Tractor, Wheeled, Industrial Backhoe Loader Nsn 2420-01-532-3399

CHAPTER 3 PMCS MAINTENANCE INSTRUCTIONS
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
EXPLANATION OF TABLE ENTRIES
GENERAL PMCS PROCEDURES
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) AND LUBRICATION INSTRUCTIONS
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.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
MANDATORY REPLACEMENT PARTS
LUBRICATION INSTRUCTIONS
Table 5. Lubricant for Hydraulic Systems.
Table 9. Lubricant for Front Axle Wheel Ends.
LUBRICATION INSTRUCTIONS CONTINUED
LUBRICATION INSTRUCTIONS CONTINUED
LUBRICATION INSTRUCTIONS CONTINUED
LUBRICATION INSTRUCTIONS CONTINUED
CHAPTER 4 MAINTENANCE INSTRUCTIONS
SERVICE UPON RECEIPT
SERVICING INSTRUCTIONS
ENGINE COOLANT SERVICE
Figure 1. Draining.
Figure 2. Filling.
ENGINE REPLACEMENT
Figure 2. Bracket.
Figure 3. Muffler Assembly.
Figure 4. Coolant Hose.
Figure 5. Wiring Harness.
Figure 6. A/C Compressor.
Figure 7. Fuel Pump Connections.
Figure 8. Throttle Cable.
Figure 9. Grid Heater.
Figure 11. Torque Converter Bolts.
Figure 12. Transmission-to-Flywheel Housing Bolts.
Figure 13. Engine Mount Bolts.
Figure 14. Engine Rollover Stand Mounting.
Figure 15. Engine Mounts and Fan Hub.
Figure 16. Intake Spacer Block.
Figure 17. Grid Heater.
Figure 18. Intake Spacer Block.
Figure 19. Grid Heater.
Figure 20. Engine Mounts and Fan Hub.
Figure 21. Access Cover.
Figure 22. Engine Rollover Stand Mounting.
INSTALLATION
Figure 23. Engine Mount Bolts.
Figure 24. Engine Mount Bolts.
Figure 25. Torque Converter Bolts.
Figure 27. Grid Heater.
Figure 28. Accelerator Cable.
Figure 29. Fuel Lines.
Figure 30. A/C Compressor.
Figure 31. Wiring Harness.
Figure 32. Coolant Hose.
Figure 33. Muffler Assembly.
Figure 34. Bracket.
Figure 35. Aspirate Check Valve Hose.
COOLANT PACK MAINTENANCE
Figure 1. Upper Radiator Hose.
Figure 3. Washer Pump.
Figure 4. Side Washer Pump Harness Clamp.
Figure 5. Axle Breather Element Hose Tiedown.
Figure 6. Axle Breather Element Hose.
Figure 7. Hydraulic Oil Cooler Hoses.
Figure 8. Lower Radiator Hose.
Figure 10. A/C Condenser.
Figure 11. Coolant Pack.
Figure 12. Upper Radiator Hose.
Figure 14. Coolant Reservoir and Mount.
Figure 15. Lower Radiator Hose.
Figure 17. Fan Shroud.
Figure 18. Right Radiator Mounting.
Figure 19. Radiator Wrapper.
Figure 21. Bracket Grommet.
Figure 22. Radiator Holddown.
Figure 24. Radiator.
Figure 25. Transmission Oil Cooler Tubes.
Figure 26. Transmission/Hydraulic Oil Cooler.
Figure 27. Transmission Oil Cooler Tubes.
Figure 29. Drain Cock.
Figure 30. Radiator Holddown.
Figure 31. Bracket Grommet.
Figure 32. Radiator Mount.
Figure 33. Radiator Wrapper.
Figure 34. Right Radiator Mounting.
Figure 35. Fan Shroud.
Figure 36. Cooler Tubes.
Figure 38. Coolant Reservoir and Mount.
Figure 39. Coolant Return Hose.
Figure 40. Upper Radiator Hose.
Figure 41. Coolant Pack.
Figure 42. A/C Condenser.
Figure 43. Transmission Oil Cooler Hoses.
Figure 45. Hydraulic Oil Cooler Hoses.
Figure 46. Axle Breather Element Hose.
Figure 47. Axle Breather Element Hose Tiedown.
Figure 48. Side Washer Pump Wiring Harness Clamp.
Figure 49. Washer Pump.
Figure 51. Upper Radiator Hose.
UPPER RADIATOR HOSE REPLACEMENT
Figure 1. Upper Radiator Hose.
Figure 2. Upper Radiator Hose.
ENGINE COOLING FAN AND ADAPTER REPLACEMENT
Figure 2. Engine Cooling Fan Adapter.
Figure 4. Engine Cooling Fan Adapter.
Figure 5. Engine Cooling Fan and Adapter.
DRIVE BELT REPLACEMENT
Figure 2. Drive Belt.
COOLANT RESERVOIR AND MOUNTS REPLACEMENT
Figure 1. Coolant Reservoir.
Figure 2. Coolant Reservoir Tube Clamp.
Figure 4. Coolant Reservoir Mount.
Figure 5. Wiper Washer Reservoir Wiring Harness Clamp.
Figure 7. Coolant Reservoir.
COOLANT RESERVOIR TUBE AND HOSES REPLACEMENT
Figure 1. Coolant Overflow Hose.
Figure 2. Coolant Recovery Hose at Radiator Nipple.
Figure 4. Upper Coolant Suction Hose.
Figure 5. Coolant Reservoir Tube Clamp.
Figure 6. Upper Coolant Suction Tube.
Figure 8. Coolant Suction Tube Clamp.
Figure 10. Lower Coolant Suction Tube.
Figure 11. Coolant Suction Tube Clamp.
Figure 13. Upper Coolant Suction Tube.
Figure 14. Coolant Reservoir Tube Clamp.
Figure 15. Upper Coolant Suction Hose.
Figure 16. Coolant Recovery Hose at Coolant Reservoir.
Figure 18. Coolant Overflow Hose.
LOWER RADIATOR AND SUCTION HOSE REPLACEMENT
Figure 2. Lower Radiator Suction Hose.
AIR CLEANER BARRIER CURTAIN REPLACEMENT
Figure 2. Air Cleaner Barrier Curtain Nuts.
