure 8. Aftercooler Core Hose.
Figure 10. Hydraulic Hose Clamp.
Figure 12. Lifting Brackets.
Figure 13. Cooling Module Bolts.
Figure 14. A/C Condenser Core.
Figure 16. Cooling Fan Assembly.
Figure 17. Fan Guard.
Figure 18. Backup Alarm.
Figure 20. Top Radiator Support.
Figure 21. Aftercooler Core.
Figure 22. Top Radiator Bracket.
Figure 24. Side Brackets.
Figure 25. Seal Brackets.
Figure 27. Bottom Plate.
Figure 28. Bottom Plate.
Figure 30. Side Brackets.
Figure 31. Top Radiator Bracket.
Figure 32. Bottom Radiator Support Bolts.
Figure 33. Aftercooler Core.
Figure 34. Top Radiator Support.
Figure 35. Radiator Mounting Bracket.
Figure 37. Fan Guard.
Figure 38. Cooling Fan Assembly.
Figure 40. A/C Condenser Core.
Figure 41. Lifting Bracket.
Figure 42. Cooling Module Bolts.
Figure 43. Bottom Frame Support.
Figure 45. Lower Radiator Hose.
Figure 47. Drain Line Clamps and Electrical Connector.
Figure 48. Hydraulic Fan Motor Hoses.
Figure 49. Left-Side Hydraulic Hose to Cooler.
Figure 50. Right-Side Hydraulic Hose to Cooler.
Figure 52. Coolant and Aftercooler Hoses.
FOLLOW-ON TASKS
RADIATOR CORE REPLACEMENT
Figure 1. Fan Guard and Radiator Mounting Bracket.
Figure 2. Mounting Brackets and Upper Radiator Support.
Figure 3. Coolant Tube Retaining Band.
Figure 5. Lower Radiator Hose.
Figure 7. Cooling Module.
Figure 8. Cooling Fan Assembly.
Figure 9. Radiator.
Figure 10. Upper and Lower Radiator Brackets.
Figure 11. Upper and Lower Radiator Brackets.
Figure 12. Radiator.
Figure 13. Cooling Fan Assembly.
Figure 14. Cooling Module.
Figure 15. Lower Radiator Support.
Figure 17. Upper Coolant Hose.
Figure 19. Mounting Brackets.
Figure 20. Fan Guard.
AFTERCOOLER CORE REPLACEMENT
Figure 1. Fan Guard.
Figure 2. Upper Radiator Bracket.
Figure 4. Lower Aftercooler Hose.
REMOVAL CONTINUED
Figure 6. Lower Aftercooler Core and Resilient Mounts.
Figure 7. Lower Aftercooler Hose.
Figure 9. Upper Radiator Bracket.
Figure 10. Fan Guard.
ENGINE COOLANT SERVICE
Figure 2. Cooling System Pressure Cap.
Figure 3. Coolant Drain Valves.
Figure 4. Coolant Level.
Figure 6. Cooling System Access Cover.
Figure 7. Cooling System Pressure Cap.
Figure 8. Pressure Cap.
COOLANT TANK AND BRACKET REPLACEMENT
Figure 1. Inlet Hose.
Figure 2. Coolant Tank and Bracket.
INSTALLATION
Figure 3. Coolant Tank and Bracket.
Figure 4. Inlet Hose.
COOLANT LINES AND SHUT-OFF VALVE (RADIATOR) REPLACEMENT
Figure 1. Coolant Tube Retaining Band.
Figure 2. Coolant Hose.
Figure 4. Coolant Tube Hose.
Figure 6. Coolant Hoses at Transmission Oil Cooler.
Figure 8. Coolant Hose at Water Pump.
Figure 9. Coolant Drain Valves.
Figure 10. Coolant Valve.
Figure 11. Coolant Drain Valves.
Figure 12. Coolant Hose at Water Pump.
Figure 14. Coolant Hoses at Transmission Oil Cooler.
Figure 16. Coolant Tube Hose.
Figure 18. Coolant Hose.
Figure 19. Coolant Tube Retaining Band.
HYDRAULIC OIL COOLER CORE REPLACEMENT
Figure 1. Right-Side Hydraulic Hose.
Figure 2. Left-Side Hydraulic Hose.
Figure 3. Hydraulic Oil Cooler Core.
Figure 4. Hydraulic Oil Cooler Core.
CLEANING AND INSPECTION
Figure 5. Hydraulic Oil Cooler Core.
Figure 6. Hydraulic Oil Cooler Core.
Figure 7. Left-Side Hydraulic Hose.
Figure 8. Right-Side Hydraulic Hose.
HYDRAULIC OIL COOLER LINES REPLACEMENT
REMOVAL
Figure 1. Hydraulic Oil Cooler.
Figure 2. Manifold.
Figure 3. AWD Bypass Valve.
Figure 4. AWD Bypass Valve.
Figure 5. Manifold.
Figure 6. Hydraulic Oil Cooler.
FOLLOW-ON TASKS
COOLING FAN GEAR MOTOR REPAIR
Figure 1. Fan Guard.
Figure 2. Fan and Fan Gear Motor Assembly.
Figure 4. Fan Gear Motor and Bracket.
Figure 5. Fan Adapter.
Figure 6. Fittings.
Figure 7. Fan Gear Motor and Bracket.
Figure 9. Engine Cooling Fan.
INSTALLATION CONTINUED
Figure 10. Fan and Gear Motor Assembly.
Figure 11. Fan Guard.
COOLING FAN WIRING HARNESS REPLACEMENT
Figure 2. Connector.
Figure 3. Fan Wiring.
Figure 4. Fan Wiring.
Figure 5. Connector.
HYDRAULIC OIL TEMPERATURE SENSOR REPLACEMENT
Figure 2. Temperature Sensor.
Figure 3. Fan Guard.
COOLING FAN AND BRAKE PISTON PUMP REPLACEMENT
Figure 1. Cooling Fan and Brake Piston Pump Tube Clamp.
Figure 2. Cooling Fan and Brake Piston Pump Tube and Hose.
Figure 3. Cooling Fan and Brake Piston Pump.
INSTALLATION
Figure 4. Cooling Fan and Brake Piston Pump Tube and Hose.
Figure 5. Cooling Fan and Brake Piston Pump Tube Clamp.
COOLING FAN AND BRAKE PISTON PUMP LINES REPLACEMENT
REMOVAL
Figure 1. Cold Start Hoses and Tubes.
Figure 2. Cooling Fan and Brake Piston Pump Hose Clamps.
Figure 3. Cooling Fan and Brake Piston Pump.
