Form No. 18234SL Rev D Outcross 9060 Models 07511AA/BA/CA/DA © 2021—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date A 10/2018 Initial Release B 11/2018 Parker hydraulic valve service information C 9/2020 TEC connector torque, 3–point hitch position sensor alignment procedure D 07/2021 Updated Hydraulic, Electrical and Traction and PTO Drive chapters.
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Reader Comments Page 4 Outcross 9060 18234SL Rev D
Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repairing the major systems and components of the Outcross 9060 traction unit (Model No. 07511AA, 07511BA, 07511CA, and 07511DA). Refer to the traction unit Operator’s Manual and accessory Installation Instructions for installation, operation, maintenance, and adjustment information.
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Jacking Instructions ..................................................................................... 1–8 Safety and Instructional Decals .
Wire Harness Diagram – Frame....................................................................A–8 Wire Harness Drawing – Platform .................................................................A–9 Wire Harness Diagram – Platform...............................................................A–10 Wire Harness Diagram – Platform (continued) ............................................A–11 Wire Harness Drawing – Engine .................................................................
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Supervisor’s Responsibilities ............................................................................................................. 1–2 Before Operating the Machine ........................................................................................................... 1–3 Operating the Machine.................
Safety Instructions The Outcross 9060 machine is tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, hazard control and accident prevention are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
Before Operating the Machine • Review and understand the contents of the traction unit Operator’s Manual, all of the operating and safety decals on the machine, and any operation information found in the Installation Instructions for accessories that are installed on the machine. Additional copies of the traction unit Operator’s Manual and accessory Installation Instructions are available at www.toro.com. • View and understand the Operator and Safety Training Videos found at www.toro.com.
Operating the Machine DANGER The exhaust fumes are hazardous and have the potential of causing injury or death. Do not run the engine in a confined area without adequate ventilation. Note: Operator advisories are automatically displayed by the InfoCenter when a machine function is prevented and additional action is required. Typically, an advisory can be eliminated with a change in machine controls by the operator. Refer to Operator Advisories (page 3–3) for additional information. 1.
Operating the Machine (continued) Careless operation, combined with terrain angles, ricochets or improperly positioned guards can lead to thrown object injuries. Do not resume operation until the area is cleared. 9. Before getting off the seat: A. Make sure any attachments are disengaged. IMPORTANT When an attachment is lowered to the ground, the pressure in the hydraulic lift circuit is released and accidentally lowering the attachment is avoided. B. Lower any attachments to the ground. C.
Maintenance and Service The maintenance procedures and recommended service intervals for your machine are covered in the traction unit Operator’s Manual and accessory Installation Instructions. Refer to this publication when performing regular equipment maintenance. Several maintenance procedures have break-in intervals identified in the traction unit Operator’s Manual and accessory Installation Instructions. Refer to the Engine Operator’s Manual for additional engine specific maintenance procedures.
Maintenance and Service (continued) • Ensure to dispose of potentially harmful waste (e.g., fuel, oil, engine coolant, filters, battery) in an environmentally safe manner. Follow all local codes and regulations when recycling or disposing of waste. • At the time of manufacture, the machine conformed to Machinery Directive 2006/42/EC, Electromagnetic Compatibility (EMC) Directive 2014/30/EU, and ISO standards for power, mass, vibration, and sound.
Jacking Instructions CAUTION Failing to properly support the machine with appropriate jack stands can cause the machine to move or fall and can result in personal injury. Approximate weights: • Base model = 2,340 kg (5,160 lbs) • Cab model = 2,640 kg (5,820 lbs) When changing the attachments, tires, or performing other service: • Before you lift the machine, remove all the attachments that may interfere with the safe and correct lift of the machine.
Raising the Rear of the Machine g232344 Figure 2 1. Rear jack point 2. Rear jack stand point (frame channel) 1. Block the 2 front wheels with chocks to prevent the machine from moving. 2. Position the jack securely under the desired rear jacking point. 3. After raising the rear of the machine, use an appropriate jack stand under the vehicle frame to support the machine.
Safety: Safety and Instructional Decals Page 1–10 Outcross 9060 18234SL Rev D
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Overall Dimensions............................................................................................................................ 2–2 Traction Unit.......................................................................................................................................
Specifications Overall Dimensions g231580 Figure 3 Outcross 9060 Specifications and Maintenance: Specifications Page 2–2 Outcross 9060 18234SL Rev D
Traction Unit Item Description Weight Model 07511AA (base model) 2,340 kg (5,160 lb) Model 07511BA (base model with front loader*) 2,680 kg (5,910 lb) Model 07511CA (cab model) 2,640 kg (5,820 lb) Model 07511DA (cab model with front loader*) 2,980 kg (6,570 lb) *Front loader attachment (bucket) and rear counterweight not included Engine Item Description Make/Designation Yanmar 4TNV86CT-DTR2: 4−Cycle, 4 Cylinder, Water Cooled, Turbocharged, EPA Tier 4 compliant Diesel Bore 86 mm (3.
Hydraulic System Item Description Piston (traction) pump (P1) and (P2) Maximum pump displacement (per pump) Gear pump Danfoss tandem variable displacement axial piston pump 37.8 cc (2.31 in³/rev) per revolution Casappa 2 section, positive displacement gear type pump Front section (P3) displacement 16.9 cc (1.03 in³) per revolution Rear Section (P4) displacement 11 cc (0.
Chassis Item Description Bed capacity/volume Outcross 9060 18234SL Rev D Standard bed 453 kg (1,000 lb), 0.6 cubic meters (0.8 cubic yards) Cargo bed (optional) 2,041 kg (4,500 lb), 1 cubic meters (1.
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These torque specifications for the installation and tightening of the fasteners will apply to all the fasteners which do not have a specific requirement identified in this Service Manual.
Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 4 Torque Conversion Factor = A / B 1. Torque wrench 3. A (effective length of torque wrench) 2. Drive-adapter wrench (crowfoot) 4. B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g.
Identifying the Fastener g206089 Figure 5 Metric Bolts and Screws 1. Class 8.8 2. Class 10.9 g206088 Figure 6 Inch Series Bolts and Screws 1. Grade 1 2. Grade 5 3. Grade 8 Fasteners with a Locking Feature IMPORTANT If a fastener with a locking feature or previously applied thread locking compound is reused, clean the fastener threads and apply new thread locker to the fastener during installation. Locking features are designed to create friction and prevent a fastener from loosening.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 and 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, and Sems with Regular Height Nuts(SAE J995 Grade 2 or Stronger Nuts) in-lb in-lb N∙cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 56 18 ± 2 30 ± 5 339 ± 56 1/4 - 20 UNC 48 ± 7 53 ± 7 1/4 - 28 UNF 53 ± 7 5/16 - 18 UNC 5/16 - 24 UNF SAE Grade 5 Bolts, Screws, Studs, and Sems with Regular Height Nuts(SAE J995 Grade 2 or Stronger Nuts)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 ± 6 in-lb 644 ± 68 N∙cm 78 ± 8 in-lb 881 ± 90 N∙cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N∙cm 133 ± 14 in-lb 1503 ± 158 N∙cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N∙m 28 ± 3 ft-lb 38 ± 4 N∙m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb Thread Cutting Screws (Zinc Plated Steel) Type 1, Type 23 or Type F Thread Size Baseline Torque** No. 6 - 32 UNC 20 ± 5 in-lb No. 8 - 32 UNC 30 ± 5 in-lb No.
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies.
Shop Supplies (continued) GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
150 LPM (40 GPM) Hydraulic Tester Toro Part No. AT40002 Use this tester to test the hydraulic circuits and components for flow and pressure capacities. The tester flow measurement maximum is 151 LPM (40 GPM). This tester includes the following: Load Valve – Turn the valve to restrict the flow to create a simulated working load in the circuit. Pressure Gauge – A glycerine filled pressure gauge 0 to 34,500 kPa (0 to 5,000 psi) to provide operating circuit pressure.
Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system.
High Flow Hydraulic Filter Kit Toro Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 LPM or 40 GPM) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bidirectional filtration which prevents filtered unwanted material from entering into the circuit regardless of the flow direction. If a component failure occurs in the closed-loop traction circuit, contamination from the damaged part will remain in the circuit until you remove it.
Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter. This excess current can damage the circuits that are not designed to carry it. Battery Terminal Protector Toro Part No.
Spring Compression Tool (continued) Toro Part No. 138–3968 Use with a press to relieve PTO clutch piston spring load during PTO clutch service.
Specifications and Maintenance: Special Tools Page 2–20 Outcross 9060 18234SL Rev D
Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ............................. 3–2 Gather Information ............................................................................................................................. 3–2 Evaluate Potential Causes ................................................................................................................. 3–2 Assess Performance.............................................
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis • Narrow down the focus of the problem Assess Performance • Ensure you have all the necessary tools for testing • Test all potential causes of the failure • Reevaluate and create a new hypothesis if nece
Operator Advisories Operator advisories are automatically displayed by the InfoCenter when a machine function is prevented and additional action is required. Typically, an advisory can be eliminated with a change in machine controls by the operator. For example; if the operator attempts to start the engine when the traction pedal is depressed, an advisory is identified on the InfoCenter Display that the traction pedal needs to be in neutral. An advisory will not be logged into any fault log.
Operator Advisories (continued) Advisory Number Advisory Name Qualifiers Instructions B2486 MODE CHANGE DENIED Traction Engaged For Mode change | Bring machine to stop B2487 MODE CHANGE DENIED Traction Pedal Engaged For Mode change | Return traction pedal to neutral B248A MODE CHANGE DENIED Auxiliary Hydraulic Switch Closed For Mode change | Disengage auxiliary hydraulics B24B2 INCH MODE DENIED Fault Active For Inch mode | Resolve active faults B24B3 INCH MODE DENIED Not in Neutral Fo
Operator Advisories (continued) Advisory Number Advisory Name Qualifiers Instructions B2526 AUXILIARY HYDRAULICS DENIED Traction Disengaged For auxiliary hydraulics | Engage traction B2527 AUXILIARY HYDRAULICS DENIED Engine Hot For auxiliary hydraulics | Let Engine cool B252E AUXILIARY HYDRAULICS DENIED Below Minimum Work Height For auxiliary hydraulics | Raise Three Point B252F AUXILIARY HYDRAULICS DENIED Above Maximum Work Height For auxiliary hydraulics | Lower Three Point B262A FUEL
Machine and Engine Faults Machine faults are generated by the Toro Electronic Controller (TEC) to identify an electrical system malfunction (fault) that occurs during machine operation. Engine faults are generated by the by the Yanmar engine Electronic Control Unit (ECU) to identify an electrical system malfunction (fault) pertaining to the engine during operation. The fault IDs conform to SAE J2012 standards.
Machine Faults (continued) Fault ID P057C P057D P05E0 P0615 P0616 Fault Title Fault Description Controller Action Decelerator Pedal Position Sensor Analog Short to Ground Short to ground detected on decelerator pedal position sensor – analog Traction is disabled until ignition key is cycled Decelerator Pedal Position Sensor Analog Open Circuit Decelerator Pedal Position Sensor Analog to Decelerator Pedal Neutral Switch – Digital Correlation Fault Start Output Open Circuit Start Output – Overcu
Machine Faults (continued) Fault ID P0617 P06E9 P0939 P0940 P100C P100D P1104 Fault Title Fault Description Engine Start Output - Short to Battery Low current detected on engine start output .
Machine Faults (continued) Fault ID P110C P110D P1114 P111C Fault Title Fault Description Traction Coil (front pump forward valve C1) Validation Failure Current Converge A current monitor which validates the intended traction coil current is indicating an unexpected variance between the desired level of current to the traction coil and the actual level of current to the traction coil.
Machine Faults (continued) Fault ID P111D P1124 P112C P112D Fault Title Fault Description Traction Coil (front pump reverse valve C2) Validation Failure - PWM Converge PWM convergence is checking 2 fault conditions. The first check is to confirm that the PWM duty cycle across the coil is decreasing when the desired current to the coil is 0.
Machine Faults (continued) Fault ID P1134 P113C P113D Fault Title Fault Description Traction Coil (rear pump reverse valve - C2) Overcurrent Overcurrent detected. Indicates a short to ground.
Machine Faults (continued) Fault ID P114C Fault Title Fault Description Front Traction Hydraulic Circuit Charge Pressure Low Charge pressure in front traction circuit is less than 1103 kPa (160 psi) Controller Action Note: If fault P115C is also present, a charge circuit issue exists outside of the traction pump (steering and/or lift operation will also be affected). Confirm charge pressure at the test port provided and perform gear pump (P4) flow test.
Machine Faults (continued) Fault ID P210E P2130 P2132 P2152 P2503 Controller Action Fault Title Fault Description Traction Pedal Sensor/Switch Analog vs Analog conflict The traction pedal has 2 position sensors (APS1 and APS2), each producing its own analog signal. The analog signals independently indicate a pedal position relative to neutral (rest). The two signals are reporting differing positions outside of an expected variance.
Machine Faults (continued) Fault ID P2504 P2530 C1013 C1014 C1015 C1020 Fault Title Fault Description System Voltage - Too High The system voltage is more than 16.3 VDC.
Machine Faults (continued) Fault ID C1023 C1024 C1025 C1093 C1094 C1095 C10A3 Fault Title Fault Description Parking Brake Disengage Output - Short to Battery Low current detected on parking brake disengage output. Indicates a short to battery.
Machine Faults (continued) Fault ID C10A4 C10A5 C10B3 C10B4 C1314 C1315 Fault Title Fault Description Parking Brake Light Output Overcurrent Overcurrent detected on parking brake light output. Indicates short to ground.