Figure 3. Air Cleaner Barrier Curtain.
AIR CLEANER ASSEMBLY, AIR PRESSURE SWITCH, AND HOSES REPLACEMENT
Figure 2. Air Intake Hose.
Figure 4. Breather Hose.
Figure 6. Air Cleaner Assembly.
Figure 7. Breather and Air Intake Hoses.
Figure 8. Air Cleaner Assembly.
Figure 9. Turbocharger Air Inlet Hose.
Figure 11. Electrical Connector.
Figure 13. Aspirate Check Valve Hose.
AIR CLEANER PRIMARY AND SECONDARY ELEMENTS REPLACEMENT
Figure 2. Primary Filter Element.
Figure 4. Primary Filter Element.
ASPIRATE CHECK VALVE AND HOSES REPLACEMENT
Figure 2. Aspirate Check Valve.
Figure 3. Tiedown Strap.
Figure 6. Tiedown Strap.
Figure 7. Aspirate Check Valve.
ASPIRATE CHECK VALVE AND HOSES REPLACEMENT - Continued
EXHAUST MUFFLER AND MOUNTING BRACKETS REPLACEMENT
Figure 2. Muffler Hose.
Figure 4. Rear Mounting Bolts.
Figure 6. Rear Mounting Bracket.
Figure 7. Support Strut.
Figure 8. Rear Mounting Bracket.
Figure 10. Rear Mounting Bolts.
Figure 13. Turbocharger Exhaust Pipe.
ENGINE MOUNTS REPLACEMENT
Figure 1. Front Lifting Ring.
Figure 2. Right Resilient Mount and Bracket.
Figure 3. Left Resilient Mount and Bracket.
ENGINE MOUNTS REPLACEMENT - Continued
Figure 4. Right Resilient Mount and Bracket.
Figure 5. Front Lifting Ring.
ENGINE OIL PAN AND OIL PUMP STRAINER REPLACEMENT
Figure 2. Drive Shaft Guard.
Figure 3. Drive Shaft.
Figure 5. Oil Pump Strainer.
Figure 6. Joint Sealant.
Figure 7. Oil Pan.
Figure 8. Drive Shaft.
Figure 9. Drive Shaft Guard.
Figure 10. Engine Oil Dipstick.
CRANKSHAFT FRONT SEAL REPLACEMENT
Figure 2. Outer Seal.
Figure 3. Crankshaft Oil Seal Installation.
TIMING COVER REPLACEMENT
Figure 2. Front Cover Sealant.
Figure 3. Front Cover.
FLYWHEEL HOUSING REPLACEMENT
Figure 1. Flywheel Housing Bolts.
Figure 2. Flywheel Housing Plugs.
FLYWHEEL HOUSING REPLACEMENT - Continued
Figure 3. Flywheel Housing Bolt Torque Sequence.
FLYWHEEL HOUSING REPLACEMENT - Continued
REAR MAIN OIL SEAL REPLACEMENT
Figure 2. Outer Rear Main Oil Seal.
Figure 3. Crankshaft Rear Seal Installer Base.
REAR MAIN OIL SEAL REPLACEMENT - Continued
ENGINE BREATHER AND FILTER REPLACEMENT
Figure 2. Engine Breather and Filter.
CYLINDER HEAD ASSEMBLY REPLACEMENT
Figure 1. Compressor Connection.
Figure 2. Bracket Tiedown.
Figure 3. A/C Compressor.
Figure 4. Coolant Wiring Harness.
Figure 5. Fuel Regulator Line.
Figure 6. Fuel Filter.
Figure 8. Fuel Pump Connections.
Figure 9. High-Pressure Fuel Lines.
Figure 10. Intake Cover Plate.
Figure 12. Cylinder Head and Gasket.
Figure 13. Cylinder Head Components.
Figure 14. Fuel Injector Crushwashers.
Figure 16. Filter Bracket.
Figure 18. Cylinder Head Components.
Figure 19. Cylinder Head and Gasket.
Figure 20. Cylinder Head Bolt Tightening Sequence.
Figure 21. Intake Cover Plate.
Figure 22. High-Pressure Fuel Lines.
Figure 23. Fuel Pump Connections.
Figure 25. Fuel Filter.
Figure 26. Fuel Regulator Line.
Figure 28. Air Compressor.
Figure 29. Bracket Tiedown.
Figure 30. Compressor Connection.
VALVE COVERS REPLACEMENT
Figure 2. Valve Cover.
ROCKER ARM ASSEMBLY REPAIR
Figure 1. Rocker Arm Assembly Removal.
Figure 2. Rocker Assembly.
Figure 3. Rocker Arm Assembly Installation.
Figure 4. Engine Turning Tool.
Figure 6. Valve Adjustment.
Figure 7. Valve Adjustment.
Figure 8. Engine Turning Tool.
INTAKE MANIFOLD AND GRID HEATER ASSEMBLY REPLACEMENT
Figure 2. Clamp.
Figure 3. Grid Heater.
Figure 5. Sleeve.
Figure 6. Grid Heater.
Figure 8. Intake Manifold Bolts.
AIR INTAKE COVER REPLACEMENT
Figure 2. Intake Manifold Cover.
EXHAUST MANIFOLD REPLACEMENT
Figure 2. Exhaust Manifold.
ENGINE FLYWHEEL REPLACEMENT
Figure 2. Flywheel Bolts.
Figure 3. Engine Turning Tool.
CRANKSHAFT PULLEYS REPLACEMENT
Figure 2. Crankshaft Pulleys.
Figure 3. Engine Turning Tool.
TURBOCHARGER ASSEMBLY REPLACEMENT
Figure 2. Exhaust Outlet.
Figure 3. Turbocharger Assembly.
ENGINE OIL FILLER TUBE REPLACEMENT
Figure 2. Engine Oil Filler Tube.
ENGINE OIL PUMP REPLACEMENT
Figure 2. Engine Oil Pump.
ENGINE OIL PRESSURE SENDING UNIT REPLACEMENT
Figure 2. Engine Oil Pressure Sending Unit.
Figure 3. Wiring Harness.
ENGINE OIL DIPSTICK AND TUBE REPLACEMENT
Figure 2. Engine Oil Dipstick and Tube.