Figure 4. Steering and Implement Pump Tube.
Figure 5. Control Manifold Tube and Hoses.
Figure 6. Hose and Tube Connection.
Figure 7. Control Manifold Tube and Hose.
Figure 8. Steering and Implement Pump Tube.
Figure 9. Cooling Fan and Brake Piston Pump.
Figure 10. Cooling Fan and Brake Piston Pump Hose Clamps.
Figure 11. Cold Start Hose and Tube.
A/C CONDENSER CORE REPLACEMENT
Figure 1. A/C Condenser and Lines.
CLEANING AND INSPECTION
MUFFLER AND BRACKET REPLACEMENT
Figure 1. Muffler and Exhaust Pipe.
Figure 2. Engine Bracket.
Figure 3. Mounting Brackets.
Figure 4. Engine Lifting and Mounting Brackets.
Figure 5. Engine Bracket.
Figure 6. Mounting Brackets.
Figure 7. Muffler and Exhaust Pipe.
FUEL WIRING HARNESS REPLACEMENT
Figure 1. FE Harness: Priming Pump and Fuel Pump Relay Plugs.
Figure 2. FE Harness: Turbocharger Inlet and Ether Aid Plugs.
Figure 3. FE Harness: Priming Pump and Fuel Pump Relay Plugs.
STARTER WIRING HARNESS REPLACEMENT
Figure 1. Left Side Starter Harness Clamps.
Figure 2. Starter Harness Clips and Clamps.
Figure 3. Right Side Starter Wiring Harness Removal.
Figure 4. Starter Wiring Harness Clamps.
Figure 5. Right Side Starter Wiring Harness Installation.
Figure 6. Starter Harness Clips and Clamps.
Figure 7. Left Side Starter Harness Clamps.
ALTERNATOR CABLES AND STARTER NEGATIVE CABLE REPLACEMENT
Figure 1. Alternator Cable.
Figure 3. Negative Alternator Cable.
Figure 4. Right Side Cable Clamps and Clips.
Figure 5. Left Side Cable Clamps.
Figure 6. Positive Alternator Cable.
Figure 7. Cable.
Figure 8. Cable.
Figure 10. Left Side Cable Clamps.
Figure 11. Right Side Cable Clamps and Clips.
Figure 12. Negative Alternator Cable.
Figure 13. Cable Clamps.
Figure 14. Alternator Cable.
ENGINE ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT
Figure 1. Fuel Filter.
Figure 2. ECM Wiring.
Figure 3. ECM.
Figure 4. ECM Mounting Bracket Top Bolts.
Figure 5. Fuel Rail Bracket.
Figure 6. Fuel Return Hose.
Figure 7. Wiring Harness.
Figure 8. ECM Mounting Bracket.
DISASSEMBLY
Figure 9. ECM.
ASSEMBLY
Figure 10. ECM.
Figure 11. ECM Mounting Bracket.
Figure 12. Wiring Harness.
Figure 13. Fuel Return Hose.
Figure 14. Fuel Rail Bracket.
Figure 15. ECM Mounting Bracket Top Bolts.
Figure 16. ECM.
Figure 17. ECM Wiring.
Figure 18. Fuel Filter.
ENGINE MOUNT REPLACEMENT
Figure 1. Engine Support Bolt.
Figure 2. Engine Support Bolt and Upper Pad.
Figure 3. Engine Support Bracket and Lower Pad.
Figure 4. Engine Support Bolt and Upper Pad.
Figure 5. Engine Support Bolt.
ENGINE ASSEMBLY REPLACEMENT
Figure 1. Aftercooler Hose.
Figure 2. A/C Compressor.
Figure 3. Rear Chassis Harness Connector.
Figure 4. Hydraulic Line Clips.
Figure 6. Heater Hose.
Figure 7. Lower Radiator Hose.
Figure 9. Fuel Supply Lines.
Figure 10. ECM Connection.
Figure 11. Main Rear Wiring Harness Connections.
Figure 12. Fuel Return Line.
Figure 14. Oil Drain Hose.
Figure 16. Gear Group Lubrication Hose.
Figure 17. Engine Lift Brackets.
Figure 18. Transmission Hydraulic Jack.
Figure 20. Left Engine Mount.
Figure 22. Engine on Vehicle Support Stands.
Figure 23. Solenoid Connections.
Figure 24. Starter Motor.
Figure 25. Engine Stand Preparation.
Figure 26. Engine on Engine Stand.
Figure 27. Engine on Engine Stand.
Figure 28. Engine on Vehicle Support Stands.
Figure 29. Engine Stand Recovery.
Figure 30. Starter Motor.
Figure 31. Solenoid Connections.
Figure 32. Engine Lift Brackets.
Figure 33. Right Engine Mount.
Figure 34. Left Engine Mount.
Figure 36. Gear Group Lubrication Hose.
Figure 38. Hydraulic Lines at Flywheel Housing.
Figure 40. Hydraulic Line Clip.
Figure 42. Main Rear Wiring Harness Connections.
Figure 43. ECM Connection.
Figure 44. Fuel Supply Lines.
Figure 45. Heater Hose Clip.
Figure 47. Heater Hose.
Figure 49. Hydraulic Line Clips.
Figure 51. A/C Compressor.
Figure 52. Aftercooler Hose.
FOLLOW-ON TASKS
OIL DRAIN HOSE AND VALVE REPLACEMENT
Figure 1. Engine Oil Drain Hose.
Figure 2. Engine Oil Drain Valve.
Figure 3. Engine Oil Drain Hose.
INLET MANIFOLD REPLACEMENT
Figure 1. Oil Breather Hose.
Figure 2. Inlet Hose.
Figure 3. Sensor.
Figure 4. Inlet Manifold.
Figure 5. Inlet Manifold.
Figure 7. Sensor.
Figure 8. Inlet Hose.
Figure 9. Oil Breather Hose.
FUEL RAIL REPLACEMENT
Figure 1. Harness and Bracket.
Figure 2. Fuel Rail.
Figure 3. Tiedown Straps.
Figure 4. High-Pressure Fuel Supply Line.
Figure 5. High-Pressure Fuel Supply Line Clamps.
Figure 6. High-Pressure Fuel Supply Line.
Figure 7. Tiedown Straps.
Figure 8. Fuel Rail.
Figure 9. Harness and Bracket.
Figure 10. Fuel Filter Water Separator.
SECONDARY FUEL FILTER AND BASE REPLACEMENT
Figure 1. Secondary Fuel Filter.
Figure 2. Base Manifold.
Figure 3. Secondary Fuel Filter.
Figure 4. Water Separator and Primary Fuel Filter.