Machine Faults (continued) Fault ID C1324 C1325 Fault Title Fault Description 3-Point Hitch Lower Output Overcurrent Overcurrent detected on 3-point hitch lower output. Indicates short to ground. 3-Point Hitch Lower Output Open Circuit Controller Action Open Circuit detected on 3-point hitch lower output. Recommended Service Actions 1. Check the 3-point hitch lower output circuit wiring and all of the output circuit connectors 2. Test the 3-point hitch lower output circuit wiring 3.
Machine Faults (continued) Fault ID C14A4 C14A5 Fault Title Fault Description Optional Solenoid Control Valve (SCV) Output Overcurrent Overcurrent detected on optional SCV output. Indicates short to ground. Optional Solenoid Control Valve (SCV) Output Open Circuit Controller Action Open Circuit detected on optional SCV output. Recommended Service Actions 1. Check the optional SCV output circuit wiring and all of the output circuit connectors 2. Test the optional SCV output circuit wiring 3.
Machine Faults (continued) Fault ID Fault Title Fault Description C14C4 PTO Output -Overcurrent Overcurrent detected on PTO output. Indicates short to ground.
Machine Faults (continued) Fault ID B1027 B1107 B1117 B1127 B1137 B1154 B1155 Fault Title Fault Description Cruise Control Speed Increase/ Decrease Switch is Broken Both CRUISE CONTROL INPUTS–SPEED INCREASE and CRUISE CONTROL INPUTS–SPEED DECREASE are active at the same time Transmission Lever Switch Broken Optional InchMode Raise/Lower Switch Broken Optional InchMode Forward/ Reverse Switch Broken Paddle Switch Broken Mode Selector - Short to Ground Mode Selector - Open Circuit Controller
Machine Faults (continued) Fault ID B1164 B1165 U0100 U012A U012B U0156 U1007 Fault Title Fault Description 3-Point Hitch Position Sensor - Short to Ground Short to ground detected on 3-point hitch position sensor 3-Point Hitch Position Sensor - Open Circuit Open circuit detected on 3-point hitch position sensor Disable autonomous 3-point hitch control Disable autonomous 3-point hitch control All machine functions disabled CAN Bus Communication Fault - Engine ECU T2: TDM display blank but m
Machine Faults (continued) Fault ID U1023 U1024 U1025 Fault Title Fault Description T1: TEC Fuse Output PWR 3 Failure Power supply for outputs 9–12 of T1: TEC has failed. T1: TEC Fuse Output PWR 4 Failure T1: TEC Fuse Output PWR 5 Failure Controller Action Recommended Service Actions Check power supply to T1: TEC outputs Power supply for outputs 5–8 of T1: TEC has failed. 1. Test fuse F-B1 7.5A 2.
Using the InfoCenter Display for Troubleshooting The Service − Input/Output screens of the InfoCenter display can be very helpful when troubleshooting machine operation issues. Electrical components and their circuit wiring can be evaluated quickly using the Input/Output screens prior to testing the component individually. The Input/Output screens show the current state of the inputs and the outputs required to allow a machine operation to proceed.
TRACTION (example): (continued) • Depress the traction pedal slowly. The TR. PEDAL SIGNAL 1 and 2 voltages • • • • • • • should increase as the pedal is depressed. Signal 1 should be approximately twice as high as signal 2. If not, the traction pedal or its circuit wiring is faulty and should be tested. Depress the decelerator pedal slowly. The BRAKE NEUTRAL input should be OFF when the pedal is depressed and ON when the pedal is fully at rest.
TRACTION (example): (continued) the parking brake switch is OFF. If the output reading is appropriate and the vehicle does not perform correctly, the solenoid valve SV3 or its circuit wiring may be faulty and should be tested. • Setting the mode selector to H then L or A should toggle RANGE HI ON and OFF. If the output reading is appropriate and the vehicle does not perform correctly, the solenoid valve SV1 or its circuit wiring may be faulty and should be tested.
General Hydraulic System Problems Problem Hydraulic fluid is leaking from the system. The hydraulic fluid foams excessively causing fluid leakage from the hydraulic tank breather. Possible Cause Corrective Action The fitting(s), hose(s), or tube(s) are loose or damaged. Secure or replace loose or damaged hydraulic connections. The O-ring(s) or seal(s) are missing or damaged. Install a new O-ring(s) or seal(s). The hydraulic fluid level in the hydraulic tank is low. Adjust the hydraulic fluid level.
Traction System Problems Problem The traction response is sluggish. Possible Cause Corrective Action The hydraulic fluid is very cold. Allow the hydraulic fluid to warm by safely operating the machine at rest. The hydraulic fluid level in the hydraulic tank is low. Adjust the hydraulic fluid level. The traction pump bypass valve(s) is open or damaged. Close or replace the traction pump bypass valve(s). Engine speed is low. Increase the engine speed. A piston pump control solenoid is damaged.
Traction System Problems (continued) Problem No traction exists in either direction. Possible Cause Corrective Action The hydraulic fluid level in the hydraulic tank is low (other hydraulic circuit performance is affected as well). Adjust the hydraulic fluid level. The traction pump bypass valve(s) is open or damaged. Close or replace the traction pump bypass valve(s). One or more orifice or screen in piston (traction) pump control assembly is partially obstructed or damaged.
Traction System Problems (continued) Problem The parking brake cannot be disengaged with engine running. Possible Cause An electrical problem exists in the solenoid valve (SV2) circuit. Corrective Action Test and replace the valve solenoid if necessary. Test the machine wire harness solenoid valve (SV2) circuit. Solenoid valve (SV2) in the main manifold is leaking or faulty. Clean the solenoid valve and replace the seals Replace solenoid valve if necessary. The differential lock will not engage.
Steering System Problems Problem Steering is sluggish, operates poorly or is inoperative. Possible Cause Steering components (e.g. rod ends, steering cylinders, steering stops) are worn or binding. Corrective Action Inspect steering components and repair or replace if necessary. Verify and adjust rod end and steering stop lengths and adjust if necessary. Oil supply to the steering control valve is insufficient (traction charge and lift circuits affected as well).
PTO System Problems Problem The PTO shaft will not engage. Possible Cause An electrical problem exists in the proportional solenoid valve (EH) circuit. Corrective Action Test and replace the valve solenoid if necessary. Test the machine wire harness proportional solenoid valve (EH) circuit. Proportional solenoid valve (EH) in the main manifold is stuck, leaking or faulty. Clean the solenoid valve and replace the seals. Replace the solenoid valve if necessary.
3-Point Hitch System Problems Problem Hitch cylinders will not raise or raise slowly. Possible Cause Corrective Action Engine speed is too low. Increase engine speed. Hitch components are binding, worn or damaged. Inspect hitch components and repair or replace if necessary. The hydraulic fluid level in the hydraulic tank is low (other hydraulic circuit performance is affected as well). Adjust the hydraulic fluid level. Relief valve (RV2) in the main manifold is stuck, leaking or damaged.
Attachment/Loader Problems Problem Possible Cause Attachment cylinder or motor operates poorly or is inoperative. A mechanical problem exists with the attachment cylinder or motor application that affects operation (example: binding or worn pivots, arms, linkage or couplings). Inspect attachment components and repair or replace if necessary. Relief valve in auxiliary load valve is stuck, leaking or damaged. Clean the relief valve and replace the seals.
Attachment/Loader Problems (continued) Problem Loader cylinder operates poorly or is inoperative. Possible Cause Corrective Action A mechanical problem exists with the loader cylinder that affects operation (example: binding or worn pivots, arms, linkage or couplings). Inspect loader components and repair or replace if necessary. Relief valve in auxiliary load valve is stuck, leaking or damaged. Clean the relief valve and replace the seals.
Chapter 4 Engine Table of Contents General Information .............................................................................................................................. 4–2 Traction Unit Operator’s Manual ........................................................................................................ 4–2 Yanmar Service and Troubleshooting Manuals .................................................................................. 4–2 Shutting Off the Engine ..............................
General Information This chapter provides information for repairing the various systems that support the Yanmar diesel engine used in the Outcross 9060. The general maintenance procedures are described in the Operator’s Manual and the Yanmar TNV Series Operation Manual supplied with the machine. Detailed information on engine troubleshooting, testing, disassembly, and assembly is identified in the Yanmar TNV (Tier 4) Series Service Manual and the Yanmar TNV (Tier 4) Series Troubleshooting Manual.
Engine Electronic Control Unit (ECU) g249798 Figure 7 1. 2. Dash cover Engine ECU 3. Yanmar SA-D connector The Yanmar engine that powers your Outcross 9060 machine uses an Electronic Control Unit (ECU) for engine management.
Yanmar Engine g249750 Figure 8 1. Diesel particulate filter (DPF) 2. Turbocharger The engine used on Outcross 9060 machine is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA Tier 4F emission regulations. The engine features include an electronic control unit (ECU) that controls a common rail fuel injection system, an exhaust gas recirculation (EGR) system, an electronic governor, a diesel exhaust particulate filter (DPF), and a turbocharger.
Diesel Particulate Filter g249683 Figure 9 1. Diesel Particulate Filter assembly (DPF) 2. Diesel Oxidation Catalyst (DOC) 3. 4. Soot filter Temperature sensor (2 each) 5. Pressure differential sensor The diesel particulate filter (DPF) used on Yanmar Tier 4F compliant engines is designed to break down the hazardous elements in the exhaust and prevent the discharge of unburned fuel or oil known as particulate matter or soot.
Regeneration (continued) Types of regeneration that are performed automatically (while the machine is operating) Type Conditions Description Passive Occurs during normal operation of the machine at high engine speed or high engine load The DPF processes high heat exhaust gasses, oxidizing harmful emissions and incinerating soot to ash. Passive regeneration occurs as part of normal engine operation. The InfoCenter does not display an icon during passive regeneration.
Regeneration (continued) Types of regeneration that are performed manually (while the machine is stationary) Type Conditions Description Parked Occurs when exhaust back pressure in the DPF increases due to continued soot buildup. The InfoCenter displays the stationary regeneration icon. May occur because the InfoCenter was set to inhibit reset regeneration and machine operation continued, adding more soot to the DPF after a reset regeneration was requested.
Service and Repairs Air Cleaner System g249816 Figure 10 1. Cover 7. Hose clamp 2. Vacuator valve 8. Hose clamp 3. Element 9. Body 4. Air cleaner mounting band 10. Pre-cleaner 5. Engine Intake hose 11. Flange nut (2 each) 6. Air cleaner inlet hose 12. Carriage screw (2 each) Removing and Installing the Air Cleaner System Note: Refer to the traction unit Operator's Manual for maintenance procedures and intervals of the air cleaner. 1. Remove the air cleaner components as necessary.
Removing and Installing the Air Cleaner System (continued) 3. Examine the hoses for wear or damage and replace them if necessary. 4. Examine the hood and radiator/oil cooler seals for wear or damage and replace the seals if necessary. IMPORTANT Leaks in the air filter system will allow dirt to enter the engine and can cause serious engine damage. Ensure that all the air cleaner components are in good condition and are properly secured during installation. 5.
Exhaust System g250054 Figure 11 1. Gasket 5. Exhaust pipe 2. Flange 6. Cap screw (2 each) 3. Flange nut (4 each) 7. Exhaust bracket 4. Muffler clamp (2 each) The engine that powers your Outcross 9060 machine is equipped with an exhaust system that includes a Diesel-Particulate Filter (DPF). The DPF includes a Diesel Oxidation Catalyst (DOC), a Soot Filter (SF), 2 temperature sensors, and a pressure differential sensor.
Radiator g250200 Figure 12 1. Radiator cap 8. Hose – coolant reservoir 15. Fuel cooler assembly 2. 3. Hose clamp (2 each) 9. Isolator mount (3 each) 16. Foam seal (4 each) Upper radiator hose 10. Flange-head screw(2 each) 17. Flange-head screw (4 each) 4. 5. Fan shroud – right 11. Bracket – top 18. Straight hydraulic fitting (2 each) Flat washer (4 each) 12. Nut plate – top 19. Hydraulic fluid cooler 6. Flange-head screw (4 each) 13. Fan shroud – left 20. Pipe plug 7.
Removing the Radiator and Hydraulic Fluid Cooler (continued) DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns. Do not open the radiator cap or drain the radiator when the coolant is hot. WARNING Ethylene-glycol antifreeze is poisonous. Keep the coolant away from children and pets. Keep the coolant in a labelled container. Discard the coolant in accordance with local hazardous waste ordinances. 3. Drain the coolant from the radiator. 4.
Installing the Radiator and Hydraulic Fluid Cooler (continued) 5. Secure the fuel cooler assembly to the hydraulic fluid cooler. 6. Remove the covers and plugs from the openings in the radiator and the hydraulic fluid cooler and the disconnected coolant and hydraulic lines that were installed during removal. 7. Connect the hydraulic lines to the hydraulic fluid cooler. 8. Connect the upper and lower radiator hoses and the reservoir hose to the radiator and secure the hoses with the hose clamps. 9.
Fuel System g250352 Figure 13 1. Fuel tank 11. Separator and pump bracket 21. Flange-head screw (4 each) 2. Fuel tank cap 12. Fuel hose – fuel pump to fuel filter 22. 3. Rubber bushing (2 each) 13. Clamp 23. Fuel sender gasket 4. Fuel/water separator 14. Fuel level sender 24. Flange nut (3 each) 5. 90° elbow fitting (2 each) 15. Rollover valve 25. Fuel cooler bracket – LH 6. Stand pipe 16. Grommet 26. Fuel cooler 7. Fuel/water separator head 17. Vent hose 27.