TURBOCHARGER ENGINE OIL SUPPLY HOSE REPLACEMENT
Figure 2. Oil Supply HoseOil Filter.
Figure 3. Oil Supply HoseTurbocharger.
TURBOCHARGER ENGINE OIL RETURN PIPE REPLACEMENT
Figure 2. Oil Return PipeTurbocharger.
Figure 4. Clamp Bracket.
Figure 6. Oil Return PipeTurbocharger.
TURBOCHARGER ENGINE OIL RETURN PIPE REPLACEMENT - Continued
ENGINE OIL AND FILTER SERVICE
Figure 1. Filler Cap.
Figure 2. Crankcase Drain.
Figure 3. Oil Filter Element.
Figure 4. Oil Dipstick.
ENGINE OIL FILTER HOUSING AND ENGINE OIL COOLER REPLACEMENT
Figure 1. Filter Head.
Figure 2. Filter Head Gasket.
Figure 4. Oil Cooler Gasket.
Figure 6. Turbocharger Oil Supply Hose Fitting.
Figure 9. Filter Head Gasket.
Figure 10. Filter Head.
WATER PUMP REPLACEMENT
Figure 2. Water Pump.
WATER INLET HOUSING REPLACEMENT
Figure 2. Heater Shutoff Valve.
Figure 3. Water Inlet Housing.
THERMOSTAT AND HOUSING REPLACEMENT
Figure 2. Sensor Connections.
Figure 3. Exhaust Bracket.
Figure 5. Thermostat.
Figure 6. Thermostat Housing.
Figure 7. Exhaust Bracket.
Figure 8. Sensor Connections.
Figure 9. Upper Radiator Hose.
COOLANT TEMPERATURE SENDER REPLACEMENT
Figure 2. Coolant Temperature Sender.
GRID HEATER COOLANT TEMPERATURE SENSOR REPLACEMENT
Figure 2. Coolant Temperature Sensor.
Figure 3. Coolant Temperature Sensor Wiring Harness.
DRIVE BELT TENSIONER REPLACEMENT
Figure 2. Drive Belt Tensioner.
Figure 4. Drive Belt Tensioner.
Figure 5. Drive Belt.
DRIVE BELT IDLER PULLEY REPLACEMENT
Figure 2. Drive Belt Idler Pulley.
Figure 3. Drive Belt.
FAN DRIVE PULLEY AND SUPPORT HUB REPLACEMENT
FAN DRIVE PULLEY AND SUPPORT HUB REPLACEMENT - Continued
FUEL TANK REPLACEMENT
Figure 1. Fuel Tank Drain.
FUEL TANK COVER AND PLATE REMOVAL
FUEL TANK REMOVAL
Figure 5. Spacer.
Figure 6. Fuel Tank.
Figure 7. Spacer.
Figure 8. Hoses.
Figure 9. Fuel Tank Cover and Plate.
FUEL HOSE ASSEMBLY REPLACEMENT
Figure 2. Fuel Tank Hose Connections.
Figure 3. Breather Hose.
Figure 4. Low-Pressure Fuel Pump Supply Hose.
Figure 5. Low-Pressure Fuel Pump Supply Hose.
Figure 7. Fuel Tank Hose Connections.
Figure 8. Fuel Tank Cover.
FUEL SENDING UNIT REPLACEMENT
Figure 2. Fuel Sending Unit.
Figure 3. Fuel Tank Cover.
FUEL SENDING UNIT REPLACEMENT - Continued
HAND THROTTLE LEVER REPLACEMENT
Figure 1. Hand Throttle Assembly.
CLEANING AND INSPECTION
THROTTLE CABLES REPLACEMENT
Figure 3. Block Clamp and Plate.
Figure 4. Mounting Bracket.
Figure 5. Clevis Assembly.
Figure 6. Hand Throttle Assembly.
Figure 7. Cable and Grommet.
Figure 8. Hand Throttle Cable Clevis.
Figure 9. Fuel Injection Pump Connection.
Figure 10. Foot Throttle Cable Fittings.
Figure 11. Fuel Injection Pump Connection.
Figure 12. Hand Throttle Cable Clevis.
Figure 13. Cable and Grommet.
Figure 14. Hand Throttle Assembly.
Figure 15. Clevis Assembly.
Figure 16. Mounting Bracket.
Figure 19. Throttle Cable Bracket Bolts.
THROTTLE CABLES REPLACEMENT - Continued
FOOT THROTTLE PEDAL ASSEMBLY REPLACEMENT
Figure 3. Block Clamp and Plate.
Figure 4. Clevis Assembly.
Figure 6. Foot Throttle Assembly.
Figure 8. Clevis Assembly.
Figure 9. Block Clamp and Plate.
Figure 11. Throttle Cable Bracket Bolts.
HIGH-PRESSURE FUEL PUMP REPLACEMENT
Figure 1. High-Pressure Fuel Pump.
Figure 3. Engine Turning Tool.
Figure 6. High-Pressure Fuel Pump Locking Bolt.
Figure 7. Coolant Hose.
Figure 8. High-Pressure Fuel Pump.
Figure 10. High-Pressure Fuel Pump Gear.
Figure 11. Pump Puller.
Figure 12. High-Pressure Fuel Pump Removal.
Figure 14. High-Pressure Fuel Pump Gear.
Figure 16. High-Pressure Fuel Pump Locking Bolt.
Figure 18. Accelerator Cable Bracket.
Figure 19. High-Pressure Fuel Pump.
Figure 20. Coolant Hose.
COLD START TEMPERATURE SWITCH REPLACEMENT
Figure 2. Cold Start Temperature Switch.
FUEL SHUTOFF WIRING HARNESS REPLACEMENT
Figure 2. High-Pressure Fuel Pump.
Figure 4. Wiring Harness.
Figure 5. Electrical Connector.
Figure 7. Solenoid.
HIGH-PRESSURE FUEL TUBES REPLACEMENT
Figure 1. High-Pressure Fuel Tubes.
Figure 2. High-Pressure Fuel Tubes Removal.
Figure 3. High-Pressure Fuel Tubes Installation.
Figure 5. High-Pressure Fuel Tubes Installation.
Figure 6. High-Pressure Fuel Tubes.