FUEL INJECTION PUMP REPLACEMENT
FUEL INJECTION PUMP REPLACEMENT - Continued
Figure 1. Fuel Injection Pump Gear.
Figure 2. Fuel Injection Pump Shaft Lock.
Figure 3. Fuel Injection Pump Gear.
Figure 4. Primary Fuel Supply Line.
Figure 5. Fuel Injection Pump Lines/Connectors.
Figure 6. Tiedown Straps.
Figure 7. High-Pressure Fuel Line.
Figure 8. Fuel Injection Pump Lines.
Figure 9. Fuel Injection Pump Support Bracket.
Figure 10. Fuel Injection Pump.
Figure 11. Fuel Injection Pump Gear.
Figure 12. Fuel Injection Pump Shaft Lock.
Figure 14. Camshaft Timing Pin.
Figure 16. Fuel Injection Pump Gear Torque.
Figure 17. Fuel Injection Pump Support Bracket.
Figure 18. Fuel Injection Pump Lines.
Figure 19. High-Pressure Fuel Line.
Figure 21. Fuel Injection Pump Lines/Connectors.
Figure 22. Primary Fuel Supply Line.
Figure 23. Water Separator and Primary Fuel Filter.
FUEL INJECTOR REPLACEMENT
FUEL INJECTOR REPLACEMENT - Continued
Figure 1. Valve Mechanism Cover.
Figure 2. Valve Bridge.
Figure 3. Fuel Injector Fuel Line.
Figure 4. Fuel Injector Electrical Connection.
Figure 5. Fuel Injector.
Figure 6. Fuel Injector Code.
Figure 7. Fuel Injector Seals.
Figure 9. Fuel Injector Fuel Line.
Figure 10. Valve Bridge.
Figure 11. Valve Mechanism Cover.
EXHAUST MANIFOLD REPLACEMENT
Figure 2. Exhaust Manifold and Gaskets.
Figure 3. Torque Sequence.
TURBOCHARGER REPLACEMENT
Figure 1. Oil Inlet Tube.
Figure 2. Exhaust Shield and Elbow.
Figure 3. Exhaust Elbow.
Figure 4. Turbocharger.
CLEANING AND INSPECTION
Figure 5. Turbocharger.
Figure 6. Exhaust Elbow.
Figure 7. Exhaust Shield and Elbow.
AIR INLET HOSES AND TUBES REPLACEMENT
Figure 1. Air Cleaner-to-Turbocharger Hose.
Figure 2. Air Cleaner-to-Muffler Hose.
Figure 3. Crankcase Breather Tube.
Figure 4. Turbocharger Elbow.
Figure 5. Aftercooler Tube Clamps.
Figure 6. Turbocharger-to-Air Cooler Intake Tube.
Figure 7. Aftercooler-to-Engine Tube Hose.
Figure 8. Air Cooler-to-Engine Intake Tube Clamps.
Figure 10. Aftercooler-to-Engine Tube.
Figure 11. Intake Manifold Air Temperature Sensor Number 2.
Figure 12. Air Cooler-to-Engine Intake Tube Clamps.
Figure 14. Turbocharger-to-Air Cooler Intake Tube.
Figure 15. Aftercooler Tube Clamps.
Figure 16. Turbocharger Elbow.
Figure 17. Crankcase Breather Tube.
Figure 18. Air Cleaner-to-Muffler Hose.
Figure 19. Air Cleaner-to-Turbocharger Tube.
WASTE GATE SOLENOID REPLACEMENT
Figure 1. Air Inlet Tube.
Figure 2. Electrical and Vacuum Connectors.
Figure 3. Waste Gate Pressure Line.
Figure 4. Waste Gate Solenoid.
Figure 5. Clamp and Clips.
Figure 6. Electrical and Vacuum Connectors.
Figure 7. Air Inlet Tube.
ENGINE CONTROL WIRING HARNESS REPLACEMENT
Figure 1. Secondary Fuel Filter.
Figure 2. Engine Harness Connectors.
Figure 3. Fuel Injection Pump Connectors.
Figure 4. Cylinder Block Connectors.
Figure 5. Fuel Injection Pump Connectors.
Figure 6. Engine Harness Connectors.
Figure 7. Secondary Fuel Filter.
WATER TEMPERATURE REGULATOR REPLACEMENT
Figure 1. Upper Radiator Hose.
CLEANING AND INSPECTION
WATER PUMP REPLACEMENT
Figure 1. Front Panel Replacement.
Figure 3. Water Pump Replacement.
Figure 4. Water Pump Replacement.
Figure 5. Water Pump Bolt Torque Sequence.
Figure 7. Front Panel Replacement.
DAMPER AND CRANKSHAFT PULLEY REPLACEMENT
Figure 1. Outer Plates.
Figure 3. Pin.
Figure 4. Chain Wrench.
Figure 5. Damper and Crankshaft Pulley.
Figure 6. Damper and Crankshaft Pulley Inspection.
Figure 7. Damper and Crankshaft Pulley.
Figure 8. Chain Wrench.
OIL FILLER ASSEMBLY REPLACEMENT
Figure 1. Oil Filler.
FRONT COVER REPLACEMENT
Figure 1. Front Cover.
FOLLOW-ON TASKS
FRONT OIL SEAL REPLACEMENT
Figure 1. Engine Front Oil Seal.
Figure 2. Engine Front Oil Seal.
FOLLOW-ON TASKS
ENGINE OIL SERVICE
Figure 1. Oil Filler Cap.
Figure 3. Oil Filter.
Figure 4. Oil Level Dipstick.
ENGINE OIL FILTER BASE REPLACEMENT
Figure 1. Engine Oil Filter.
Figure 2. Engine Oil Filter Base.
Figure 3. Engine Oil Filter Base.
Figure 4. Engine Oil Filter.
Figure 5. Oil Level Dipstick.
ENGINE OIL COOLER REPAIR
Figure 1. Engine Oil Cooler.
Figure 2. Engine Oil Cooler.
ASSEMBLY
Figure 3. Engine Oil Cooler.
Figure 4. Engine Oil Cooler.
Figure 5. Torque Sequence.
ENGINE OIL PAN REPLACEMENT
Figure 1. Engine Oil Drain Plug.
Figure 2. Engine Oil Pan.
Figure 3. Engine Oil Pan Torque Sequence.
Figure 4. Engine Oil Pan.
Figure 5. Engine Oil Drain Plug.
ENGINE OIL DIPSTICK TUBE REPLACEMENT
Figure 1. Engine Oil Dipstick.