DANGER Diesel fuel is highly flammable and explosive. A fire or an explosion from the fuel can burn you, burn other people, and damage property. • Use caution whenever you store or handle diesel fuel. • Do not smoke while handling diesel fuel. • Do not handle diesel fuel while the engine is running, while the engine is hot, or when the machine is in an enclosed area. • Handle diesel fuel outside whenever possible and wipe up any spilled diesel fuel before starting the engine.
Removing and Installing the Fuel Tank (continued) IMPORTANT To prevent damage to the fuel hoses, numerous cable ties and clamps are used to secure the hoses to the machine components. Record the location of all cable ties and clamps that are removed from the machine so they can be properly replaced. 8. Label the fuel hoses for assembly purposes. Loosen the hose clamps and disconnect the hoses from the fuel tank. 9.
Engine g250402 Figure 14 1. Side shield – RH 5. Coolant reservoir assembly 2. Side shield – LH 6. Top nut plate 3. Fuel filter 7. 4. Fuel cooler 8. 9. Flange nut (4 each) 10. Carriage screw (4 each) Fan shroud – RH 11. Radiator and mount assembly Fan shroud – LH 12. Lifting lug Removing the Engine 1. Park the machine on a level surface, lower any attachments, shut off the engine and remove the key from the key switch. 2.
Removing the Engine (continued) IMPORTANT To prevent damage to the fuel hoses, numerous cable ties and clamps are used to secure the hoses to the machine components. Record the location of all cable ties and clamps that are removed from the machine so they can be properly replaced. 7. Disconnect the fuel hoses; refer to Fuel System (page 4–14): A. Disconnect the hose between the engine fuel filter and the fuel cooler at the engine fuel filter. B.
Removing the Engine (continued) 14. Remove the exhaust pipe from the engine; refer to Exhaust System (page 4–10). 15. Remove the Operator’s platform; refer to Removing the Operator’s Platform (page 8–6). CAUTION The hydraulic pump assembly weighs approximately 73 kg (160 lbs). 16. Support the hydraulic pump assembly. 17. Disconnect the hydraulic pump assembly at the front PTO gearbox. 18.
Removing the Engine (continued) g250065 Figure 15 1. Fusible link 7. Cap screw (8 each) 13. Bolt – rear (2 each) 2. Bracket – front left (for machines without air conditioning shown) 8. Engine mount – front (2 each) 14. Snubbing washer – rear (2 each) 3. Flange nut (10 each) 9. Snubbing washer – front (2 each) 15. Engine mount – rear (2 each) 4. Bracket – front right 10. Bolt – front (2 each) 16. Flange nut (2 each) 5. Lock washer (8 each) 11. Flange-head screw 17.
Removing the Engine (continued) IMPORTANT When removing the engine ensure that you do not damage the engine, fuel hoses, hydraulic lines, electrical harnesses or other parts. 23. Carefully raise the engine from the machine moving it toward the front of the machine. 24. Locate and retrieve the hydraulic pump drive coupler and O-ring. Discard the O-ring. 25. If necessary, remove the wire harness and engine mount brackets from the engine. 26.
Installing the Engine (continued) IMPORTANT When installing the engine ensure that you do not damage the engine, fuel hoses, hydraulic lines, electrical harnesses or other parts. 4. Carefully lower the engine into the machine while aligning the hydraulic pump drive coupler. 5. Install the cap screws, snubbing washers and lock nuts securing the engine mounts to the engine brackets. 6. Remove the pump support and secure the hydraulic pump to the front PTO gearbox.
Flywheel Housing and Drive Coupler g250524 Figure 16 1. Flywheel housing 4. Hardened washer (8 each) 2. Flange head screw (8 each) 5. Cap screw (8 each) 3. Flywheel coupler Removing and Installing the Flywheel Housing and Drive Coupler Note: Removing the engine from the machine before removing the flywheel housing and drive coupler is required. 1. Remove the flywheel housing and drive coupler components as necessary. 2. Position the drive coupler to the engine flywheel and align mounting holes.
Engine: Service and Repairs Page 4–24 Outcross 9060 18234SL Rev D
Chapter 5 Hydraulic System Table of Contents General Information .............................................................................................................................. 5–3 Traction Unit Operator’s Manual and Accessory Installation Instructions............................................ 5–3 Relieving Pressure from the Hydraulic System .................................................................................. 5–3 Towing the Traction Unit.......................................
Axle Motor Service ........................................................................................................................... 5–78 Axle Differential Locks...................................................................................................................... 5–79 Hydraulic Brake Assembly ............................................................................................................... 5–80 Hydraulic Brake Service....................................................
General Information Traction Unit Operator’s Manual and Accessory Installation Instructions The traction unit Operator’s Manual and accessory Installation Instructions provide information regarding the operation, general maintenance and maintenance intervals for the machine and its accessories. Refer to the traction unit Operator’s Manual and accessory Installation Instructions for additional information.
Towing the Traction Unit g234000 Figure 17 1. Access panel 4. Manual valve 2. 6 mm hex wrench 5. Hand pump 3. Bypass valves (4 each) IMPORTANT If towing limits are exceeded, severe damage to the piston (traction) pump may occur If it becomes necessary to tow or push the machine, the tandem piston (traction) pump must be set to bypass hydraulic fluid and the hydraulic brake circuit must be manually pressurized to release the brake. Move the machine at a speed below 3.
Towing the Traction Unit (continued) g233998 Figure 18 1. Bypass valve assembly 4. Plunger (normal operating position) 2. 6 mm hex wrench 5. Plunger (bypass position for towing) 3. Plug Note: To prevent hydraulic fluid leakage, do not loosen the bypass valve assemblies. 2. Set the valves to the bypass position by inserting a 6 mm hex wrench through the valve plug and turning the plunger all the way in clockwise. Repeat this step for each bypass valve assembly (4 total). 3.
Traction Circuit (Closed-Loop) Component Failure The traction system of the Outcross 9060 machine consists of two closed-loop circuits, each with it’s own piston (traction) pump, drive axle motor, and control valves. The two traction pumps (P1) and (P2) are part of the tandem piston (traction) pump. Pump (P1) supplies the front traction circuit, and pump (P2) supplies the rear traction circuit.
Hydraulic Hoses The hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, in addition to mishandling during operation and maintenance. These conditions can cause damage to the hose or deterioration to the hose material. Some hoses are more susceptible to these conditions than others. Examine all of the hydraulic hoses of the machine frequently and repair or replace them as necessary.
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) g212099 Figure 19 1. Tube or hose 2. Swivel nut 3. 4. O-ring Fitting body 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the face seal O-ring when you open the connection. Ensure that the O-ring is installed and correctly seated in the groove of the fitting.
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (continued) Hose/Tube Installation Torque Table Fitting Dash Size Hose/Tube Side Thread Size (inch)—threads per inch) Installation Torque 4 9/16—18 25 to 29 N∙m (18 to 22 ft-lb) 6 11/16—16 37 to 44 N∙m (27 to 33 ft-lb) 8 13/16—16 51 to 63 N∙m (37 to 47 ft-lb) 10 1—14 82 to 100 N∙m (60 to 74 ft-lb) 12 1–3/16—12 116 to 142 N∙m (85 to 105 ft-lb) 16 1–7/16—12 150 to 184 N∙m (110 to 136 ft-lb) 20 1–11/16—12 190 to 233 N∙m (140 to 172
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) Installing a Non-Adjustable Fitting g212226 Figure 21 1. Fitting 2. O-ring 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. 3. Lightly lubricate the O-ring with clean hydraulic fluid.
Installing an Adjustable Fitting g212224 Figure 22 1. Locknut 2. Back-up washer 3. O-ring g212225 Figure 23 1. Step 1: clearance the lock nut 3. Step 3: align the fitting 2. Step 2: seat the back-up washer 4. Step 4: tighten the lock nut 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. 3.
Installing an Adjustable Fitting (continued) A. Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the lock nut to the recommended torque value within the specified range of torque values; refer to the Fitting Installation Torque Table (page 5–12). This tightening procedure requires a drive-adapter wrench (e.g., crowfoot wrench); refer to Calculating the Torque Values When Using a Drive-Adapter Wrench (page 2–7) B.
Hydraulic Schematic The hydraulic schematic for the Outcross 9060 machine is located in Appendix A (page A–1).
Hydraulic Flow Diagrams Traction Circuit g235767 Traction Circuit Diagram (AUTO HIGH – Forward) Hydraulic System: Hydraulic Flow Diagrams Page 5–14 Outcross 9060 18234SL Rev D
g233999 Figure 24 1. Tandem piston (traction) pump (P1 and P2) 4. Solenoid AB-C2 (front pump valve C2 – reverse) 2. Solenoid AB-C1 (front pump valve C1 – forward) Solenoid CD-C2 (rear pump valve C2 – reverse) 3. Solenoid CD-C1 (rear pump valve C1 – forward) 5. The traction circuit of the Outcross 9060 machine consists of two closed-loop circuits, each with it’s own piston (traction) pump, axle motor, and control valves.
traction pedal is pushed, solenoid AB-C2 on the front pump and solenoid CD-C2 on the rear pump are energized. Front and rear drive axle motors are positive displacement, 2 position axial piston motors. The 2 position drive motors can operate in either a low speed range or high speed range. The motors are spring biased to maximum displacement for low speed and are hydraulically shifted to minimum displacement for high speed.
Traction Charge Circuit (continued) charge pressure is limited to 2,000 kPa (290 psi) in the pump by a relief valve located in the tandem piston (traction) pump. Charge pressure at each traction (piston) pump can be viewed while the vehicle is stationary using the InfoCenter SERVICE–TRACTION–TRACTION INPUTS–FRONT TRACTION and REAR TRACTION readings. Charge pressure can also be measured at the charge pressure test port located near the charge filter assembly.
Steering Circuit g235914 Steering Circuit Diagram (neutral position) Hydraulic System: Hydraulic Flow Diagrams Page 5–18 Outcross 9060 18234SL Rev D
g235915 Outcross 9060 18234SL Rev D Steering Circuit Diagram (turning to the right) Page 5–19 Hydraulic System: Hydraulic Flow Diagrams
A two (2) section gear pump is coupled directly to the tandem piston (traction) pump. The gear pump section furthest from the piston pump, gear pump section (P4), supplies fluid to the steering, hitch lift and traction charge circuits. Gear pump section (P4) also supplies flow to the 2 speed drive motor control, brake release, differential lock and PTO clutch circuits.
Right Turn (continued) Without load sense flow, pressures on the ends of the steering priority valve (EC1) start to equalize causing (EC1) to move toward its un-shifted “neutral” position which directs the fluid needed to turn the machine to the steering valve. Fluid is routed out manifold port ST, into steering valve port P, through the steering valve spool, passes through the rotary meter and out the R port to the steering cylinders.
Hitch Cylinder Circuit g236340 Hitch Cylinder Circuit Diagram (raising) Hydraulic System: Hydraulic Flow Diagrams Page 5–22 Outcross 9060 18234SL Rev D
g236339 Hitch Cylinder Circuit Diagram (lowering) The 3-point hitch on the machine uses two (2) hydraulic cylinders to raise and lower the hitch arms. The cylinders are controlled by the paddle located below the left side of the steering wheel. A position sensor is connected to the hitch arm pivot shaft, allowing the T1: TEC to monitor the position of the 3-point hitch. Some attachments may be configured to control the 3-point hitch automatically.
(SP1). Fluid is also sent to one end of the flow regulator valve (EC2) spool. As long as circuit flow is blocked at solenoid valve (SP1), the flow regulator valve (EC2) spool is shifted to direct flow to the traction charge, 2 speed drive motor control, brake release, differential lock and PTO clutch circuits. Note: Depending on the programmable attachment settings, raising and lowering the hitch may also disengage or engage the PTO.
Brake Circuit g262079 Brake Circuit Diagram (disengaged) A hydraulically actuated wet multi-disc brake is installed between the rear axle motor and the rear axle assembly. When engaged, the brake prevents the rear axle input shaft from rotating. The gear pump section furthest from the piston pump, gear pump section (P4), supplies fluid to a variety of circuits including the brake release.
Differential Lock Circuit g237540 Differential Lock Circuit Diagram (engaged) Hydraulic System: Hydraulic Flow Diagrams Page 5–26 Outcross 9060 18234SL Rev D
Differential Lock Circuit (continued) The drive axles include hydraulically actuated differential locks. The differential locks are engaged when the engine is running and the differential lock button is pressed, or while the engine is running and the parking brake is engaged. The gear pump section furthest from the piston pump, gear pump section (P4), supplies fluid to a variety of circuits including the differential lock.
PTO Clutch Circuit g237541 Hydraulic System: Hydraulic Flow Diagrams PTO Circuit Diagram (engaged) Page 5–28 Outcross 9060 18234SL Rev D
PTO Clutch Circuit (continued) The PTO RPM is directly related to engine speed. A gear box located between the engine and the tandem piston (traction) pump (P1 and P2) includes a 1:0.42 gear reduction and a hydraulically actuated clutch for the PTO. The gear pump section furthest from the piston pump, gear pump section (P4), supplies fluid to a variety of circuits including the PTO clutch.
Attachment Circuit g262196 Attachment Circuit Diagram (engaged) The machine includes a single function hydraulic circuit to support the hydraulic demands of a rear mount attachment. Gear pump (P3), a 5-position auxiliary load valve located between the operator and passenger seats, and a pair of hydraulic lines with quick disconnect fittings are part of the standard attachment circuit.