HIGH-PRESSURE FUEL TUBES REPLACEMENT - Continued
FUEL INJECTOR REPLACEMENT
Figure 1. Injection Nozzle Assembly.
Figure 3. Injection Nozzle Assembly.
FUEL FILTER WITH WATER SEPARATOR ELEMENT REPLACEMENT
Figure 1. Fuel Filter Assembly.
FUEL FILTER WITH WATER SEPARATOR HOUSING AND BRACKET REPLACEMENT
Figure 1. Filter Assembly Tubes and Mounting.
Figure 3. Filter Assembly Tubes and Mounting.
LOW-PRESSURE FUEL PUMP REPLACEMENT
Figure 1. Low-Pressure Fuel Pump.
Figure 2. Fittings.
Figure 3. Fittings.
Figure 4. Low-Pressure Fuel Pump.
LOW-PRESSURE FUEL TUBE REPLACEMENT
Figure 1. Low-Pressure Fuel Tube.
LOW-PRESSURE FUEL TUBE REPLACEMENT - Continued
HIGH-PRESSURE FUEL PUMP SUPPLY TUBE REPLACEMENT
Figure 1. High-Pressure Fuel Pump Supply Tube.
Figure 3. High-Pressure Fuel Pump Supply Tube.
Figure 4. High-Pressure Fuel Pump Supply Tube.
HIGH-PRESSURE FUEL PUMP SUPPLY TUBE REPLACEMENT - Continued
STARTER REPLACEMENT
Figure 2. Starter Solenoid Connection.
Figure 3. Ground Strap.
Figure 4. Starter.
Figure 5. Ground Strap.
Figure 6. Starter Solenoid Connection.
Figure 7. Starter Cables.
ALTERNATOR AND PULLEY REPLACEMENT
Figure 1. Drive Belt Tensioner.
Figure 2. Alternator and Bracket.
Figure 3. Alternator Connections.
Figure 4. Alternator Pulley and Fan.
Figure 5. Alternator Connections.
Figure 6. Alternator and Bracket.
Figure 7. Drive Belt Tensioner.
MAIN CHASSIS WIRING HARNESS REPLACEMENT
Figure 2. Alternator.
Figure 3. Starter.
Figure 4. Transmission Differential Solenoid.
Figure 6. Return-to-Dig Switch Bracket.
Figure 9. Fuel Injection Pump.
Figure 10. Grid Heater Wiring Harness.
Figure 12. Transmission Temperature Sender.
Figure 14. Left Parking Brake Switch.
Figure 16. Right Parking Brake Switch.
Figure 17. Right Parking Brake Switch.
Figure 18. Loader Control Valve.
Figure 20. Hydraulic Oil Filter Housing.
Figure 23. Grid Heater Wiring Harness.
Figure 24. Fuel Injection Pump.
Figure 26. Return-to-Dig Switch.
Figure 28. Return-to-Dig Wiring.
Figure 29. Transmission Differential Solenoid.
Figure 30. Starter.
Figure 32. Temperature Sender/Sensor.
MAIN CHASSIS WIRING HARNESS REPLACEMENT - Continued
FWD/REV JUMPER HARNESS REPLACEMENT
Figure 2. FWD/REV Jumper Harness Connectors.
4WD JUMPER HARNESS REPLACEMENT
Figure 2. 4WD Jumper Harness Connectors.
BATTERIES AND BRACKET MAINTENANCE
Figure 1. Battery Cover.
Figure 2. Battery Cable Connection.
Figure 3. Batteries.
Figure 4. Battery Cable Connection.
Figure 5. Battery Cover.
BATTERY CABLES REPLACEMENT
Figure 1. Battery Cover.
Figure 2. Battery Cable Connection.
Figure 4. Equalizer Cover.
Figure 5. Equalizer.
INSTALLATION
Figure 6. Equalizer.
Figure 7. Equalizer Cover.
Figure 9. Battery Cable Connection.
Figure 10. Battery Cover.
STARTER CABLES REPLACEMENT
Figure 1. Starter.
Figure 2. Alternator Cable Tiedown Straps.
Figure 3. Alternator.
Figure 4. Starter Cable Tiedown Straps.
Figure 5. Starter Cable to Cab 24-V Junction Tiedown Straps.
Figure 6. Cab 24-V Junction Block.
Figure 7. Clamp.
Figure 8. Grid Heater Fuse.
Figure 9. Starter 24-V Supply Cable Tiedown Straps.
Figure 11. Equalizer Cover.
Figure 12. 24-V Junction Cables.
Figure 13. Equalizer Cover.
Figure 14. Right Hose Cover.
Figure 16. Grid Heater Fuse.
Figure 17. Clamp.
Figure 18. Cab 24-V Junction Block.
Figure 19. Starter Cable to Cab 24-V Junction Tiedown Straps.
Figure 20. Starter Cable Tiedown Straps.
Figure 21. Alternator.
Figure 22. Alternator Cable Tiedown Straps.
Figure 23. Starter.
GRID HEATER POWER CABLE AND GRID HEATER CONTROL ASSEMBLY REPLACEMENT
Figure 2. Relay.
Figure 5. Controller Connector.
Figure 6. Relay Mount.
Figure 7. Bus Bar.
Figure 8. Relay Mount.
Figure 9. Controller Connector.
Figure 11. Grid Heater.
Figure 13. Tiedown Straps.
GRID HEATER WIRING HARNESS AND JUMPER HARNESS REPLACEMENT
Figure 1. Main Chassis Wiring Harness Connector.
Figure 3. Wiring Harness Connections.
Figure 5. Grid Heater.
Figure 6. Grid Heater.
Figure 8. Wiring Harness Connections.
Figure 9. Mounting Bolts.
Figure 10. Main Chassis Wiring Harness Connector.
FRONT CONSOLE WIRING HARNESS REPLACEMENT
Figure 2. Powershift and Front Console Options Wiring Harness Connection.
Figure 4. Main Chassis Wiring Harness, Power, and Ground Connections.
Figure 5. Relays.
Figure 6. Relay Sockets.
Figure 7. Relays.
Figure 8. Main Chassis Wiring Harness, Power, and Ground Connections.
Figure 10. Powershift and Front Console Options Wiring Harness Connection.