CLEANING AND INSPECTION
ENGINE OIL PUMP AND SUCTION TUBE REPLACEMENT
Figure 2. Engine Oil Pump.
Figure 3. Idler Gear Backlash.
DRIVE BELT AND TENSIONER REPLACEMENT
Figure 2. Drive Belt Cover.
Figure 3. Drive Belt.
Figure 4. Drive Belt Tensioner.
Figure 5. Drive Belt.
Figure 6. Drive Belt Cover.
Figure 7. Front Panel.
ALTERNATOR REPAIR
Figure 1. Alternator.
Figure 2. Alternator Pulley.
Figure 3. Alternator Component Inspection.
Figure 4. Alternator Pulley.
Figure 5. Alternator.
FOLLOW-ON TASKS
ALTERNATOR MOUNTING BRACKET REPLACEMENT
Figure 1. Right Front Access Panel.
Figure 3. Bracket.
Figure 4. Alternator Mounting Bracket.
Figure 5. Bracket.
Figure 7. Right Front Access Panel.
REFRIGERANT COMPRESSOR REPLACEMENT
Figure 1. A/C Compressor Electrical Connections.
Figure 2. Air Conditioning Compressor Fitting and O-Rings.
Figure 3. Air Conditioning Compressor.
Figure 4. A/C Compressor Fitting and O-Rings.
Figure 5. A/C Compressor Electrical Connections.
REFRIGERANT COMPRESSOR PRESSURE SWITCHES REPLACEMENT
Figure 1. Pressure Switch.
Figure 2. Low Pressure Switch.
Figure 3. Pressure Switch.
REFRIGERANT COMPRESSOR RESISTOR AND SUPPRESSOR REPLACEMENT
Figure 1. Thermostat Pull Resistor.
Figure 2. Arc Suppressor.
FOLLOW-ON TASKS
STARTER MOTOR REPLACEMENT
Figure 1. Air Inlet Tube.
Figure 2. Cable Clamps.
Figure 3. Solenoid Connections.
Figure 4. Hydraulic Hose Bundle Clamp.
Figure 5. Starter Motor.
Figure 6. Hydraulic Hose Bundle Clamps.
Figure 7. Solenoid Connections.
Figure 8. Cable Clamps.
Figure 9. Air Inlet Tube.
TORSIONAL COUPLER, FLYWHEEL, AND REAR GEAR GROUP REPLACEMENT
Figure 1. Torsional Coupler.
Figure 2. Crankshaft Bolts.
Figure 4. Flywheel Guide Bolts.
Figure 5. Lifting Equipment Attached to Flywheel.
Figure 7. Gears.
Figure 8. Drive Gear.
INSTALLATION CONTINUED
Figure 9. Gears.
Figure 10. Guide Bolts.
Figure 11. Flywheel.
Figure 12. Flywheel Guide Bolts.
Figure 13. Crankshaft Bolts.
Figure 14. Flywheel.
Figure 15. Torsional Coupler.
FLYWHEEL HOUSING REPLACEMENT
Figure 1. Right Side Bracket.
Figure 2. Left Side Bracket.
Figure 3. Center Bracket.
Figure 5. Lower Flywheel Housing Bolts.
Figure 6. Flywheel Housing Gasket.
Figure 7. Flywheel Housing Oil Seal.
Figure 8. Flywheel Housing Gasket.
Figure 9. Lower Flywheel Housing Bolts.
Figure 10. Upper Flywheel Housing Bolts.
Figure 12. Left Side Bracket.
Figure 13. Right Side Bracket
REAR OIL SEAL REPLACEMENT
Figure 1. Crankshaft Rear Seal Assembly.
CLEANING AND INSPECTION
Figure 2. Crankshaft Rear Seal Assembly.
VALVE MECHANISM COVER AND BASE, AND FUEL INJECTOR WIRING HARNESS REPLACEMENT
Figure 1. Valve Mechanism Cover.
Figure 2. Fuel Injector Harness Replacement.
Figure 3. Valve Mechanism Cover Base.
Figure 5. Fuel Injector Harness.
Figure 6. Valve Mechanism Cover.
FOLLOW-ON TASKS
ENGINE OIL PRESSURE SENSOR REPLACEMENT
Figure 1. Pressure Sensor.
INSTALLATION
INTAKE MANIFOLD AIR TEMPERATURE SENSOR NUMBER 1 REPLACEMENT
Figure 1. Temperature Sensor.
FOLLOW-ON TASKS
INTAKE MANIFOLD AIR TEMPERATURE SENSOR NUMBER 2 REPLACEMENT
Figure 1. Intake Manifold Air Temperature Sensor Number 2.
INTAKE MANIFOLD PRESSURE SENSOR REPLACEMENT
Figure 1. Pressure Sensor.
INSTALLATION
ENGINE COOLANT TEMPERATURE SENSOR REPLACEMENT
Figure 1. Temperature Sensor.
INSTALLATION
SECONDARY ENGINE SPEED SENSOR REPLACEMENT
Figure 1. Speed Sensor.
INSTALLATION
ENGINE SPEED SENSOR REPLACEMENT
Figure 1. Speed Sensor.
INSTALLATION
FUEL RAIL PRESSURE SENSOR REPLACEMENT
Figure 1. Clamp.
CLEANING AND INSPECTION
TURBOCHARGER INLET AIR PRESSURE SENSOR REPLACEMENT
Figure 1. Pressure Sensor.
Figure 2. Sensor Inspection.
ROCKER ASSEMBLY REPLACEMENT
Figure 1. Rocker Shaft.
INSTALLATION
CYLINDER HEAD ASSEMBLY REPLACEMENT
Figure 1. Hose.
Figure 2. Fuel Injector.
Figure 4. Heater Hoses.
Figure 5. Oil and Waste Gate Pressure Lines.
Figure 7. Cylinder Head Bolts.
Figure 9. Cylinder Head Lifting Device.
Figure 11. Glow Plug Hole Plugs.
Figure 12. Lift Bracket.
Figure 13. Muffler Shield.
Figure 15. Cylinder Head Pipe Fittings.
Figure 16. Cylinder Head Plug.
Figure 18. Lift Bracket.
Figure 19. Coolant Control Valve.
Figure 21. Cylinder Head Lifting Device.
Figure 22. Cylinder Head Bolts.
Figure 24. Bypass Tube.
Figure 25. Heater Hoses.
Figure 26. Oil and Waste Gate Pressure Lines.
Figure 28. Injector Alignment.
Figure 30. Fuel Injector Harness.
Figure 31. Valve Mechanism Cover.
Figure 33. Engine ECM Bracket.