Front Loader Circuit g262210 Outcross 9060 18234SL Rev D Front Loader Circuit Diagram (arms raising) Page 5–31 Hydraulic System: Hydraulic Flow Diagrams
Front Loader Circuit (continued) The machine includes a hydraulic circuit to support the hydraulic demands of an optional front mounted loader. Gear pump (P3), a 5-position auxiliary load valve located between the operator and passenger seats, a multi-position loader control valve located on the operator console, and a series of hydraulic supply lines with quick disconnect fittings are part of the loader circuit.
Selector Control Valve (SCV) Circuit (optional) g262197 Attachment (rear) SCV Kit Circuit Diagram The hydraulic circuit for the attachment (rear) or loader (front) can be expanded to provide flow to an additional hydraulic load by installing a selector control valve kit. The kit is installed between the auxiliary load valve and the attachment, or between the loader valve and the loader.
Testing the Hydraulic System The most effective way to isolate hydraulic system problems is to use hydraulic test equipment, such as pressure gauges and flow meters, in the hydraulic circuit during circuit operation; refer to Special Tools (page 2–14). WARNING Opening the hydraulic system without releasing pressure from the system will cause the hydraulic fluid to escape, causing possible injury.
IMPORTANT Use 2 people to perform all the tests, with 1 person in the operators seat and the other available to read and record the test results. 1. Use the following resources to assist with hydraulic system troubleshooting. • The Hydraulic Schematic in Appendix A (page A–1) • Hydraulic Flow Diagrams (page 5–14) • General and system specific troubleshooting tables in Chapter 3 – Troubleshooting 2. Always wear the eye protection when you performing hydraulic system tests. 3.
12. Record the results of all hydraulic tests performed.
Hydraulic Test Selection Before beginning any hydraulic test, identify if the problem is related to the traction circuit, steering circuit, hitch cylinder circuit, or the attachment circuit. Once the faulty system has been identified, perform tests that relate to that circuit. If a traction circuit problem exists, consider performing one or more of the following tests: Charge Pressure Test, and/or Traction Pump (P1) and (P2) Flow and Relief Valve Test.
Steering/Hitch Cylinder Circuit Testing – Steering Relief Valve (RV1) Pressure Test g262713 Figure 25 Steering Relief Valve (RV1) Pressure Test (turning to the right shown) 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. 2. Park the machine on a level surface, lower the attachments and stop the engine. Remove the key from the key switch. 3. Make sure the hydraulic tank is full. 4. Open the main instrument panel.
Steering/Hitch Cylinder Circuit Testing – Steering Relief Valve (RV1) Pressure Test (continued) g262545 Figure 26 1. Relay assembly 2. Main hydraulic manifold 3. G3 port 5. Remove the relay mounting plate from the dash frame without disconnecting any of the relays from the wire harness. Move the relay assembly to one side. 6. Thoroughly clean the main hydraulic manifold and plug at the G3 port. 7.
Steering/Hitch Cylinder Circuit Testing – Steering Relief Valve (RV1) Pressure Test (continued) A. If 3-point hitch raise/lower problems also exist, gear pump (P4) should be suspected of wear and inefficiency. B. If steering wheel continues to turn at end of cylinder travel (with lower than normal effort), the steering cylinders or steering control valve should be suspected of wear or damage. C.
Steering/Hitch Cylinder Circuit Testing – Hitch Cylinder Relief Valve (RV2) Pressure Test g262737 Figure 27 Hitch Cylinder Relief Valve (RV2) Pressure Test CAUTION For machines with an optional cargo bed installed, remove the cargo bed before testing the hitch cylinder relief valve. The hitch cylinder lift stroke is limited electrically on machines with an optional cargo bed installed. 1.
Steering/Hitch Cylinder Circuit Testing – Hitch Cylinder Relief Valve (RV2) Pressure Test (continued) g262545 Figure 28 1. Relay assembly 2. Main hydraulic manifold 3. G3 port 5. Remove the relay mounting plate from the dash frame without disconnecting any of the relays from the wire harness. Move the relay assembly to one side. 6. Thoroughly clean the main hydraulic manifold and plug at the G3 port. 7.
Steering/Hitch Cylinder Circuit Testing – Hitch Cylinder Relief Valve (RV2) Pressure Test (continued) 12. Release the paddle switch, stop the engine and record the test results. 13. If lift cylinder relief pressure reading is incorrect: A. If steering problems also exist, gear pump (P4) should be suspected of wear and inefficiency. B. Adjust relief valve (RV2) to obtain correct relief pressure; refer to Adjusting the Manifold Relief Valves (page 5–48). C.
Attachment/Loader Circuit Testing – Relief Valve Pressure Test (continued) g263149 Figure 30 1. rear attachment upper quick-disconnect (A or retract port) 3. Remove the cap and connect a 34,500 kPa (5000 PSI) pressure gauge to the rear attachment upper quick-disconnect (A or retract port) at the rear of the machine. 4. Start engine and increase engine speed to (2300 RPM). 5. Shift the auxiliary load valve into the A position (rearward). 6.
Attachment/Loader Circuit Testing – Gear Pump (P3) Flow Test g263134 Figure 31 Gear Pump (P3) Flow Test A gear pump flow test should be performed to make sure that the circuits being supplied by the pump have adequate hydraulic flow. Over time, the gears and wear plates in a gear pump can wear. A worn pump will by-pass oil and make the pump less efficient. Eventually, enough oil loss will occur to cause circuit problems (e.g. attachment performance issues or the loader stalling when lifting heavy loads).
Attachment/Loader Circuit Testing – Gear Pump (P3) Flow Test (continued) g263043 Figure 32 1. Auxiliary load valve 2. P port fitting 3. Hydraulic hose assembly 2. Remove the operator’s console; refer to Removing and Installing the Operator’s Console (page 8–17). 3. Connect the wire harness to the key switch if previously removed. 4. Thoroughly clean the junction of the hydraulic hose and the fitting at the auxiliary load valve P port and disconnect the hydraulic hose from the fitting.
Attachment/Loader Circuit Testing – Gear Pump (P3) Flow Test (continued) IMPORTANT Do not fully restrict oil flow through the hydraulic tester. In this test, the hydraulic tester is positioned before the circuit relief valve and pump damage can occur if the oil flow is fully restricted. 9. Watch pressure gauge carefully while slowly closing the flow control valve until 6895 kPa (1000 PSI) is obtained. Verify with the Status Display that the engine is still running at the correct high idle speed (3000 RPM).
Adjustments Adjusting the Manifold Relief Valves g237542 Figure 33 1. Relief valve 2. Valve cap 3. Adjustment socket The main manifold includes 2 adjustable pressure relief valves; (RV1) relieves the steering circuit and (RV2) relieves the 3-point hitch lift circuit. An adjustment may be required to these valves if testing determines that the circuit pressure setting is incorrect; refer to Testing the Hydraulic System (page 5–34). Use the following process if a valve adjustment is required.
Service and Repairs General Precautions for Removing and Installing the Hydraulic System Components Before Repairing or Replacing the Components 1. Before removing any parts from the hydraulic system, park the machine on a level surface, lower and attachments, turn the engine OFF, and remove the key from the key switch. 2. Clean the machine before you disconnect, remove, or disassemble the hydraulic components. Note: Cleanliness is necessary whenever you work on the hydraulic equipment.
After Repairing or Replacing the Components (continued) (page 5–8) and Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–10). 5. After you complete the repairs, check the control linkages or cables for proper adjustment, binding, or broken parts. 6. Whenever hydraulic fluid has been drained from the pumps (system drain, flush, or pump removal/installation) it is important to properly prime the hydraulic pumps, refer to Priming the Hydraulic Pumps (page 5–58). 7.
Checking the Hydraulic Lines and Hoses WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid. • Use a piece of cardboard or paper to find hydraulic leaks.
Flushing the Hydraulic System IMPORTANT If a component failure occurs in the traction circuit; refer to Filtering the Closed-Loop Traction Circuit (page 5–54) for additional information. IMPORTANT Flush the hydraulic system whenever there is a severe component failure or the system is contaminated (for example, the fluid appears milky, black, or contains metal particles). 1. Park the machine on a level surface, lower any attachments and stop the engine. Remove the key from the key switch. 2.
Flushing the Hydraulic System (continued) 8. Fill the hydraulic tank with the correct type and quantity of new hydraulic fluid; refer to the traction unit Operator’s Manual. 9. Prime the hydraulic pumps; refer to Priming the Hydraulic Pumps (page 5–58). 10. Charge the hydraulic system; refer to Charging the Hydraulic System (page 5–59).
Filtering the Closed-Loop Traction Circuit The traction circuit of the Outcross 9060 machine consists of two closed-loop circuits, each with it’s own piston (traction) pump, drive axle motor, and control valves. The two traction pumps (P1) and (P2) are part of the tandem piston (traction) pump. Pump (P1) supplies the front traction circuit, and pump (P2) supplies the rear traction circuit.
Filtering the Closed-Loop Traction Circuit (continued) g262333 Figure 34 Front Circuit Connection 1. Front drive motor 2. M1 port A. If the front drive motor was serviced or replaced, disconnect the hydraulic hose at the M1 port (left) of the front drive motor. g262334 Figure 35 Rear Circuit Connection 1. Outcross 9060 18234SL Rev D Rear drive motor 2.
Filtering the Closed-Loop Traction Circuit (continued) B. If the rear drive motor was serviced or replaced, disconnect the hydraulic hose at the M1 port (right) of the rear drive motor. g262503 Figure 36 (shown with front axle drive motor removed) 1. Tandem piston (traction) pump (P1) and (P2) 2. B port 3. D port C.
Filtering the Closed-Loop Traction Circuit (continued) CAUTION Use extreme caution when performing this test. The wheels will be rotating during the test. IMPORTANT While engaging the traction circuit, monitor the indicator on the high flow hydraulic filter. If the indicator should show red, either reduce pressure on the traction pedal or reduce engine speed to decrease hydraulic flow through the filter. 8.
Priming the Hydraulic Pumps Whenever hydraulic fluid has been drained from the pumps (system drain, flush, or pump removal/installation) it is important to properly prime the hydraulic pumps. Priming the hydraulic pumps ensures that the tandem piston (traction) pump and gear pumps have sufficient fluid while charging the hydraulic system.
Charging the Hydraulic System IMPORTANT Air must be purged from the system to reduce the chance of component damage. When initially starting the hydraulic system with new or rebuilt components such as motors, pumps, or cylinders, it is important that the hydraulic system is charged properly to remove air from the system. IMPORTANT Flush the hydraulic system whenever there is a severe component failure or the system is contaminated; refer to Flushing the Hydraulic System (page 5–52). 1.
Charging the Hydraulic System (continued) E. Make sure the charge relief valve (CV1) is not blocked or damaged (closed) F. Test gear pump (P3) for damage 9. Operate the traction pedal in the forward and reverse directions. Make sure the wheels are turning in the proper direction and allow the wheels to turn slowly for ten (10) minutes. 10. Lower the machine to the ground. 11.
Hydraulic Tank g258304 Figure 38 1. Hydraulic tank 2. 12. Cap 23. Suction hose (to pump assembly) Hydraulic hose assembly (breather 13. from front PTO gear box) Dipstick 24. Flange nut (4 each) 3. Elbow fitting 14. Seal ring 25. Magnetic plug 4. Elbow barb fitting 15. Plug 26. Straight fitting (2 each) 5. Hose clamp 16. Cap screw (2 each) 27. Elbow fitting 6. Hydraulic hose (breather from rear 17. PTO gear box) Plug 28. Elbow fitting 7.
Removing and Installing the Hydraulic Tank 1. Remove the operator’s platform; refer to Removing the Operator’s Platform (page 8–6). IMPORTANT Follow all local codes and regulations when recycling or disposing hydraulic fluid. 2. Empty the hydraulic tank (approximate total volume 48 L (12.8 gal)). 3. Thoroughly clean the exterior of the reservoir, fittings and hoses to prevent contamination of the hydraulic system. 4.
Hydraulic Fluid Cooler g250200 Figure 39 1. Radiator cap 8. Hose – coolant reservoir 15. Fuel cooler assembly 2. 3. Hose clamp (2 each) 9. Isolator mount (3 each) 16. Foam seal (4 each) Upper radiator hose 10. Flange-head screw(2 each) 17. Flange-head screw (4 each) 4. 5. Fan shroud – right 11. Bracket – top 18. Straight hydraulic fitting (2 each) Flat washer (4 each) 12. Nut plate – top 19. Hydraulic fluid cooler 6. Flange-head screw (4 each) 13. Fan shroud – left 20.
Tandem Piston (Traction) Pump (P1) and (P2) g267354 Figure 40 1. Manifold support assembly 5. Gear pump 2. Air flap 6. Cap screw (2 each) 3. Servo control solenoid valves (4 each) 7. O-ring 4. Traction pressure sensor (2 each) 8. Tandem piston (traction) pump 9. 10.
Removing the Tandem Piston (Traction) Pump (P1) and (P2) (continued) 6. Remove the manifold support assembly. 7. Remove the air flap (item 2 in Figure 40). 8. Label and disconnect the wire harness at the 4 piston pump servo control solenoid coils. 9. Label and disconnect the wire harness at the 2 traction pressure sensors. 10.