FRONT CONSOLE WIRING HARNESS REPLACEMENT - Continued
FRONT CONSOLE OPTIONS WIRING HARNESS REPLACEMENT
Figure 2. Front Firewall.
Figure 4. Front Console Options Wiring Harness.
Figure 5. A/C Relay.
Figure 7. Front Console Options Wiring Harness.
FRONT CONSOLE OPTIONS WIRING HARNESS REPLACEMENT - Continued
TURN SIGNAL SWITCH REPLACEMENT
Figure 3. Turn Signal Switch.
Figure 4. Cover.
Figure 5. Steering Column and Turn Signal Switch.
POWERSHIFT LEVER REPLACEMENT
Figure 3. Turn Signal Switch.
Figure 4. Cover.
Figure 5. Steering Column and Turn Signal Switch.
BRAKE LIGHT SWITCH MAINTENANCE
Figure 2. Brake Light Switch.
Figure 3. Brake Light Switch Wires.
Figure 4. Brake Light Switch Adjustment.
POWERSHIFT WIRING HARNESS REPLACEMENT
Figure 2. Left Brake Pressure Sensor Connector.
Figure 3. Powershift Wiring Harness.
Figure 4. Left Brake Pressure Sensor Connector.
POWERSHIFT WIRING HARNESS REPLACEMENT - Continued
TRANSMISSION CONTROLLER REPLACEMENT
Figure 2. Transmission Controller Wiring Harness.
Figure 3. Transmission Controller.
BRAKE PRESSURE SWITCH AND FITTING REPLACEMENT
Figure 1. Brake Pressure Sensor Connections.
Figure 2. Brake Pressure Sensor.
Figure 3. Brake Pressure Sensor.
Figure 4. Brake Pressure Sensor Connections.
BRAKE PRESSURE SWITCH AND FITTING REPLACEMENT - Continued
SIDE CONSOLE WIRING HARNESS REPLACEMENT
Figure 2. Alarm.
Figure 3. Wiring Connector Bolt.
Figure 5. Instrument Cluster.
Figure 6. Wiper Switch.
Figure 8. Wiring Harness Connector.
Figure 9. Parking Brake Lever Assembly.
Figure 10. Wiper Switch.
Figure 11. Cluster.
Figure 12. Ground Stud.
Figure 15. Wiring Connector.
SIDE CONSOLE WIRING HARNESS REPLACEMENT - Continued
CHASSIS OPTIONS WIRING HARNESS REPLACEMENT
Figure 1. A/C High-Pressure Switch Connection.
Figure 3. Windshield Washer Pump Connections.
Figure 4. A/C Compressor Connection.
Figure 6. Loader Quick-Coupler Solenoid Connections.
Figure 7. Ride Control Solenoid Connections.
Figure 8. Loader Quick-Coupler Solenoid Connections.
Figure 10. A/C Compressor Connection.
Figure 11. Windshield Washer Pump Connections.
Figure 13. A/C High-Pressure Switch Connection.
SIDE CONSOLE SWITCHES REPLACEMENT
Figure 2. Cluster Switches.
Figure 3. Throttle Panel.
Figure 4. Throttle Panel Switches.
Figure 5. Throttle Panel.
Figure 6. Cluster Switches.
Figure 7. Cluster Screws.
SIDE CONSOLE ALARM REPLACEMENT
Figure 2. Alarm.
Figure 3. Alarm Hardware.
Figure 4. Alarm.
Figure 5. Wiring Connector.
INSTRUMENT PANEL FRONT COVERS REPLACEMENT
Figure 3. Light Control Switch Controls/Indicators and Bracket.
Figure 5. Top Cover Screws.
Figure 6. Front Cover Screws.
Figure 8. FNR Selector Switch.
Figure 11. Bottom Bolt.
Figure 12. Switches.
Figure 13. Switches.
Figure 15. Front Bolt.
Figure 17. FNR Selector Switch.
Figure 19. Upper and Lower Covers.
Figure 20. Turn Signal Switch.
Figure 22. Light Control Switch Controls/Indicators and Bracket.
Figure 24. Plugs.
LIGHT CONTROL SWITCH AND BRACKET REPLACEMENT
Figure 2. Light Control Switch.
Figure 3. Right Front of Cab.
Figure 4. Light Control Switch.
INSTRUMENT PANEL RIGHT-SIDE COVERS REPLACEMENT
Figure 3. Front Vent Base.
Figure 4. Front Console Lower Bolts.
Figure 7. Fire Extinguisher Handles.
Figure 8. Top Rear Console Bolts.
Figure 11. Rear Air Vent.
Figure 12. Rear Vent Base.
Figure 15. Front Instrument Bezel.
Figure 16. Storage Box.
Figure 17. Right-Side Cover (Rear).
Figure 19. Front Instrument Bezel.
Figure 20. Rear Instrument Bezel.
Figure 23. Rear Air Vent.
Figure 25. Console Locknut.
Figure 27. Fire Extinguisher Handles.
Figure 29. Front Console Upper Bolt.
Figure 30. Front Console Lower Bolts.
Figure 32. Front Air Vent.
INSTRUMENT PANEL RIGHT-SIDE COVERS REPLACEMENT - Continued
INSTRUMENT PANEL AND CLUSTER REPLACEMENT
Figure 2. Instrument Cluster Connector.
Figure 5. Instrument Cluster.
Figure 6. Instrument Panel Screws.
Figure 9. Heater Temperature Control.
Figure 10. Switch Connectors.
Figure 11. Instrument Panel Switches.
Figure 12. Ignition Switch.
Figure 13. Instrument Panel Switches.
Figure 14. Switch Connectors.
Figure 15. Heater Temperature Control.
Figure 17. Temperature Control Knobs.
Figure 19. Instrument Cluster.
Figure 22. Instrument Cluster Connector.
Figure 23. Instrument Panel.
FRONT AND REAR DRIVING AND WORK LIGHTS REPLACEMENT
Figure 2. Harness Connection.
Figure 5. Light Housing.
Figure 7. Lamp Wires.
Figure 8. Light Bulb.
Figure 9. Lamp Wires.
Figure 12. Light Bracket.
Figure 14. Harness Connection.
Figure 15. Tiedown Strap.
FRONT BLACKOUT MARKER LIGHTS REPLACEMENT
Figure 2. Harness Connection.
Figure 5. Light Base.