Figure 34. Wiring Harness.
Figure 35. Fuel Return Hose.
Figure 36. ECM.
Figure 37. Connection of Wiring to ECM.
Figure 38. Fuel Filter.
Figure 39. Hose.
AIR CLEANER REPLACEMENT
Figure 1. Air Cleaner Tube and Clamp.
Figure 2. Air Cleaner Tube to Turbocharger.
Figure 3. Air Cleaner and Check Valve.
Figure 4. Air Cleaner Housing.
Figure 5. Air Cleaner and Check Valve.
Figure 6. Air Cleaner Tube to Turbocharger.
Figure 7. Air Cleaner Tube and Clamps.
ALL-WHEEL DRIVE (AWD) PUMP REPLACEMENT
Figure 1. Hydraulic Hose to AWD Pump.
Figure 2. AWD Hydraulic Hose to Pump.
Figure 4. Return Manifold Rear Hoses.
Figure 5. AWD Hydraulic Hose to Pump.
Figure 7. AWD Hydraulic Hose to Pump.
Figure 9. Rear Charge Pump AWD Tubes.
Figure 10. AWD Pump Bolts.
Figure 11. Front Charge Pump Fittings.
Figure 12. Rear Piston Pump Fittings.
Figure 13. Front Piston Pump Bottom Fitting.
Figure 14. Front Piston Pump Top Fitting.
Figure 16. Front Piston Pump Bottom Fitting.
Figure 17. Rear Piston Pump Fittings.
Figure 18. Front Charge Pump Fittings.
Figure 19. AWD Pump Bolts.
Figure 20. Rear Charge Pump AWD Tubes.
Figure 21. Forward Charge Pump AWD Tubes.
Figure 23. AWD Hydraulic Hose to Pump.
Figure 24. AWD Hydraulic Hose to Pump.
Figure 25. Return Manifold Rear Hoses.
Figure 26. AWD Hydraulic Hose to Pump.
Figure 28. Hydraulic Hose to AWD Pump Tube.
FRONT (LEFT CIRCUIT) ALL-WHEEL DRIVE CONTROL VALVE REPLACEMENT
Figure 1. Access Panel.
Figure 2. AWD Control Valve.
Figure 3. AWD Control Valve.
Figure 4. Access Panel.
ALL-WHEEL DRIVE (AWD) PUMP LINES REPLACEMENT
Figure 1. AWD Control Manifold and AWD Pumps.
Figure 2. AWD Rear Charge Pump Lines.
REMOVAL CONTINUED
Figure 4. AWD Pump Lines.
Figure 5. Right-Side Clamps.
Figure 7. Charge Filter Lines.
Figure 8. Charge Filter Lines.
Figure 9. Rear Clamps.
Figure 11. AWD Pump Lines.
Figure 12. AWD Rear Piston Pump Line.
Figure 14. AWD Control Manifold and AWD Pumps.
REAR (RIGHT CIRCUIT) ALL-WHEEL DRIVE CONTROL VALVE REPLACEMENT
Figure 1. AWD Control Valve.
INSTALLATION
IMPLEMENT AND STEERING PUMP REPLACEMENT
IMPLEMENT AND STEERING PUMP REPLACEMENT - Continued
Figure 1. Implement and Steering Pump Hose.
Figure 2. Implement and Steering Pump Removal.
Figure 3. Implement and Steering Pump Fitting.
Figure 4. Implement and Steering Pump Fitting.
Figure 5. Implement and Steering Pump.
Figure 6. Implement and Steering Pump Hose.
FOLLOW-ON TASKS
IMPLEMENT AND STEERING PUMP CONTROL VALVE REPLACEMENT
Figure 1. Enclosure Panel.
Figure 2. Implement and Steering Pump Control Valve.
Figure 3. Enclosure Panel.
ETHER STARTING VALVE REPLACEMENT
Figure 1. Ether Starting Valve.
CLEANING AND INSPECTION
CHAIN ASSEMBLY REPLACEMENT
Figure 1. Vehicle Support Stands.
Figure 2. Wheel and Tire Assembly.
Figure 4. Tandem Housing Access Covers.
Figure 6. Chain Puller.
Figure 8. Chain Puller.
Figure 9. Chain Removal.
Figure 10. Chain Installation.
Figure 11. Chain Puller.
Figure 13. Chain Puller.
Figure 15. Walkway.
Figure 17. Vehicle Support Stands.
COVER AND TANDEM HOUSING REPLACEMENT
Figure 1. Brake Hose.
Figure 2. Lifting Brackets.
REMOVAL CONTINUED
Figure 4. O-ring on Sprocket Assembly.
Figure 5. O-ring on Sprocket Assembly.
Figure 6. Cover and Tandem Housing.
Figure 7. Cover and Tandem Housing Bolts.
Figure 9. Brake Hose.
Figure 10. Retainer Hole Spacing
Figure 11. Shim Installation.
TANDEM DRIVE OIL SERVICE
Figure 1. Tandem Oil Drain Plug.
Figure 2. Tandem Oil Level Check Plug and Walkway Plate.
Figure 3. Oil Fill Access Cover.
Figure 4. Oil Fill Access Cover Gasket Removal.
Figure 5. Tandem Oil Drain Plug.
Figure 7. Oil Fill Access Cover Gasket.
Figure 9. Walkway Plate and Cover.
TANDEM BREATHER REPLACEMENT
Figure 2. Tandem Breather.
Figure 3. Step Plate.
TRANSMISSION OIL FILLER REPLACEMENT
Figure 1. Powertrain Oil Filler.
INSTALLATION
TRANSMISSION OIL SERVICE
Figure 1. Transmission Drain Plug.
Figure 2. Differential Drain Plug.
Figure 4. Breather.
Figure 6. Transmission Drain Plug.
Figure 7. Configuration Selection.
Figure 8. Module and Lube Parameters Selection.
Figure 9. Change Parameter Value Menu.
Figure 10. Select Correct Transmission Oil.
FOLLOW-ON TASKS
POWER TAKE-OFF LINES REPLACEMENT
Figure 1. Power Take-Off Line.
'TM 5-3805-293-23-3.book' by ndesantis - Page 1023 of 1468
BRAKE CONTROL LINES REPLACEMENT
Figure 1. Brake Return Hose.
Figure 2. Front Clamp.
Figure 4. Brake Control Line Clamps.
Figure 6. Front Hose Retainer Assembly.
Figure 7. Hose Plate Blocks.
Figure 8. Brake Control Line.
Figure 9. Retaining Clip.
Figure 10. Supply Hose.
Figure 11. Right Forward Hose.