Removing the Tandem Piston (Traction) Pump (P1) and (P2) (continued) CAUTION Use an appropriate lift to remove the piston pump from the machine. The piston pump assembly weighs approximately 68 kg (150 lbs). 17. Remove the 2 cap screws and plain washers that secure the piston pump to the front PTO gear box and slide the piston pump rearward and out of the machine. 18. Locate and discard the O-ring between the piston pump and the front PTO gear box. 19.
Installing the Tandem Piston (Traction) Pump (P1) and (P2) (continued) 14. Install the main hydraulic manifold; Installing the Main Hydraulic Manifold (page 5–85). 15. Install the front loader control valve (if equipped); refer to Installing the Front Loader Control Valve (page 5–107). 16. Install the auxiliary load valve; refer to Installing the Auxiliary Load Valve (page 5–103). 17. Install the operator platform; refer to Installing the Operator’s Platform (page 8–13). 18. Replace the hydraulic filters.
Tandem Piston (Traction) Pump (P1) and (P2) Service g242412 Figure 42 Hydraulic System: Service and Repairs Page 5–68 Outcross 9060 18234SL Rev D
Tandem Piston (Traction) Pump (P1) and (P2) Service (continued) Figure 42 (continued) 1. Housing (front) 22. Cap screw (4 each) 43. 2. Center section assembly 23. Orifice (4 each) 44. Bearing (2 each) Coupling 3. Housing (rear) 24. Dowel pin (4 each) 45. Valve plate CW 4. Shaft (front) 25. EDC feedback link (2 each) 46. Plug with O-ring (6 each) 5. Swashplate bearing kit (2 each) 26. Gasket (2 each) 47. Lifting lug 6. Swashplate (2 each) 27. EDC housing (2 each) 48.
Gear Pump (P3) and (P4) g263311 Figure 43 1. Gear pump (P3) and (P4) 4. Cap screw (2 each) 2. Elbow fittings (2 each) 5. Plain washer (2 each) 3. Suction hose fitting 6. Piston (traction) pump 7. O-ring Removing the Gear Pump (P3) and (P4) Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–49) prior to removing hydraulic system components. 1.
Removing the Gear Pump (P3) and (P4) (continued) 7. Slide the gear pump rearward then upward and out of the machine to the left of the manifold support. 8. Plug the gear pump ports, then locate and discard the O-ring between the gear pump and the piston pump. Installing the Gear Pump (P3) and (P4) 1. Apply clean petroleum jelly or light grease to a new O-ring (item 7 in Figure 32) and position the O-ring onto the gear pump flange. 2. Apply anti-seize lubricant to the splines of the gear pump shaft.
Gear Pump (P3) and (P4) Service g240377 Figure 44 1. Retaining ring 2. Shaft seal 3. Front cover 8. Thrust plate (4 each) 15. Drive shaft/gear 9. Drive shaft/gear 16. Driven shaft/gear 10. Driven shaft/gear 17. Pump body (P4) 4. Dowel pin (4 each) 11. Pump body (P3) 18. Rear cover 5. Seal (4 each) 12. Dowel pin (2 each) 19. Washer (4 each) 6. Uni-ring (4 each) 13. Flange 20. Cap screw (4 each) 7. Pressure seal (4 each) 14.
Disassembling the Gear Pump 1. Plug the pump ports and thoroughly clean the exterior of the pump with cleaning solvent. Make sure the work area is clean. g240402 Figure 45 1. Marker line 2. Use a marker to make diagonal lines across the gear pump sections for assembly purposes; refer to Figure 45. IMPORTANT Use caution when clamping gear pump in a vise to avoid distorting any pump components. 3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 4.
Inspecting the Gear Pump (continued) CAUTION Use eye protection such as goggles when using compressed air. 2. Clean all parts with solvent. Dry all parts with compressed air. g240513 Figure 46 1. Gear shaft spline 3. Gear teeth 2. Gear shaft 4. Gear face edge 3. Inspect the drive gears and idler gears for the following: A. The gear shafts should be free of rough surfaces and excessive wear at the thrust plate points and sealing areas. B.
Assembling the Gear Pump (continued) A. Install the pressure seals, flat side outward, into the grooves in the thrust plates. Follow by carefully placing the uni-rings, flat side outward, between the pressure seals and the grooves in the thrust plate. B. Apply a light coating of petroleum jelly to the exposed side of the front flange. C. Lubricate the drive shaft/gear with clean hydraulic oil.
Axle Motors g264149 Figure 47 (rear axle shown) 1. Axle motor 4. Hydraulic brake assembly (rear axle 7. only) 2. Cap screw (2 each) 5. Drive coupler 3. Gasket (rear axle only) 6. Speed sensor Motor mount Removing the Axle Motors Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–49) prior to removing hydraulic system components. 1.
Removing the Axle Motors (continued) 4. Remove the 2 cap screws that secure the axle motor to the motor mount. Separate the motor from the motor mount or hydraulic brake and remove the motor from the machine. 5. If removing the rear axle motor, retrieve and discard the gasket between the axle motor and the hydraulic brake assembly. 6. Remove and inspect the front drive coupler, or, remove and support the hydraulic brake assembly then remove and inspect the rear drive coupler. 7.
Axle Motor Service g240678 Figure 48 1. Plug with O-ring (2 each) 11. Bearing 2. Minimum angle stop 12. Gasket 22. Seal 3. Bias spring 13. Valve plate 23. Support washer 4. Servo piston 14. Cylinder block kit 24. Plug with O-ring (2 each) 5. O-ring 15. Swashplate 25. Plug with O-ring 6. O-ring 16. Swashplate bearing asm 26. Plug and spring asm (2 each) 7. Socket head screw (5 each) 17. Output shaft 27. Spool 8. End cap 18. Housing 28. Relief valve poppet 9.
Axle Motor Service (continued) to the Danfoss K and L Frame Variable Motors Service Manual for axle motor service information. Axle Differential Locks The hydraulically actuated differential lock assemblies are incorporated into the axle assemblies; refer to the Carraro DriveTech Model 26.09M Axle Repair Manual for additional information.
Hydraulic Brake Assembly g264149 Figure 49 1. Axle motor 4. Hydraulic brake assembly (rear axle 7. only) 2. Cap screw (2 each) 5. Drive coupler 3. Gasket (rear axle only) 6. Speed sensor Motor mount Removing the Hydraulic Brake Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–49)prior to removing hydraulic system components. 1. Remove the rear axle motor; refer to Removing the Axle Motors (page 5–76). 2.
Installing the Hydraulic Brake 1. Lubricate new O-rings and place them onto the fitting. If previously removed, install the fitting into the brake port using alignment mark made during removal; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–10). 2. Apply anti-seize lubricant to the splines of the drive coupler. Align the drive coupler splines and slide the drive coupler all the way onto the axle input shaft. 3.
Hydraulic Brake Service g241747 Figure 50 1. Housing 2. Torque pin (2 each) Oil seal 17. Backup ring 10. Primary disc 18. Power plate 3. 4. Compression spring (10 each) 11. Rotating disc (4 each) 19. Piston Spring retainer 12. Stationary disc (4 each) 20. Hex head screw (4 each) 5. Compression spring (10 each) 13. Gasket 21. Fill/drain plug (2 each) 6. Shaft 14. Backup ring 22. Bleeder 7. Bearing 15. O-ring 23. Gasket (2 each) 8. Snap ring 16. O-ring 9.
Disassembling the Hydraulic Brake (continued) 4. Remove and discard the O-rings and backup washers. IMPORTANT If the shaft seal or bearing are removed for any reason, both must be replaced. 5. Press the shaft from the bearing and remove the shaft seal, retaining ring, and bearing. Assembling the Hydraulic Brake 1. If previously removed, install a new bearing and retaining ring. Install a new shaft seal in the housing with the face of the seal toward the bearing.
Main Hydraulic Manifold g264296 Figure 51 1. Straight fitting 5. Straight fitting 2. Elbow fitting (3 each) 6. Elbow fitting (2 each) 3. Straight fitting (4 each) 7. Swivel tee fitting 4. Swivel elbow fitting (2 each) 8. Flange head screw (3 each) 9. 10. Flange head screw Manifold block The ports on the main manifold are marked for easy identification of components and connections.
Removing the Main Hydraulic Manifold (continued) 1. Remove the operator’s platform; refer to Removing the Operator’s Platform (page 8–6). 2. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of manifold and fittings. 3. Label and disconnect wire harness connectors from the solenoid valves. 4. Label and disconnect the hydraulic lines from the manifold and put caps or plugs on open hydraulic lines and fittings to prevent system contamination. 5.
Main Manifold Service g264342 Figure 52 1. Solenoid coil (2 each) 9. Relief valve – RV1/RV2 (2 each) 17. Solenoid valve – SP1 2. Coil nut (2 each) 3. Manual valve – pull to open 10. Flow regulator – FR 18. Proportional valve – SP2 11. Pressure compensating valve – EC1 #6 zero-leak plug with O-ring (3 each) 19. Solenoid valve – EH 4. Hand pump 12. 20. Check valve – CV1/CV2 (2 each) 5. Socket head screw (8 each) 13. Pressure compensating valve – EC2 21.
Main Manifold Service (continued) IMPORTANT A removable control orifice exists under the fitting in the LS/OR1 port, and under the plugs in the OR2 and OR3 ports of the main hydraulic manifold. If the fitting or plug is removed, remove the orifice for cleaning and label its position for assembly purposes. Note: For cartridge valve service procedures, refer to Cartridge Valve Service (page 5–88).
Cartridge Valve Service Note: For solenoid style cartridge valve coil testing information; refer to Hydraulic Solenoid Valve Coils (page 6–73). Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–49) prior to removing hydraulic system components. 1. Park the machine on a level surface. Lower any attachments, stop the engine, and remove the key from the key switch. 2.
Cartridge Valve Service (continued) while energized procedure 5 or 6 times. Remove the solenoid from the cartridge. 7. Install the cartridge valve: A. Lubricate the new O-rings and the backup rings of the seal kit with clean hydraulic fluid and install them on the cartridge valve. The O-rings and the backup rings must be arranged correctly on the cartridge valve for proper operation and sealing; refer to notes taken during the seal removal. IMPORTANT Use care when installing the cartridge valve.
Steering Control Valve g249176 Figure 53 1. 4. Steering column Plate 7. Alignment bushing 8. Steering control valve 2. Flange head screw (4 each) 5. Washer (4 each) 3. Mount (4 each) 6. Flange nut (4 each) Removing the Steering Control Valve Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–49) prior to removing hydraulic system components. 1.
Installing the Steering Control Valve 1. Lubricate new O-rings and place them onto the fittings. If previously removed, install the fittings into the valve ports using alignment marks made during removal; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–10). 2. Apply anti-seize to the splines of the steering control valve and the bottom splines of the steering column. Aplly loctite to the four flange head screws (item 2 in Figure 53).
Steering Control Valve Service g243145 Figure 55 1. Housing 10. Shaft seal 19. Cardan shaft 2. Spool 11. Bearing 20. Spacer 3. Sleeve 12. Ring 21. O-ring (3 each) 4. Relief valve 13. Cross pin 22. Distributor plate 5. Dust seal 14. Spring set 23. Gearwheel set 6. 7. Check valve Ball (3 each) 15. 16. LS check valve Threaded bushing 24. 25. End cover Washer (7 each) 8. Spring (2 each) 17. Ball 26. Special screw 9. Pin (2 each) 18.
Steering Cylinders Removing and Installing the Front Steering Cylinder Removing and installing the front steering cylinder is accomplished by first removing the front axle assembly from the machine; refer to Front Axle (page 7–7). Removing the Rear Steering Cylinder g265161 Figure 56 1. Rear speed sensor 3. Cap screw (2 each) 5. Flange nut (4 each) 2. Tie rod (2 each) 4. Cap screw (2 each) 6.
Removing the Rear Steering Cylinder (continued) 5. Disconnect the tie rods from the rear steering cylinder. 6. Clean the fitting and hydraulic line connections before disconnecting the hydraulic lines to prevent system contamination. 7. Disconnect the hydraulic hoses. Cap the fittings and plug the hoses to prevent system contamination. 8. Remove the fasteners securing the cylinder to the cylinder supports and remove the cylinder from the machine. 9.
Steering Cylinder Service g240877 Figure 57 1. Barrel 7. Back-up ring (2 each) 13. Wear ring 2. Set screw (2 each) 8. O-ring (2 each) 14. Piston assembly 3. External collar (2 each) 9. Head (2 each) 15. Roll pin 16. Rod (female) 4. Rod (male) 10. Spacer (2 each) 5. Dust seal (2 each) 11. O-ring 6. Head seal (2 each) 12. Piston seal The front and rear cylinder bores, strokes and mounting brackets are different, but the cylinder design is the same.
Disassembling the Steering Cylinder (continued) 2. Mount the steering cylinder securely in a vise by clamping on the mounting brackets. 3. Remove the collar set screws and use a strap, chain, or spanner wrench to remove the collars from each end of the barrel. 4. Use a twisting motion to carefully pull the rod, piston, and head assemblies from the barrel. 5. Carefully push the remaining head assembly from the barrel. 6. Remove and discard the roll pin that secures the rods together.
Assembling the Steering Cylinder (continued) 4. Mount the steering cylinder barrel in a vise by clamping on the cylinder mounting brackets. 5. Coat the inner bore of the cylinder with clean hydraulic fluid and fit the piston and rod assembly into the cylinder barrel. 6. Install the 2 spacers and the 2 head assemblies. 7. Secure the heads in the barrel with the external collars. Tighten the external collars with a strap, chain, or spanner wrench. 8. Install and tighten the set screws in the external collars.