Figure 6. Light Base.
Figure 7. Light Socket.
Figure 9. Harness Connection.
FRONT BLACKOUT MARKER LIGHTS REPLACEMENT - Continued
FRONT AND REAR TURN SIGNAL/HAZARD LIGHTS REPLACEMENT
Figure 2. Harness Connections.
Figure 4. Rear Light Base.
Figure 5. Rear Light Base.
Figure 7. Harness Connections.
Figure 8. Tiedown Strap.
CAB WIRING HARNESS REPLACEMENT
Figure 3. Right Duct.
Figure 4. Side Console Connection.
Figure 5. Vent.
Figure 6. Blower Connection.
Figure 7. Cab Wiring Harness.
Figure 8. Blower Connection.
Figure 10. Side Console Connection.
Figure 12. Duct Tape.
Figure 13. Domelight Switch.
DOMELIGHT SWITCH REPLACEMENT
Figure 2. Domelight Switch Wiring.
Figure 4. Domelight Switch Wiring.
Figure 5. Domelight Switch Bracket.
FRONT LIGHTS AND WIPER WIRING HARNESS REPLACEMENT
Figure 1. Front Tiedown Straps.
Figure 2. Marker Light Lens.
Figure 3. Marker Light Ground Wire.
Figure 4. Crossmember.
Figure 5. Side Tiedown Straps.
Figure 6. Wiring Harness Connector.
Figure 8. Wiring Harness Connector.
Figure 10. Side Tiedown Straps.
Figure 11. Crossmember.
Figure 12. Marker Light Ground Wire.
Figure 13. Marker Light Lens.
Figure 14. Front Tiedown Straps.
FRONT LIGHTS AND WIPER WIRING HARNESS REPLACEMENT - Continued
REAR LIGHTS WIRING HARNESS REPLACEMENT
Figure 2. Rear Wiper Motor Connections.
Figure 3. Left-Hand Turn/Hazard Light Connections.
Figure 4. Right-Hand Rear Work Light Connections.
Figure 5. Right-Hand Turn/Hazard Light Connections.
Figure 6. Right-Hand Turn/Hazard Light Connections.
Figure 7. Right-Hand Turn/Hazard Light Connections.
Figure 8. Right-Hand Turn/Hazard Light Connections.
Figure 9. Right-Hand Rear Work Light Connections.
Figure 10. Left-Hand Turn/Hazard Light Connections.
Figure 11. Rear Wiper Motor Connections.
REAR LIGHTS WIRING HARNESS REPLACEMENT - Continued
HORN AND BRACKET REPLACEMENT
Figure 2. Horn Wires.
Figure 3. Horn.
BACKUP ALARM REPLACEMENT
Figure 1. Swing Cushion Valve.
Figure 3. Swing Cushion Valve.
PILOT CONTROLS WIRING HARNESS REPLACEMENT
Figure 2. Pilot Controls Wiring Harness Tiedown Straps.
Figure 3. Cover.
Figure 4. Joystick Connectors.
Figure 5. Pilot Control Valve.
Figure 7. Left Stabilizer Pressure Switch.
Figure 9. Pilot Controls Wiring Harness.
Figure 11. Left Stabilizer Pressure Switch.
Figure 12. Control Unit and Relay.
Figure 14. Joystick Connectors.
Figure 15. Cover.
Figure 16. Pilot Controls Wiring Harness Tiedown Straps.
Figure 17. Cover.
RIGHT-HAND TOWER PILOT WIRING HARNESS REPLACEMENT
Figure 2. Tower Pilot Wiring Harness.
Figure 3. Pilot Control Switches.
BACKHOE PILOT CONTROL SWITCHES REPLACEMENT
Figure 2. Pilot Control Switches Connectors.
Figure 3. Pilot Control Switches.
STABILIZER CONTROL SWITCHES REPLACEMENT
Figure 2. Stabilizer Control Switches Connectors.
Figure 3. Plate.
Figure 4. Stabilizer Control Switches Connectors.
STABILIZER CONTROL SWITCHES REPLACEMENT - Continued
PILOT CONTROLS CONTROLLER REPLACEMENT
Figure 2. Pilot Control Module.
TAILLIGHT ASSEMBLY REPLACEMENT
Figure 1. Taillight Assembly.
CLEANING AND INSPECTION
FRONT BLACKOUT LAMP REPLACEMENT
Figure 2. Front Blackout Lamp Mount.
Figure 3. Front Blackout Lamp.
A-POST BLACKOUT LAMP WIRING HARNESS REPLACEMENT
Figure 2. Left Hose Cover.
Figure 4. Wiring Harness Connection.
Figure 6. A-Post Blackout Wiring Harness.
Figure 7. Wire Lock.
Figure 8. Wiring Harness Connection.
Figure 9. Left Hose Clamp.
Figure 11. Front Blackout Lamp.
BATTERY EQUALIZER REPLACEMENT
Figure 2. Equalizer Cover.
Figure 3. Equalizer.
Figure 4. Equalizer Cover.
BATTERY EQUALIZER REPLACEMENT - Continued
EQUALIZER CABLES REPLACEMENT
Figure 2. Equalizer Cover.
Figure 4. Junction Block.
Figure 5. 12-V Junction Block.
Figure 6. Junction Block.
Figure 7. Equalizer.
Figure 8. Equalizer Cover.
EQUALIZER CABLES REPLACEMENT - Continued
NATO SLAVE RECEPTACLE REPLACEMENT
Figure 2. Equalizer Cover.
Figure 3. NATO Slave Receptacle.
Figure 4. NATO Slave Receptacle Terminal Marking.
Figure 5. NATO Slave Receptacle.
Figure 7. Right Hose Cover.
NATO SLAVE CABLES REPLACEMENT
Figure 2. Equalizer Cover.
Figure 4. NATO Slave Receptacle.
Figure 6. Equalizer Cover.
Figure 7. Right Hose Cover.
STEERING WHEEL REPLACEMENT
Figure 3. Puller.
Figure 5. Steering Wheel.
STEERING COLUMN REPLACEMENT
CLEANING AND INSPECTION
Figure 2. Steering Column.
STEERING CONTROL VALVE REPLACEMENT
Figure 1. Steering Control Valve and Hoses.