Figure 13. Right Intermediate Hose.
Figure 15. Left Forward Hose.
Figure 17. Left Intermediate Hose.
Figure 18. Tandem Housing Step.
Figure 19. Front Brake Line.
Figure 20. Rear Brake Line.
Figure 21. Manifold.
Figure 22. Manifold.
Figure 23. Front Brake Line.
Figure 24. Tandem Housing Step.
Figure 25. Left Intermediate Hose.
Figure 26. Left Forward Hose.
Figure 28. Left Forward Hose Connection.
Figure 30. Forward Brake Hose Under Cab.
Figure 32. Supply Hose.
Figure 33. Retaining Clip.
Figure 34. Brake Control Line.
Figure 35. Hose Plate and Blocks.
Figure 36. Hose Retainer Assembly.
Figure 38. Brake Return Hose Clamps.
Figure 40. Front Clamp.
FOLLOW-ON TASKS
DIFFERENTIAL LOCK CONTROL VALVE AND LINES REPAIR
REMOVAL
Figure 1. Differential Lock Control Lines and Hose.
Figure 3. Hose Clamp.
Figure 5. Solenoid Valve.
Figure 6. Solenoid Valve.
Figure 7. Differential Hose.
Figure 9. Mounting Bracket.
Figure 10. Differential Lock Control Lines and Hose.
STEERING CYLINDER LINES REPLACEMENT
Figure 1. Wheel Lean Lock Bolt.
Figure 2. Steering Cylinder Hoses and Hardware.
Figure 3. Steering Cylinder Hose.
INSTALLATION
Figure 4. Steering Cylinder Hoses and Hardware.
Figure 5. Wheel Lean Arm.
WHEEL LEAN CYLINDER LINES REPLACEMENT
Figure 1. Wheel Lean Lock Bolt.
Figure 2. Wheel Lean Cylinder Hose.
Figure 3. Steering Hose Clamp.
Figure 5. Hose and Plug Clamp.
Figure 6. Valve Bank and Tubes.
Figure 7. Hose and Plug Clamp.
Figure 9. Steering Hose Clamp.
Figure 10. Wheel Lean Cylinder Hoses.
Figure 11. Wheel Lean Arm.
TRANSMISSION OIL COOLER CORE AND BRACKET REPAIR
Figure 1. Left Front Access Cover.
Figure 2. Left Rear Access Cover.
Figure 3. Transmission Oil Cooler Core Tubes.
Figure 4. Coolant Hoses.
Figure 5. Coolant Hoses at Coolant Drain Valves.
Figure 6. Wiring Harness and Tube Clamps.
Figure 7. Transmission Oil Cooler Core.
Figure 8. Clip and Clamp.
Figure 9. Transmission Oil Cooler Bracket.
Figure 10. Transmission Oil Cooler.
INSPECTION
Figure 11. Transmission Oil Cooler Bracket.
Figure 12. Clip and Clamp.
Figure 13. Transmission Oil Cooler Core.
Figure 14. Wiring Harness and Tube Clamps.
Figure 15. Coolant Hoses at Coolant Drain Valves.
Figure 16. Coolant Hoses.
Figure 17. Transmission Oil Cooler Core Tubes.
Figure 18. Left Rear Access Cover.
FOLLOW-ON TASKS
UNIVERSAL JOINT REPLACEMENT
Figure 1. Universal Joint.
Figure 2. Yokes.
Figure 3. Yokes.
Figure 4. Universal Joint.
STEERING POSITION SENSOR HARNESS REPLACEMENT
Figure 1. Left-Hand Sensor Guard.
Figure 2. Steering Position Sensor.
Figure 4. Right-Hand Sensor Harness and Plug.
Figure 6. Right-Hand Sensor Harness Connector.
Figure 7. Right-Hand Sensor Harness Connector.
Figure 8. Left-Hand Sensor Harness Connector.
Figure 10. Right-Hand Sensor Guard.
Figure 11. Steering Position Sensor.
TRANSMISSION ECM REPLACEMENT
Figure 2. Transmission ECM Mounting and Ground Strap.
Figure 3. Transmission ECM.
TRANSMISSION MOUNT REPLACEMENT
Figure 1. Right-Side Transmission Mount.
Figure 2. Left-Side Transmission Mount.
Figure 3. Right-Side Transmission Mount Support.
Figure 5. Left-Side Transmission Mount.
Figure 6. Right-Side Transmission Mount.
WHEEL AND TIRE ASSEMBLY REPAIR
WHEEL AND TIRE ASSEMBLY REPAIR - Continued
Figure 1. Wheel and Tire.
Figure 2. Wheel and Tire.
Figure 3. Tire.
Figure 4. Demountable Side Ring Flange.
Figure 5. Lockring and Ring Flange.
Figure 7. Mounting Tire.
ASSEMBLY CONTINUED
Figure 8. Wheel and Tire.
Figure 9. Wheel and Tire.
INSTALLATION CONTINUED
SERVICE BRAKE REPLACEMENT
Figure 1. Guard.
Figure 2. Line.
Figure 3. Service Brake.
CLEANING AND INSPECTION
INSTALLATION
Figure 5. Torque Pattern.
Figure 6. Line.
FOLLOW-ON TASKS
REAR AXLE REPLACEMENT
Figure 1. Rear Axle Connections.
Figure 2. Wiring Harness and Hydraulic Hose Clamps.
Figure 3. Axle Link.
Figure 4. Axle Link.
Figure 5. Sling.
Figure 7. Front Axle Bolts.
Figure 8. Top Axle Bolts.
Figure 9. Sling.
Figure 10. Front Axle Bolts.
Figure 11. Axle Bolt Torque Sequence.
Figure 13. Axle Link.
Figure 14. Axle Link.
Figure 16. Wiring Harness and Hydraulic Hose Clamps.
Figure 17. Rear Axle Connections.
TRANSMISSION REPLACEMENT
Figure 1. Aftercooler Tube and Clamps.
Figure 2. All-Wheel Drive Hose Clamps.
Figure 4. Hydraulic Hose Clamps at Transmission.
Figure 5. Filter Hoses.
Figure 7. Filter Bracket.
Figure 9. Main Wiring Harness Connector.
Figure 10. Transmission ECM Connectors.
Figure 12. Fan Bypass Solenoid.
Figure 14. Implement and Steering Manifold Hoses.
Figure 15. Hose Assemblies.
Figure 17. Transmission Oil Cooler Tubes.
Figure 18. Coolant Hoses at Coolant Drain Valves.
Figure 19. Transmission Oil Cooler Hoses.
Figure 20. Transmission Oil Cooler.