3-Point Hitch Cylinders g265015 Figure 58 9. Flat washer Lift arm 10. Cap screw Lower pin 11. Flange nut Spacer 12. 3-point hitch cylinder 1. Stabilizer assembly 5. Retaining ring (2 each) 2. Lift link assembly 6. 3. Standard arm assembly 7. 4. Upper pin 8. Removing the 3-Point Hitch Cylinder Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–49) prior to removing hydraulic system components. 1.
Installing the 3-Point Hitch Cylinder 1. Lubricate new O-rings and place them onto the fittings. If previously removed, install the fittings into the cylinder ports; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–10). 2. Apply general purpose grease to the lower cylinder clevis. Position the hitch cylinder to the machine frame and install the lower pin. 3.
3-Point Hitch Cylinder Service g241398 Figure 59 1. Barrel 7. Wear ring 13. Backup washer 2. 3. Rod External collar 8. 9. Piston seal O-ring 14. 15. Shaft seal Dust seal 4. 5. Set screw Lock nut 10. 11. Head Wear ring 16. Set screw 6. Piston 12. O-ring Disassembling the Hitch Cylinder 1. Slowly pump the cylinder over a drain pan to remove any hydraulic fluid from the cylinder. Plug both cylinder ports and clean the outer surface of the cylinder.
Disassembling the Hitch Cylinder (continued) 3. Remove the set screw then use a strap, chain, or spanner wrench to loosen and remove the external collar. 4. Extract the shaft with head and piston by carefully twisting and pulling on the shaft. IMPORTANT When you clamp the shaft in a vise, clamp against the shaft clevis only to prevent damage. Do not clamp the vise onto the shaft. 5. Mount shaft securely in a vise and remove lock nut from the shaft. Slide the piston, head, and external collar off the shaft.
Assembling the Hitch Cylinder (continued) IMPORTANT When you clamp the cylinder in a vise, clamp against the cylinder clevis only to prevent damage. Do not clamp the vise onto the barrel. 5. Mount the cylinder in a vise by clamping on the cylinder clevis. 6. Use a strap, chain, or spanner wrench to tighten the external collar. Install and tighten the set screw.
Auxiliary Load Valve g265282 Figure 60 1. Auxiliary load valve assembly 2. Cap screw (4 each) Removing the Auxiliary Load Valve Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–49) prior to removing hydraulic system components. 1. Remove the operator’s console: refer to Removing and Installing the Operator’s Console (page 8–17). 2. Disconnect the frame wire harness from the hydraulic (AUX) switch. 3.
Installing the Auxiliary Load Valve (continued) 5. Operate the auxiliary load valve. Check for hydraulic leaks and correct if necessary. 6. Install the operator’s console; refer to Removing and Installing the Operator’s Console (page 8–17). 7. Test the attachment/loader circuit relief valve pressure before returning the machine to service; refer to Attachment/Loader Circuit Testing – Relief Valve Pressure Test (page 5–43). 8.
Auxiliary Load Valve Service g265226 Figure 61 1. Relief valve assembly 4. Extended handle assembly 7. Spool seal 2. Seal kit 5. Dust boot 8. Section seal kit (2 each) 3. Hydraulic (AUX) switch 6. 5-position float spool positioner Servicing the Auxiliary Load Valve For complete service information; refer to the Gresen/Parker Hydraulics Model V10 Sectional Body Directional Control Valve Service Manual. 1. Disassemble the auxiliary load valve as necessary. 2.
Front Loader Control Valve g266811 Figure 62 1. Front loader control valve 2. Cap screw (4 each) Removing the Front Loader Control Valve Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–49) prior to removing hydraulic system components. 1. Remove the operator’s console: refer to Removing and Installing the Operator’s Console (page 8–17). 2.
Installing the Front Loader Control Valve 1. Lubricate new O-rings and place them onto the fittings. If previously removed, install the fittings into the valve ports; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–10). 2. Secure the valve assembly to the machine with 4 cap screws. 3.
Front Loader Control Valve Service g266855 Figure 63 1. Relief plug seal kit 4. Spring return spool positioner 7. Dust boot 2. Section seal kit (3 each) 5. 4-position float spool positioner 8. Joystick assembly 3. Work port cavity plug seal kit (2 each) 6. Spool seal (3 each) Servicing the Loader Control Valve For complete service information; refer to the Gresen/Parker Hydraulics Model V10 Sectional Body Directional Control Valve Service Manual. 1.
Selector Control Valve Manifolds (optional) g266960 Figure 64 1. Loader kit manifold bracket 5. Straight fitting (4 each) 2. Flange nut (2 per kit) 6. Union fitting (2 each) 10. Straight fitting (2 each) 3. Cap screw (2 per kit) 7. Quick disconnect fitting – female 11. Elbow fitting (4 each) 4. Selector control valve manifold (2 per kit) 8. Quick disconnect fitting – male 9. Rear kit manifold bracket Two different optional selector control valve kits are available.
Installing the Selector Control Valve Manifolds 1. Lubricate new O-rings and place them onto the fittings. If previously removed, install the fittings into the valve ports; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–10). 2. Position the manifolds to the bracket and secure with 2 cap screws. 3. Remove the caps and plugs from the fittings and hoses.
Selector Control Valve Manifold (optional) Service g266963 Figure 65 1. Manifold block 5. Solenoid valve – normally closed 2. Coil nut 6. Solenoid valve – normally open 3. Coil nut 7. #8 zero-leak plug with O-ring 4. Solenoid coil (2 each) The ports on the selector control valve manifolds are marked for easy identification of components and connections; refer to the hydraulic schematic in Appendix A (page A–1) to identify the function of the hydraulic lines and cartridge valves at each port.
Hydraulic System: Service and Repairs Page 5–112 Outcross 9060 18234SL Rev D
Chapter 6 Electrical System Table of Contents General Information .............................................................................................................................. 6–3 Traction Unit Operator’s Manual and Accessory Installation Instructions............................................ 6–3 Yanmar Engine Electrical Components.............................................................................................. 6–3 InfoCenter Display .........................................
Diode Assemblies ............................................................................................................................ 6–69 Resistor Assembly ........................................................................................................................... 6–70 CAN bus Terminator Resistors ......................................................................................................... 6–71 Hydraulic Solenoid Valve Coils................................................
General Information IMPORTANT Before performing any welding on the machine, turn the key switch to the OFF position. To prevent damage to the machine electrical system, disconnect the ground (-) cable to the frame when welding on the frame, or disconnect the ground (-) cable to the operator platform when welding on the operator platform.
InfoCenter Display g259277 Figure 66 The InfoCenter Display is a five button LCD device located on the main instrument panel. The InfoCenter provides information to the machine operator during machine operation, provides electrical system diagnostic assistance for technicians and allows access to adjustable machine and attachment settings. Power for the InfoCenter is available when the main power relay is energized (key switch is in the ON or START position).
InfoCenter Display (continued) g259842 Figure 67 InfoCenter Screens Outcross 9060 18234SL Rev D Page 6–5 Electrical System: General Information
Primary Controller (T1: TEC) g259266 Figure 68 (main instrument panel removed) 1. Primary controller (T1: TEC) 2. Platform harness connector Outcross 9060 machines use a primary controller (T1: TEC) to manage machine electrical functions. The T1: TEC is a 5004 series microcontroller that monitors the condition of various machine switches and sensors (inputs) and directs electrical power to control appropriate machine functions (outputs) based on the state of the inputs.
Status Display Controller (T2: TDM) g259278 Figure 69 1. Status display module (T2: TDM) 2. LED fault active indicator 3. Status display screen select button The status display module (T2: TDM) is an LCD device located on the main instrument panel that presents operating hours, fuel level, engine coolant temperature, hydraulic oil temperature, electrical system voltage, engine RPM, 3-point hitch position, and active faults.
Status Display Controller (T2: TDM) (continued) g259775 Figure 70 Status Display Screens 1. Engine hour meter 7. Engine RPM 2. 3. Fuel level Active fault 8. 9. Hitch raise limit Hitch maximum work height (PTO disengage) 4. Engine coolant temperature 10. Hitch minimum work height (PTO disengage) 5. Hydraulic fluid temperature 11. Hitch lower limit 6. System voltage 12.
Engine Electronic Control Unit (ECU) g249798 Figure 71 1. 2. Dash cover Engine ECU 3. Yanmar SA-D connector The Yanmar engine that powers your Outcross 9060 machine uses an Electronic Control Unit (ECU) for engine management. The engine ECU is located under the right side of the dash cover. All wire harness electrical connectors should be plugged into the ECU before the machine key switch is moved from the OFF position to either the ON or START position.
InchMode Controller (T3: TEC) (optional) g259289 Figure 72 The optional InchMode feature includes the InchMode controller (T3: TEC) to manage traction, hitch lift, and PTO functions while standing next to the machine. The T3: TEC is a 2002 series microcontroller that monitors the condition of various machine switches and sensors (inputs) and communicates the status of these inputs to the T1: TEC via the CAN.
CAN bus Communications The primary controller (T1: TEC), the status display controller (T2: TDM), the Yanmar Engine Control Unit (ECU), the InfoCenter Display, and the optional InchMode controller (T3: TEC) used on the Outcross 9060 machine communicate with each other on a Controller Area Network (CAN) bus system. Using this network allows the traction unit to fully integrate all the different electrical components of the machine and bring them together as one.
Electrical Drawings The electrical schematic and wire harness drawings for the Outcross 9060 machine are located in Appendix A (page A–1).
Electrical System Quick Checks Testing the Charging System The Outcross 9060 uses a single 12 Volt maintenance free battery mounted below the left side of the operator’s platform. The battery is charged by an 80 Amp 12 volt alternator mounted to the engine, which is driven by a single row V-belt. Use the T2: TDM display to monitor the 12 Volt electrical system. It will tell you if the charging system has an output, but not its capacity. 1.
Electrical Component Testing Fuses g256641 Figure 74 (main instrument panel removed) 1. 60 Amp Maxi fuse (3 each) 2. Main fuse block 3. Accessory fuse block The main power supply, cab power supply, and rear attachment power supply are protected by three separate 60 Amp maxi fuses. The maxi fuse holders are part of the operator platform wire harness and are located under the main instrument panel.
Fuse Identification, Location and Function (continued) • Fuse F−D2 ( 15 Amp) supplies unswitched power to the cab control panel for an optional radio, and to the International (EC) road light kit. • Fuse F−A3 (10 Amp) supplies power to the optional hour meter, optional bed active switch, backup alarm, traction speed sensors, cruise control auto off switch, and ECO mode switch bulb. • Fuse F−B3 (2 Amp) supplies power to the InfoCenter display.
Fuse Identification, Location and Function (continued) g257658 Figure 76 (shown with roof removed) 1. Fuse – RH tail light 3. Fuse – LH brake/turn 2. Fuse – RH brake/turn 4. Fuse – LH tail light Optional Road Light Kit Wire Harness • Four (5 Amp) fuses are integrated into the optional turn signal/hazard wire harness. Each fuse is in a separate covered fuse holder. The harness is located under the roof. Testing Fuses 1. Make sure that key switch is OFF and key is removed from switch. 2.
Fusible Link Harness g256582 Figure 77 1. Starter motor 4. To engine wire harness P22 connector 2. Fusible link harness 5. Fusible link for glow plug circuit 3. To starter B+ terminal 6. Fusible link for starter circuit The Outcross 9060 uses two (2) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the engine wire harness. If either of these links should fail, current to the protected circuits will be interrupted.
CAN bus The machine controllers communicate with each other on a Controller Area Network (CAN) bus system. Using this network allows full integration of all the different electrical components of the machine, allowing them to operate together as one. The integration of the controllers allows the InfoCenter Display to assist with electrical system diagnostics. Two specially designed, twisted wires form the CAN bus. These wires provide the data pathways between the components on the network.
Primary Controller (T1: TEC) g328863 Figure 79 (main instrument panel removed) 1. Primary controller T1: TEC 2. Harness connector screw 3. Platform harness connector Outcross 9060 machines use a primary controller (T1: TEC) to manage machine electrical functions. The T1: TEC is a 5004 series microcontroller that monitors the condition of various machine switches and sensors (inputs) and directs electrical power to control appropriate machine functions (outputs) based on the state of the inputs.
Primary Controller (T1: TEC) (continued) T1: TEC Inputs INPUT NUMBER DESCRIPTION INPUT NUMBER DESCRIPTION IN 1 Bed Active Switch IN 11 Hydraulic AUX Switch IN 2 AC (air conditioning) Active Switch IN 12 SCV (Selector Control Valve) Switch IN 3 Parking Brake Switch IN 13 Front Speed Sensor IN 4 Seat Switch IN 14 Rear Speed Sensor IN 5 Transmission Forward Switch AIN1 Traction Pedal – APS1 IN 6 Transmission Reverse Switch AIN2 Traction Pedal – APS2 IN 7 Decelerator Neutral Switch
Primary Controller (T1: TEC) (continued) IMPORTANT When testing for wire harness continuity at the connector for the controller, take care to not damage the connector pins with multimeter test leads. If connector pins are enlarged or damaged during testing, connector repair may be necessary for proper machine operation. g259215 Figure 80 1. Platform wire harness connector P74 2. Tab 3. Primary controller (T1: TEC) A 50 pin platform wire harness connector is attached to the controller.
Status Display Controller (T2: TDM) g259278 Figure 81 1. Status display module (T2: TDM) 2. Status display screen select button The status display module (T2: TDM) is an LCD device located on the main instrument panel that presents operating hours, fuel level, engine coolant temperature, hydraulic oil temperature, electrical system voltage, engine RPM, 3-point hitch position, and active faults. The status display button located below the T2: TDM is used to select the various display screens.