Figure 2. Steering Control Valve Fittings.
Figure 3. Steering Control Valve Fittings.
Figure 4. Steering Control Valve and Hoses.
STEERING HYDRAULIC HOSES REPLACEMENT
Figure 2. Upper Hydraulic Pump Hose.
Figure 3. Lower Hydraulic Pump Hose.
Figure 5. Left Frame Rail.
Figure 7. Right Frame Rail.
Figure 8. Right Turn Hose.
Figure 10. Left Turn Hose.
Figure 11. Left Frame Rail.
Figure 13. Lower Hydraulic Pump Hose.
Figure 15. Steering Control Valve.
FRONT WHEEL AND TIRE ASSEMBLY REPAIR
Figure 1. Lifting Device and Trestle.
Figure 3. Removing Rim From Tire.
Figure 4. Installing Rim On Tire.
Figure 5. Wheel and Tire Assembly.
Figure 6. Wheel and Tire Assembly.
FRONT AXLE ASSEMBLY REPLACEMENT
Figure 3. Lubrication Fitting.
Figure 4. Pivot Pin and Retaining Ring.
FRONT AXLE ASSEMBLY REPLACEMENT - Continued
Figure 5. Pivot Pin.
Figure 6. Lubrication Hose and Fitting.
Figure 7. Retaining Ring.
Figure 8. Lubrication Hose and Fitting.
Figure 9. Front Axle Assembly.
Figure 10. Pivot Pin and Retaining Ring.
Figure 12. Axle Vent Hose.
FRONT AXLE ASSEMBLY DRAIN AND REFILL
Figure 2. Front Axle Wheel End.
Figure 3. Front Axle Center Bowl.
Figure 4. Front Axle Wheel End.
Figure 5. Front Axle Wheel End.
Figure 6. Front Axle Center Bowl.
FRONT DRIVE SHAFT GUARD REPLACEMENT
FRONT AXLE BREATHER HOSE AND ELEMENT REPLACEMENT
Figure 2. Front Axle Breather Hose Tiedown Straps.
Figure 3. Front Axle Breather Hose Clamp.
Figure 4. Front Axle Breather Hose at Axle.
Figure 5. Front Axle Breather Hose at Axle.
Figure 6. Front Axle Breather Hose Clamp.
Figure 7. Front Axle Breather Hose Tiedown Straps.
Figure 8. Front Axle Breather Element.
FRONT DRIVE AXLE STEERING CYLINDER REPLACEMENT
Figure 1. Hydraulic Lines.
Figure 2. Steering Cylinder.
Figure 3. Cylinder Bolts.
Figure 4. Steering Cylinder.
Figure 6. Hydraulic Lines.
FRONT DRIVE AXLE STEERING CYLINDER REPLACEMENT - Continued
FRONT DRIVE AXLE STEERING CYLINDER TIE ROD ENDS REPLACEMENT
Figure 2. Front Wheel and Tire Assemblies.
Figure 4. Locknut.
Figure 6. Tie Rod.
Figure 8. Tie Rod Jamnut.
Figure 9. Front Wheel and Tire Assemblies.
Figure 11. Toe-in Measurement.
Figure 12. Tie Rod Jamnut.
Figure 13. Trestles.
FRONT AXLE DRIVE SHAFT REPAIR
Figure 3. Retaining Rings.
Figure 4. U-Joint.
Figure 5. Retaining Rings.
Figure 7. Drive Shaft Guard.
TRANSMISSION/HYDRAULIC OIL COOLER HOSES REPLACEMENT
Figure 1. Left-Side Hydraulic Oil Cooler Hoses.
Figure 2. Right-Side Transmission Oil Cooler Hoses.
Figure 4. Right-Side Transmission Oil Cooler Hose Clamps.
Figure 6. Transmission Oil Cooler Hoses at Transmission.
Figure 8. Hydraulic Oil Cooler Hose at Fitting.
Figure 9. Hydraulic Oil Cooler Hose at Fitting.
Figure 10. Hydraulic Oil Cooler Hose at Hydraulic Oil Cooler Filter.
Figure 12. Left-Side Hydraulic Oil Cooler Hose Clamps.
Figure 15. Right-Side Transmission Oil Cooler Hoses.
Figure 16. Left-Side Hydraulic Oil Cooler Hoses.
TRANSMISSION FLUID TEMPERATURE SENDER REPLACEMENT
Figure 1. Transmission Fluid Temperature Sensor.
INSTALLATION
TRANSMISSION REPLACEMENT
Figure 1. Alternator.
Figure 2. Wiring Harness.
Figure 3. Heater Grid.
Figure 4. Fuel Lines.
Figure 5. A/C Compressor.
Figure 6. Hydraulic Pump Connections.
Figure 7. Hydraulic Pump Cooler Hoses.
Figure 8. Hydraulic Pump Bottom Bolts.
Figure 9. Hydraulic Pump Top Bolts.
Figure 10. Heater Hose Clamps.
Figure 11. Transmission Wiring Harness.
Figure 12. Harness.
Figure 13. Differential Lock.
Figure 14. Lifting Equipment.
Figure 15. Engine Mount Bolts.
Figure 17. Right Transmission Mount.
Figure 18. Left Transmission Mount Bracket.
Figure 19. Right Transmission Mount Bracket.
Figure 20. Engine and Transmission Assembly.
Figure 21. Bracket Links.
Figure 23. Torque Converter Bolts.
Figure 24. Transmission Bolts.
Figure 25. Drive Plate Ring.
Figure 26. Transmission Fittings.
Figure 28. Transmission Plate.
Figure 29. Transmission Plate Bolts.
Figure 30. Transmission Fittings.
Figure 31. Drive Plate Ring.
INSTALLATION CONTINUED
Figure 32. Transmission Bolts.
Figure 33. Torque Converter Bolts.
Figure 34. Access Plate.
Figure 35. Bracket Links.
Figure 36. Engine and Transmission Assembly.
Figure 37. Right Transmission Mount Bracket.
Figure 38. Left Transmission Mount Bracket.
Figure 39. Right Transmission Mount.
Figure 40. Left Transmission Mount.
Figure 42. Lifting Equipment.
Figure 43. Differential Lock.
Figure 44. Harness.
Figure 45. Transmission Wiring Harness.