Figure 21. Transmission Oil Cooler Bracket.
Figure 23. Battery Cable Bracket.
Figure 25. All-Wheel Drive Thermal Bypass Valve.
Figure 27. Transmission Brackets.
Figure 29. Transmission Mounts.
Figure 30. Engine Support Brackets.
Figure 31. Transmission Bolts.
Figure 32. Transmission Stand.
Figure 33. Drain Tube.
Figure 35. Sensor.
Figure 36. Transmission Fittings.
Figure 37. Transmission Oil Filter Housing.
Figure 39. AWD Valve.
Figure 40. Transmission ECM.
Figure 41. Charge Pump.
Figure 42. Cover.
Figure 43. Charge Pump.
Figure 44. Transmission ECM.
Figure 46. Bypass.
Figure 47. Transmission Oil Filter Housing.
Figure 48. Transmission Fittings.
Figure 49. Sensor.
Figure 51. Drain Tube.
Figure 52. Transmission Stand.
Figure 53. Transmission Bolts.
Figure 54. Engine Support Brackets.
Figure 55. Transmission Mounts.
Figure 56. Engine Bracket.
Figure 58. All-Wheel Drive Thermal Bypass Valve Solenoid.
Figure 60. Transmission Hose.
Figure 61. Battery Cable Bracket.
Figure 63. Transmission Oil Cooler Bracket.
Figure 64. Transmission Oil Cooler.
Figure 65. Transmission Oil Cooler Hoses.
Figure 66. Coolant Hoses at Coolant Drain Valves.
Figure 67. Transmission Oil Cooler Lines.
Figure 69. Hose Assemblies.
Figure 70. Implement and Steering Manifold Hoses.
Figure 71. Transmission Bypass Solenoid.
Figure 73. Bypass Tube.
Figure 75. Main Wiring Harness Connector.
Figure 76. Transmission Oil Tube Clamp.
Figure 77. Filter Bracket.
Figure 79. Filter Hoses.
Figure 80. Hydraulic Hose Clamps at Transmission.
Figure 82. All-Wheel Drive Hose Clamps.
Figure 83. Aftercooler Tube and Clamps.
TRANSMISSION SCAVENGE MAGNETIC FILTER AND SUCTION SCREEN REPLACEMENT
Figure 1. Suction Screen and Magnetic Filter.
INSTALLATION
MAGNETIC FILTER REPLACEMENT
Figure 1. Suction Screen and Magnetic Filter.
INSTALLATION
TRANSMISSION OIL FILTER REPLACEMENT
Figure 1. Transmission Oil Filter Housing and Drain Plug.
Figure 2. Transmission Oil Filter.
FOLLOW-ON TASKS
PARKING BRAKE REPLACEMENT
Figure 1. Harness and Guard.
Figure 2. Yoke and Spring Plates.
Figure 3. Coned Disc Springs.
Figure 4. Piston and O-ring.
Figure 6. Clutch Housing.
Figure 7. Clutch Disc, Plates, and Dowel Pins.
Figure 8. Case O-rings.
Figure 9. Clutch Disc, Plates, and Dowel Pins.
Figure 10. Clutch Housing.
Figure 11. Piston Seals.
Figure 13. Coned Disc Springs.
Figure 14. Yoke and Spring Plate.
FOLLOW-ON TASKS
TRANSMISSION MAIN RELIEF VALVE REPLACEMENT
Figure 1. Hose Assemblies.
Figure 3. Transmission Hydraulic Relief Valve.
Figure 4. Transmission Relief Valve.
Figure 5. Wiring Harness Clamps and Cover.
FOLLOW-ON TASKS
TRANSMISSION OUTPUT 1 & 2 SPEED SENSORS AND GUARD REPLACEMENT
Figure 2. Transmission (Output 1 & 2) Speed Sensors.
CLEANING AND INSPECTION
Figure 3. Transmission Guard.
TRANSMISSION INPUT SPEED SENSOR REPLACEMENT
Figure 1. Enclosure Panel.
CLEANING AND INSPECTION
TRANSMISSION INTERMEDIATE 1 & 2 SPEED SENSORS REPLACEMENT
Figure 1. Right Rear Access Panel.
Figure 2. Transmission (Intermediate 1 & 2) Speed Sensors.
Figure 3. Transmission (Intermediate 1 & 2) Speed Sensors.
Figure 4. Right Rear Access Panel.
TRANSMISSION OIL TEMPERATURE SENSOR REPLACEMENT
Figure 1. Transmission Oil Temperature Sensor.
INSTALLATION
TRANSMISSION PUMP PRESSURE SENSOR AND ADAPTER REPLACEMENT
Figure 1. Enclosure Panel.
Figure 3. Transmission Pump Pressure Sensor Adapter.
Figure 4. Transmission Pump Pressure Sensor Adapter.
Figure 6. Enclosure Panel.
PARKING BRAKE PRESSURE SWITCH REPLACEMENT
Figure 1. Parking Brake Pressure Switch.
Figure 2. Parking Brake Pressure Switch.
TRANSMISSION RELIEF VALVE REPLACEMENT
Figure 1. Transmission Oil Cooler Tube.
Figure 2. Lubrication Relief Valve Cover.
Figure 3. Transmission Oil Cooler Relief Valve.
Figure 4. Lubrication Relief Valve Cover.
Figure 5. Transmission Oil Cooler Tube.
CLUTCH MODULATING VALVES REPLACEMENT
Figure 2. Wire Harness Clamps.
Figure 4. Transmission Clutch Modulating Valve.
Figure 5. Transmission Clutch Modulating Valve.
Figure 7. Wiring Harness Clamps.
Figure 8. Hose Assemblies.
PARKING BRAKE SOLENOID VALVE REPLACEMENT
Figure 2. Parking Brake Solenoid Valve.
Figure 3. Parking Brake Solenoid Valve.
SENSOR WIRING HARNESS REPLACEMENT
Figure 1. Sensor Harness and Hardware.
CLEANING AND INSPECTION
TRANSMISSION WIRING HARNESS REPLACEMENT
Figure 1. Left Rear Bottom Side Panel.
Figure 2. Hose Assemblies.
Figure 4. Transmission Wiring Harness.
Figure 5. Transmission Oil Temperature Sensor.
Figure 6. Transmission Wiring Harness.
Figure 7. Wiring Harness Clamps and Cover.
Figure 9. Left Rear Bottom Side Panel.
CHARGING PUMP REPLACEMENT
Figure 1. Access Panel.
Figure 2. Charging Pump Hoses.
Figure 3. Charging Pump Tube.