Status Display Controller (T2: TDM) (continued) T2: TDM Inputs INPUT NUMBER DESCRIPTION INPUT NUMBER DESCRIPTION IN 2 Cruise Speed Increase/Decrease Switch – Decrease IN 7 Cruise Speed Increase/Decrease Switch – Increase IN 3 Differential lock switch AIN1 Mode Selector Switch IN 4 Economy (ECO) Mode Switch AIN2 Status Display Button IN 5 Cruise Control Off/On/Set Switch – ON (enable) AIN3 Hydraulic Fluid Temperature Sender IN 6 Cruise Control Off/On/Set Switch – SET (engage) AIN4 Fuel
Status Display Controller (T2: TDM) (continued) A 20 pin platform wire harness connector is attached to the controller. The connection terminal function for the controller and the wire harness connector pins are shown above. Because of the solid state circuitry built into the controller, there is no method to test the controller directly. A controller may be damaged if an attempt is made to test it with an electrical test device (e.g. digital multimeter or test light).
InchMode Controller (T3: TEC) (optional) g259289 Figure 83 The optional InchMode feature includes the InchMode controller (T3: TEC) to manage traction, hitch lift, and PTO functions while standing next to the machine. The T3: TEC is a 2002 series microcontroller that monitors the condition of various machine switches and sensors (inputs) and communicates the status of these inputs to the T1: TEC via the CAN.
InchMode Controller (T3: TEC) (optional) (continued) T3: TEC Outputs OUTPUT NUMBER DESCRIPTION OUT 1 Not Used OUT 2 Not Used OUT 3 Not Used The machine electrical schematic and wire harness drawings in Appendix A (page A–1) can be used to identify possible circuit problems between the controller and the input or output devices. IMPORTANT When testing for wire harness continuity at the connector for the controller, take care to not damage the connector pins with multimeter test leads.
Key Switch POSITION CLOSED CIRCUITS OFF 1 + 6, 4 + 5 RUN 1+3+4+5+6 START 1+2+4+5+6 The key switch on the console has three (3) positions − OFF, RUN and START. The key switch is an input used by the T1: TEC to manage various machine functions. Testing the Key Switch The key switch and its circuit wiring can be tested as a T1: TEC input using the InfoCenter Display; refer to Using the InfoCenter Display for Troubleshooting (page 3–23).
Mode Selector POSITION SIGNAL VOLTAGE (E) ±0.2 VDC 0° – A (attachment mode) 0.5 VDC 40° – H (auto high mode) 1.5 VDC 80° – L (auto low mode) 2.5 VDC 120° – I (InchMode) 3.5 VDC 160° – S (setup mode) 4.5 VDC The mode selector is an analog hall effect sensor that communicates the desired mode of operation to the T2: TDM. The selector is located on the main instrument panel. The T2: TDM communicates the mode signals to the T1: TEC via the CAN network.
Parking Brake Switch POSITION CLOSED CIRCUITS ON 2 + 3, 5 + 6 OFF 1 + 2, 4 + 5 The parking brake switch is located on the main instrument panel. Push down on the top of the switch to engage the parking brake (switch light illuminated) and push down on the bottom of the switch to disengage the parking brake. The T1: TEC monitors the position of the parking brake switch. The parking brake is spring loaded and engages automatically when hydraulic pressure is not present.
Power Take Off (PTO) Enable Switch POSITION CLOSED CIRCUITS OFF (DOWN) COM B + NC B ON (UP) COM B + NO B COM C+ NC C COM C+ NO C The power take off (PTO) enable switch is located on the console. This switch is pulled up to engage the PTO shaft and pushed down to disengage the PTO shaft. The T1: TEC monitors the position of the PTO switch. Using information from the PTO switch and other inputs, the T1: TEC energizes the hydraulic solenoid valve (EH) to engage the PTO clutch.
Economy (ECO) Mode Switch POSITION CLOSED CIRCUITS ON 2 + 3, 5 + 6 OFF 1 + 2, 5 + 4 The ECO mode switch is located on the main instrument panel. Push down on the top of the switch to enable ECO mode (switch light illuminated) and push down on the bottom of the switch to disable ECO mode. The T2: TDM monitors signals from the ECO mode switch. The T2: TDM communicates the switch position to the T1: TEC via the CAN network.
Hydraulic Auxiliary (AUX) Switch g258283 Figure 85 (shown with operator’s console removed) 1. Auxiliary load valve assembly 2. Hydraulic Auxiliary (AUX) switch Note: Hydraulic AUX switch functionality is dependant on attachment configuration. The hydraulic AUX switch is a normally open ball switch that is held closed while the joystick is in the neutral position (N.O.H.C.). The switch is located in the joystick assembly of the auxiliary load valve.
Testing the Hydraulic AUX Switch (continued) 6. Replace the switch if necessary. 7. If the switch tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 8. Connect the wire harness and install the operator’s console after testing.
Seat Switch g257914 Figure 86 1. Seat switch harness connector The seat switch and its electrical connector are located in the operator seat assembly. The seat switch is a normally open proximity switch that closes when the operator is on the seat. Testing of the switch can be done without seat removal by disconnecting the switch wire from the platform wire harness. The T1: TEC monitors the position of the seat switch.
Paddle (3-Point Hitch) and Transmission Lever Switches g249604 Figure 87 1. Paddle and transmission lever assembly 2. Paddle switch (closed with paddle in RAISE position) 3. Paddle switch (closed with paddle in LOWER position) 4. Transmission lever switch (closed with shift lever in FORWARD position) 5.
Testing the Paddle and Transmission Lever Switches (continued) 4. Replace the switch if testing determines that it is faulty. 5. If the switch tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 6. After testing is complete, connect machine wire harness connector to the switch. 7. Install the dash cover; refer to Installing the Steering Wheel, Instrument Panels and Dash Cover (page 8–16).
Headlight/Worklight Switch POSITION CLOSED CIRCUITS HEADLIGHTS ON 2 + 3, 5 + 6 OFF NONE WORKLIGHTS ON 1 + 2, 4 + 5 The headlight/worklight switch is located on the steering instrument panel. Pushing down on the top of the switch energizes the headlights, and on machines with an optional North American Light Kit, energizes the hazard lights. Pushing down on the bottom of the switch energizes the headlights and the optional Worklights. Testing the Headlight/Worklight Switch 1.
Cruise Control Off/On/Set Switch POSITION CLOSED CIRCUITS OFF NONE CRUISE ON (enable) 2 + 3 CRUISE SET (engage) 2 + 3 5 + 6 The cruise control switch is located on the console. When the bottom of the switch is depressed, the cruise control feature is off. When the switch is moved to the center position, the cruise control feature is enabled but no speed is set.
Cruise Control Speed Increase/Decrease Switch POSITION CLOSED CIRCUITS INCREASE SPEED 2 + 3, 5 + 6 NEUTRAL NONE DECREASE SPEED 2 + 1, 5 + 4 The cruise control speed increase/decrease switch is located on the console. When the cruise control feature is engaged and top of the switch is depressed, the cruise control speed will increase. When the cruise control feature is engaged and bottom of the switch is depressed, the cruise control speed will decrease. The amount of change can be as low as 0.
Air Conditioning On/Off Switch POSITION CLOSED CIRCUITS OFF NONE ON 1+ 2 + 3 Testing the Air Conditioning On/Off Switch The air conditioning on/off switch, working with the AC switch signal relay, and its circuit wiring can be tested as a T1: TEC input using the InfoCenter Display; refer to Using the InfoCenter Display for Troubleshooting (page 3–23). If testing determines that the switch and its circuit wiring are not functioning correctly, proceed with the following test procedure: 1.
Heater/Air Conditioning Blower Speed Switch POSITION CLOSED CIRCUITS OFF NONE LOW B+C+L MED B+C+M HIGH B+C+H Testing the Heater/Air Conditioning Blower Speed Switch 1. Park the machine on a level surface, lower any attachments and stop the engine. 2. Disconnect the battery negative (-) cable at the battery. 3. Remove the roof from the cab. 4. Disconnect the wire harness connector from the switch and remove the switch from the AC control panel if necessary. 5.
InchMode Enable Switch (optional) POSITION CLOSED CIRCUITS OFF 2 + 3, 5 + 6 ON 2 + 1, 5 + 4 Note: Once the InchMode feature is enabled through the InfoCenter, the InchMode enable switch must be depressed before any of the InchMode operations will function. The InchMode enable switch is located on the InchMode control box. Pushing down on the top of the switch supplies power to the InchMode raise/lower, forward/reverse, and PTO switches. The switch returns to the OFF position when released.
InchMode Raise/Lower and Forward/Reverse Switches (optional) POSITION CLOSED CIRCUITS RAISE or FORWARD 2 + 3, 5 + 6 OFF NONE LOWER or REVERSE 2 + 1, 5 + 4 Note: Once the InchMode feature is enabled through the InfoCenter, the InchMode enable switch must be depressed before any of the InchMode operations will function. The InchMode raise/lower and forward/reverse switches are located on the InchMode control box. The T3: TEC monitors signals from the InchMode raise/lower and forward/reverse switches.
Loader Selector Control Valve (SCV) Switch (optional) POSITION CLOSED CIRCUITS ON (forward) 2 + C OFF NONE MOMENTARY (rearward) 1 + C A 3 position rocker switch located on the loader control valve joystick is used to control the loader SCV valves. When the switch is in the OFF (center) position, all of the kit solenoid valves are de-energized and hydraulic flow is directed to the manifold ports marked 3.
Traction Pedal Assembly g257736 Figure 88 The traction pedal assembly includes 2 analog hall effect sensors that do not require calibration. The sensors operate on 5 VDC supplied by the T1: TEC. Signal voltage from the pedal sensors are used by the T1: TEC (along with information from additional inputs) to determine appropriate current flow to the tandem piston (traction) pump control valves. The sensor signals are also constantly monitored for traction fault detection.
Testing the Traction Pedal Assembly (continued) 8. Connect the pedal assembly to the platform wire harness.
Decelerator Pedal Position Sensor g257847 Figure 89 1. 2. Pin Retaining ring 6. 7. Retainer Sensor pivot 3. Torsion Spring 8. Decelerator pedal sensor 4. Decelerator pedal assembly 9. Flange nut (2 each) 5. Cap screw (2 each) The decelerator pedal position sensor is a potentiometer (variable resistor).
Testing the Decelerator Pedal Position Sensor (continued) Note: Before taking the small resistance readings with a digital multimeter, short the multimeter test leads together. The meter displays a small resistance value (usually 0.5 ohms or less). This resistance is because of the internal resistance of the multimeter and test leads. Subtract this value from the measured value of the component that you are testing. 4.
Decelerator Pedal Neutral Switch g257859 Figure 90 1. Pin 5. Nut plate 2. Retaining ring 6. Switch and connector 3. Torsion Spring 7. cap screw (2 each) 4. Decelerator pedal assembly The decelerator pedal neutral switch is a normally open switch held closed when the decelerator pedal is at rest (N.O.H.C.). The switch is located directly above the decelerator pedal assembly. When the decelerator pedal is depressed, the switch plunger is extended, opening the switch contacts.
Testing the Decelerator Pedal Neutral Switch (continued) 3. Check the continuity of the switch by connecting a multimeter (ohms setting) across the connector terminals. 4. When the switch plunger is depressed (decelerator pedal at rest) there should be continuity (zero ohms resistance) between the switch terminals. 5. When the switch plunger is extended (decelerator pedal depressed) there should be no continuity (infinite ohms resistance) between the switch terminals. 6. Replace the switch if necessary. 7.
3-Point Hitch Position Sensor g258812 Figure 91 1. Screw (2 each) 4. Spacer 2. Position sensor 5. V-ring 3. Wire harness connector The 3-point hitch position sensor is an analog hall effect sensor that communicates the height of the 3-point hitch to the T1: TEC. The sensor is located on the left end of the lift arm pivot shaft. The T1: TEC uses information from the sensor to control the attachment height while operating in attachment mode.
Testing the 3-Point Hitch Position Sensor (continued) A. Ensure that the sensor shaft orientation is correct. B. Loosen the jam nut C. Thread the sensor shaft into the lift arm pivot shaft until it bottoms out. D. Turn the sensor shaft out until the scallops in the shaft align with the dimples in the lift arm. g337735 Figure 92 1. Sensor shaft “scallops” 2. Jam nut 3. Lift arm “dimples” E. Tighten the jam nut to lock the sensor shaft in position. F.
Hydraulic Fluid Temperature Sender g257926 Figure 93 (view from below) 1. Hydraulic tank 2. Hydraulic temperature sender The hydraulic fluid temperature sender is attached to the left side of the hydraulic tank. The resistance of the temperature sender decreases as the fluid temperature in the tank increases. The hydraulic fluid temperature sender is an input to the T2: TDM and provides information for the TDM hydraulic temperature gauge. Testing the Hydraulic Fluid Temperature Sender 1.
Testing the Hydraulic Fluid Temperature Sender (continued) g228834 Figure 94 4. Put the sensing end of the sender in a container of oil with a thermometer and slowly heat the oil. Note: Prior to taking resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
Speed Sensors g258929 Figure 95 1. Front axle motor mount 3. Rear speed sensor (view from above) 2. Front speed sensor (view from underneath) 4. Rear steering cylinder The traction system uses two speed sensors to monitor the ground speed of the machine. One speed sensor is located in the front axle hydraulic motor mount and the second speed sensor is located in the rear axle hydraulic motor mount.