Figure 46. Heater Hose Clamps.
Figure 47. Hydraulic Pump Top Bolts.
Figure 49. Hydraulic Pump Cooler Hoses.
Figure 50. Hydraulic Pump Connections.
Figure 51. A/C Compressor.
Figure 52. Fuel Lines.
Figure 53. Heater Grid.
Figure 54. Wiring Harness.
Figure 55. Alternator.
TRANSMISSION MOUNTS REPLACEMENT
Figure 1. Lifting Equipment.
Figure 2. Left Transmission Mount.
Figure 3. Right Transmission Mount.
Figure 4. Left Transmission Mount Bracket.
Figure 5. Left Transmission Mount.
Figure 6. Right Transmission Mount Bracket.
Figure 7. Right Transmission Mount.
Figure 8. Right Transmission Mount Bracket.
Figure 9. Left Transmission Mount.
Figure 11. Right Transmission Mount.
Figure 12. Left Transmission Mount.
Figure 13. Lifting Equipment.
TRANSMISSION DIPSTICK AND TUBE REPLACEMENT
Figure 1. Transmission Dipstick.
Figure 3. Transmission Dipstick Tube.
Figure 4. Holding Clamp.
TRANSMISSION DIPSTICK AND TUBE REPLACEMENT - Continued
TRANSMISSION OIL AND FILTER SERVICE
Figure 1. Transmission Oil Drain Plug.
Figure 2. Transmission Oil Filter Assembly.
Figure 3. Transmission Dipstick and Tube.
REAR WHEEL AND TIRE ASSEMBLY REPAIR
Figure 2. Tire Assembly.
Figure 3. Removing Rim from Tire.
Figure 4. Wheel and Tire Assembly.
Figure 5. Wheel and Tire Assembly.
Figure 6. Jack and Trestle.
REAR AXLE DIFFERENTIAL LOCK HOSE REPLACEMENT
Figure 1. Differential Lock Hose at Rear Axle.
Figure 3. Differential Lock Hose at Transmission.
Figure 4. Tiedown Straps.
Figure 5. Differential Lock Hose at Rear Axle.
REAR DRIVE AXLE HOUSING REPLACEMENT
Figure 1. Trestles.
Figure 2. Rear Drive Axle Housing Connections.
Figure 3. Rear Drive Axle Removal.
CLEANING AND INSPECTION
Figure 4. Rear Drive Axle Installation.
Figure 5. Rear Drive Axle Housing Connections.
REAR DRIVE AXLE HOUSING OIL SERVICE
Figure 2. Wheel End.
Figure 3. Rear Drive Axle Housing Plugs.
Figure 4. Wheel Hub.
FILL REAR DRIVE AXLE HOUSING OIL
Figure 6. Rear Drive Axle Housing Plugs.
REAR DRIVE AXLE OIL TEMPERATURE SENDING UNIT REPLACEMENT
Figure 1. Rear Drive Axle Oil Temperature Sending Unit.
INSTALLATION
REAR AXLE DRIVE SHAFT REPAIR
Figure 2. Retaining Rings.
Figure 4. Retaining Rings.
Figure 5. Rear Axle Drive Shaft.
PARKING BRAKE LIGHT SWITCH MAINTENANCE
Figure 2. Parking Brake Light Switch.
Figure 3. Parking Brake Light Switch Wires.
Figure 4. Switch Adjustment.
PARKING BRAKE LIGHT SWITCH MAINTENANCE - Continued
BRAKE MASTER CYLINDERS AND TUBES MAINTENANCE
Figure 1. Brake Tube.
Figure 2. Brake Tube Connection.
Figure 3. Hydraulic Brake Hose.
Figure 4. Brake Rod Pin.
Figure 5. Master Cylinder.
Figure 6. Master Cylinder Clevis.
Figure 7. Master Cylinder Clevis.
Figure 8. Master Cylinder.
Figure 9. Brake Rod Pin.
Figure 10. Hydraulic Brake Hose.
Figure 11. Brake Tube.
Figure 12. Brake Tube Connection.
Figure 13. Brake Master Cylinder Reservoir.
Figure 15. Right Brake Bleeder.
Figure 17. Left Brake Bleeder.
Figure 19. Brake Clevis.
BRAKE MASTER CYLINDERS AND TUBES MAINTENANCE - Continued
BRAKE MASTER CYLINDER RESERVOIR AND TUBES REPLACEMENT
Figure 1. Return Hose.
Figure 3. Return Hose Tiedown Strap.
Figure 4. Reservoir.
Figure 5. Reservoir Tubes.
Figure 6. Reservoir.
Figure 7. Return Hose Tiedown Strap.
Figure 9. Return Hose.
BRAKE PEDALS AND BRACKET MAINTENANCE
Figure 2. Fuse Box.
Figure 4. Brake Pedal Pins.
Figure 5. Brake Pedal Bracket Bolts.
Figure 7. Brake Return Springs.
Figure 8. Brake Pedal Rod.
Figure 9. Pedal Stops.
Figure 10. Brake Pedal Lock.
Figure 12. Brake Lamp Arm.
Figure 14. Brake Pedal Lock.
Figure 15. Pedal Stops.
Figure 16. Brake Pedal Rod.
Figure 17. Brake Return Springs.
Figure 19. Brake Pedal Bracket Bolts.
Figure 20. Brake Pedal Pins.
Figure 21. Brake Pedal Bracket Support.
Figure 23. Brake Light Wires.
Figure 24. Brake Pedal Height Adjustment.
PARKING BRAKE LEVER ASSEMBLY REPLACEMENT
Figure 2. Parking Brake Lever Assembly.
PARKING BRAKE CABLE REPLACEMENT
Figure 3. Brake Cable.
Figure 4. Brake Cable Hangar.
Figure 6. Parking Brake Cable Clevis.
Figure 7. Cable Clevis.
Figure 8. Brake Cable Guide.
Figure 9. Brake Cable.
Figure 10. Floor Panel.
Figure 11. Parking Brake Lever Assembly.
Figure 12. Rear Cable Adjustment.
Figure 13. Handle Adjustment.

Western Governors University

Privacy Statement
Press Release
Contact

Integrated Publishing, Inc. - A (SDVOSB) Service Disabled Veteran Owned Small Business