INSTALLATION
Figure 4. Charging Pump Hoses.
Figure 5. Access Panel.
RIGHT WHEEL LEAN ARM REPLACEMENT
Figure 1. Wheel Lean Lock Bolt.
Figure 2. Wheel Lean Arm.
Figure 3. Wheel Lean Arm.
Figure 4. Wheel Lean Lock Bolt.
LEFT WHEEL LEAN ARM REPLACEMENT
Figure 1. Wheel Lean Lock Bolt.
Figure 2. Wheel Lean Arm.
REMOVAL CONTINUED
Figure 3. Wheel Lean Arm.
Figure 4. Wheel Lean Lock Bolt.
WHEEL LEAN BAR REPLACEMENT
Figure 2. Left-Side Wheel Lean Bar Retainer.
Figure 3. Left-Side Wheel Lean Bar Pin.
Figure 4. Right-Side Wheel Lean Bar Retainer.
Figure 6. Wheel Lean Bar.
Figure 7. Wheel Lean Bar.
Figure 8. Right-Side Wheel Lean Pin.
Figure 9. Right-Side Wheel Lean Bar Retainer.
Figure 11. Left-Side Wheel Lean Bar Retainer.
STEERING TIE ROD REPAIR
Figure 2. Tie Rod.
Figure 3. Tie Rod.
RIGHT ALL-WHEEL DRIVE PISTON MOTOR REPLACEMENT
Figure 1. All-Wheel Drive Piston Motor Guard.
Figure 2. Right Wheel Drive Motor Cover Plate.
Figure 4. Right Wheel Drive Motor Cover.
Figure 5. Right Wheel Drive Motor Cover.
Figure 6. Right Wheel Drive Motor Guard.
Figure 7. Steering Link and Cover.
Figure 9. All-Wheel Drive Piston Motor Sensor Connector and Line.
Figure 10. All-Wheel Drive Piston Motor Tube and Line.
Figure 11. All-Wheel Drive Piston Motor.
Figure 12. All-Wheel Drive Piston Motor.
Figure 13. All-Wheel Drive Piston Motor Tube and Line.
Figure 14. All-Wheel Drive Piston Motor Sensor Connector and Lines.
Figure 15. Steering Cylinder.
Figure 17. Right Wheel Drive Motor Guard.
Figure 18. Right Wheel Drive Motor Cover.
Figure 20. Right Wheel Drive Motor Cover.
Figure 21. Right Wheel Drive Motor Cover Plate.
Figure 22. All-Wheel Drive Piston Motor Guard.
LEFT ALL-WHEEL DRIVE PISTON MOTOR REPLACEMENT
Figure 1. All-Wheel Drive Piston Motor Guard.
Figure 2. Left Wheel Drive Motor Cover Plate (Serial Number Prefix RMY).
Figure 3. Left Wheel Drive Motor Cover (Serial Number Prefix RMY).
Figure 5. Left Wheel Drive Motor Cover (Serial Number Prefix RMY).
Figure 6. Left Wheel Drive Motor Guard.
Figure 7. Steering Link and Cover.
Figure 9. AWD Sensor.
Figure 10. All-Wheel Drive Piston Motor Line.
Figure 11. All-Wheel Drive Piston Motor Hose.
Figure 12. All-Wheel Drive Piston Motor.
Figure 13. All-Wheel Drive Piston Motor.
Figure 14. All-Wheel Drive Piston Line.
Figure 15. All-Wheel Drive Piston Motor Lines.
Figure 16. AWD Sensor.
Figure 17. Steering Cylinder.
Figure 18. Steering Link and Cover.
Figure 19. Left Wheel Drive Motor Guard (Serial Number Prefix RMY).
Figure 20. Left Wheel Drive Motor Cover (Serial Number Prefix RMY).
Figure 22. Left Wheel Drive Motor Cover (Serial Number Prefix RMY).
Figure 23. Left Wheel Drive Motor Cover Plate (Serial Number Prefix RMY).
Figure 24. All-Wheel Drive Piston Motor Guard.
LEFT AND RIGHT FRONT DRIVE MOTOR SPEED SENSORS REPLACEMENT
Figure 1. Guard Plate.
Figure 2. Speed Sensor.
Figure 3. Speed Sensor
Figure 4. Guard Plate.
LEFT AND RIGHT FRONT DRIVE MOTOR SPEED SENSORS REPLACEMENT (SERIAL NUMBER PREFIX RMY)
Figure 1. Left Wheel Drive Motor Cover Plate.
Figure 2. Left Wheel Drive Motor Cover.
Figure 4. Speed Sensor.
Figure 5. Speed Sensor.
Figure 6. Left Wheel Drive Motor Cover.
Figure 8. Left Wheel Drive Motor Cover Plate.
ALL-WHEEL DRIVE (AWD) WHEEL MOTOR LINES REPLACEMENT
REMOVAL
Figure 1. Left AWD Motor Guards.
Figure 2. Left AWD Motor Hoses.
Figure 3. Hose Under Left AWD Motor.
Figure 4. Left Clamp and Strap.
Figure 5. Right AWD Motor Guards.
Figure 6. Right AWD Motor Sensor and Hoses.
Figure 7. Right AWD Motor Hoses.
Figure 8. Right Clamp and Strap.
Figure 9. Left AWD Control Manifold.
Figure 10. Clamp.
Figure 11. Right AWD Control Manifold.
Figure 12. Right-Side Clamp.
Figure 13. Left-Side Clamp.
Figure 14. Center Clamp.
Figure 15. Wiring Harnesses.
Figure 16. Center Clamp.
Figure 17. Right AWD Motor Hoses.
Figure 18. Right AWD Motor Sensor and Hoses.
Figure 19. Right AWD Motor Guards.
Figure 20. Left AWD Motor Sensor and Hoses.
Figure 21. Left AWD Motor Hoses.
Figure 22. Left AWD Motor Guards.
Figure 23. Right-Side Clamp.
Figure 24. Left-Side Clamp.
Figure 25. Left AWD Control Manifold.
Figure 26. Clamp.
Figure 27. Right AWD Control Manifold.
Figure 28. Right Clamp and Strap.
Figure 29. Left Clamp and Strap.
Figure 30. Locknuts.
ALL-WHEEL DRIVE (AWD) GEAR OIL SERVICE
Figure 1. All-Wheel Drive Gear Oil Fill Plug.
Figure 2. All-Wheel Drive Gear Oil Drain Plug.
Figure 3. All-Wheel Drive Gear Oil Fill Plug.
Integrated Publishing, Inc. - A (SDVOSB) Service Disabled Veteran Owned Small Business