Testing the Speed Sensors (continued) A. Set the key switch to the RUN position. g261413 Figure 96 1. Frame harness connector 2. Multimeter probe 3. 12 VDC power supply B. Use a multimeter set to DC voltage and check for approximately 12 VDC across the supply (+) pin A and ground (−) pin B of the frame wire harness connector. This confirms the integrity of the circuit supply and ground wires. C.
Traction Pressure Sensors g259058 Figure 97 1. Tandem piston (traction) pump 2. Front axle pressure sensor (view from underneath) 3. Rear axle pressure sensor (view from above) Two pressure sensors are used to monitor the traction circuit hydraulic pressure when the machine is moving in the forward direction.
Testing the Pressure Sensors (continued) g259079 Figure 98 1. Frame harness connector 2. 1.5 V dry cell battery 3. Multimeter probe C. Connect a 1.5 VDC dry cell battery across the signal (+) pin C and ground (−) pin B of the frame wire harness connector. A fully charged battery should produce a pressure reading of approximately 8960 kPa (1300 psi) on the InfoCenter Display. This confirms the integrity of the circuit ground and signal wires. D.
Fuel Pump g232343 Figure 100 1. Fuel pump 4. Fuel/Water separator 2. Fuel hose (from tank) 5. Fuel hose (to engine) 3. Fuel hose (separator to pump) Fuel Pump Specifications Pump Capacity 700 ml (23.5 fluid ounces) per minute Pressure 22.8 kPa (3.3 psi) Current Draw 0.9 amp Testing the Fuel Pump The electric fuel pump is located inside the right side frame rail behind the hydraulic reservoir.
Testing the Fuel Pump (continued) g232341 Figure 101 1. Engine fuel filter 2. Fuel hose (from pump) IMPORTANT When testing the fuel pump output, do not turn the key switch to the START position 5. Place the disconnected hose end into a 0.95 liter (1 quart) graduated cylinder and set the key switch to the ON/RUN position for 30 seconds. The pump should deliver approximately 350 ml (11.8 ounces) in 30 seconds. Replace the fuel pump if necessary. 6. Connect fuel hoses and secure with hose clamps. 7.
Fuel Level Sender g257560 Figure 102 1. Wire harness connector 2. Float in full (up) position 3. Float in empty (down) position The fuel level sender is attached to the top of the fuel tank. The resistance of the fuel sender increases as the fuel level in the fuel tank decreases. The fuel sender is an input to the T2: TDM and provides information for the TDM fuel gauge. The fuel sender is a sliding float design with a single wire harness connector. Testing the Fuel Level Sender 1.
Warning Buzzer g259909 Figure 103 (main instrument panel removed) The warning buzzer sounds to notify the operator when a machine problem exists. Electrical current for the buzzer is provided as an output from the T2: TDM . The warning buzzer is attached to the machine under the main instrument panel. Testing the Warning Buzzer 1. Remove the dash cover; refer to Removing the Steering Wheel, Instrument Panels and Dash Cover (page 8–16) 2. Disconnect the platform wire harness connector from the buzzer.
Relays with 4 Terminals Outcross 9060 machines use a number of electrical relays that have four (4) terminals. A tag near the wire harness relay connector can be used to identify each relay. g256781 Figure 104 1. Main power relay 4. Start Relay 2. Rear attachment relay 5. Glow plug relay 3.
Testing Relays with 4 Terminals (continued) 2. Disconnect the ground cable at the battery; refer to Removing the Battery (page 6–81). 3. Access the relay to be tested and disconnect the wire harness connector from the relay. Remove the relay from the mounting bracket for testing. g256779 Figure 105 Relay with 4 Terminals Note: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.
Relays with 5 Terminals Outcross 9060 machines use a number of electrical relays that have five (5) terminals. A tag near the wire harness relay connector can be used to identify each relay. g257158 Figure 106 1. EGR relay 2. Brake light relay (optional) The Exhaust Gas Recirculation (EGR) relay is located under the main instrument panel. The EGR relay is used to provide current to the engine EGR valve. The EGR relay is energized by the Yanmar engine ECU.
g257157 Figure 107 (shown with bed removed) 1. Rear SCV hydraulic manifolds 2. Rear SCV relay The optional rear Selector Control Valve (SCV) relay is located below the rear SCV hydraulic manifolds. The rear SCV relay is used to provide current to the 4 rear SCV hydraulic solenoid valves. The rear SCV relay is energized by the T1: TEC. g267770 Figure 108 1. Refrigerant receiver drier 3. AC switch signal relay 2. AC condenser fans relay 4.
The three relays used to control the air conditioning (AC) system are located under the cab cover. • The AC condenser fans relay provides current to both of the condenser fans and the AC clutch relay. The AC condenser fans relay is energized by the air conditioning system thermostat. • The AC switch signal relay is an input to the T1: TEC. The relay is energized by the AC On/Off switch. The T1: TEC monitors the condition of the signal relay and increases the engine low idle RPM when the AC system is On.
Testing Relays with 5 Terminals (continued) make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85. 6. Connect multimeter (ohms setting) leads to relay terminals 30 and 87A. Apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87A as +12 VDC is applied and removed from terminal 85. 7. Replace the relay as necessary. 8.
Diode Assemblies Multimeter Red (+) Lead Multimeter Black (-) Lead Resistance DIODE TERMINAL A DIODE TERMINAL B VERY LOW DIODE TERMINAL B DIODE TERMINAL A VERY HIGH Five (5) different diodes are used on the Outcross 9060 machines. The maximum current allowed through any of the diodes is 6 amps. The diodes can be identified by their black color and diode symbol on the end of the diode body.
Resistor Assembly g257660 Figure 110 A 1.6K ohm (1600 ohm) resistor assembly is used for proper 12 Volt alternator operation. The resistor plugs into the engine wire harness near the starter. The resistor can be identified by its gray color and resistor symbol on the end of the resistor body. Testing the Resistor Assembly 1. Disconnect the resistor from the wire harness. 2. Measure the resistance across the resistor terminals using a digital multimeter (ohms setting).
CAN bus Terminator Resistors System communication between various electrical components on Outcross 9060 machines is accomplished on a CAN bus communications network. Two specially designed, twisted wires form the CAN–bus. These wires provide the data pathways between the components on the network. The engineering term for these cables are CAN High and CAN Low. The CAN bus wires are yellow (CAN High) and green (CAN Low). A 120 ohm termination resistor is located at each end of the CAN bus.
Testing the CAN bus Terminator Resistors (continued) g261759 Figure 112 1. 2. Dash cover Engine ECU 3. Yanmar SA-D connector 2. One CAN bus termination resistor is integrated into the Yanmar engine ECU. A. Make sure that key switch is OFF and key is removed from switch. B. Unplug the external terminator resistor from the platform wire harness (located near the rear attachment electrical connector below the right rear corner of the operator platform). C.
Hydraulic Solenoid Valve Coils g256538 Figure 113 8. Replaceable coil 1. Main manifold 2. 3. Solenoid valve SP1 Solenoid valve SP2 9. 10. Coil nut Cap screw 4. Solenoid valve EH 11. SCV manifold (optional) 5. Solenoid valve SV2 12. Solenoid valve SCV Enable (N.C.) 6. Solenoid valve SV3 13. Solenoid valve SCV Enable (N.O.) 7. Solenoid valve SV1 Electric coil actuated hydraulic valves are used on the main manifold and the optional Selector Control Valve (SCV) manifolds.
Testing the Hydraulic Solenoid Valve Coils (continued) Note: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from the measured value of the component you are testing to obtain an accurate reading. 2.
Tandem Traction (Piston) Pump Control Solenoid Coils g233999 Figure 114 1. Tandem piston (traction) pump (P1 and P2) 4. Solenoid AB-C2 (front pump valve C2 – reverse) 2. Solenoid AB-C1 (front pump valve C1 – forward) Solenoid CD-C2 (rear pump valve C2 – reverse) 3. Solenoid CD-C1 (rear pump valve C1 – forward) 5. The tandem traction (piston) pump uses two separate electronic control assemblies. One assembly controls the output for the front pump and one for the rear pump.
Testing the Pump Control Solenoid Coil Typically, a failed solenoid coil will either be shorted (very low or no resistance) or open (infinite resistance). 1. Locate the pump control solenoid coil to be tested and disconnect the wire harness connector from the coil. Note: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less).
Service and Repairs Note: For engine component repair information, see the Yanmar Model 4TNV86CT−DTR Service Manual or Troubleshooting Manual. Caring for the Battery WARNING • Wear safety goggles and rubber gloves when working with electrolyte. • Charge battery in a well ventilated place so gasses produced while charging can dissipate. • Since the gases are explosive, keep open flames and electrical sparks away from the battery; do not smoke. • Nausea may result if the gases are inhaled.
Caring for the Battery (continued) terminal protector or a light coat of petroleum jelly to the terminals to reduce corrosion after you make the connections. 7. Check the battery-electrolyte level every 25 operating hours and every 30 days if machine is in storage. Note: Do not fill the cells above the fill line. 8. Maintain the cell level with the distilled or demineralized water.
Storing the Battery If you store the machine for more than 30 days: 1. Remove the battery and charge it fully; refer to Charging the Battery (page 6–84). 2.
Servicing the Battery g256614 Figure 116 1. 2. Battery 3. Starter motor Operator platform terminal block 4. Engine ground connection 5. Chassis ground connection Battery Specifications Battery-electrolyte specific gravity Fully Charged: 1.25 to 1.28 at 27°C (80°F) Discharged: less than 1.24 Battery specifications BCI Group 34 690 CCA at -18°C (0°F) Reserve Capacity of 110 minutes at 27°C (80°F) Battery dimensions (including terminal posts and caps) Length 19.6 cm (10.9 inches) Width 13.
Removing the Battery g254790 Figure 117 1. Negative (-) battery cable 5. Side cover 2. Positive (+) battery cable 6. Washer (2 each) 3. Battery 7. Knob (2 each) 4. Battery retainer IMPORTANT Be careful when removing the battery cables and ensure that you do not damage the terminal posts or cable connectors. 1. Ensure that the key switch and all accessories are in the OFF position. 2. Remove the knobs, washers and side cover from the left side of the machine. 3.
Installing the Battery (continued) 1. Ensure that the key switch and all accessories are in the OFF position. 2. Ensure that the battery tray is clean and install the battery and retainer. 3. Ensure that all the battery terminals, battery cables and battery hold down components are in good condition. 4. Connect the positive (+) cable connector onto the positive (+) battery terminal. 5. Connect a digital multimeter (set to A) between the negative (-) battery post and the negative (-) cable connector.
Inspecting, Maintaining, and Testing the Battery (continued) IMPORTANT Before cleaning the battery, tape or block the vent holes of the filler caps and ensure that the caps are secure. C. Check for the signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap, overcharging, loose terminal post, or overfilling. Also, check the battery case for dirt and oil.
Inspecting, Maintaining, and Testing the Battery (continued) CAUTION Follow the manufacturer's instructions when using a battery load tester. A. Check the voltage across the battery terminals before testing the battery. If the voltage is less than 12.0 VDC, charge the battery before continuing the test. B. If you charge the battery, apply a 150 A load for 15 seconds to remove the surface charge. Use a battery load tester following the manufacturer's instructions. C.
Charging the Battery (continued) To minimize damage to the battery and allow the battery to charge fully, use the following slow charging procedure. You can accomplish this charging procedure with a constant current battery charger that is available locally. IMPORTANT Follow the manufacturer's instructions when using a battery charger. Note: Using the specific gravity of the battery cells is the most accurate procedure of determining the battery condition. 1.
Electrical System: Service and Repairs Page 6–86 Outcross 9060 18234SL Rev D
Chapter 7 Traction and PTO Drive Table of Contents General Information .............................................................................................................................. 7–2 Traction Unit Operator’s Manual and Accessory Installation Instructions............................................ 7–2 Adjustments .......................................................................................................................................... 7–3 Adjusting the Tie Rod Length .....
General Information Traction Unit Operator’s Manual and Accessory Installation Instructions The traction unit Operator’s Manual and accessory Installation Instructions provide information regarding the operation, general maintenance and maintenance intervals for the machine and its accessories. Refer to the traction unit Operator’s Manual and accessory Installation Instructions for additional information.
Adjustments Adjusting the Tie Rod Length g254281 Figure 118 1. Jam nut 2. Tie rod length 1. Loosen the jam nut and turn the inner tie rod shaft to adjust the tie rod length: • Front Tie Rod Length = (10.22 ± 0.03 inch). • Rear Tie Rod Length = (10.45 ± 0.03 inch). 2. Tighten the jam nut. Adjusting Axle Stop Bolts g254450 Figure 119 1. Outcross 9060 18234SL Rev D Front axle 2.
Adjusting Axle Stop Bolts (continued) Adjust the axle stop bolts after the axle has been installed on the machine and the tie rods have been installed.
Service and Repairs Tie Rods Removing the Tie Rods g254285 Figure 120 1. Cotter pin 4. Jam nut 2. 3. Slotted nut Outer tie rod 5. Inner tie rod 1. Remove and discard the cotter pin. Note: Move or remove the axle stop bolts to access the slotted nuts. 2. Remove the slotted nut. 3. Use a suitable tool (pickle fork) to separate the outer tie rod from the axle assembly. 4.
Installing the Tie Rods (continued) 3. Secure the outer tie rod to the axle with the slotted nut. Tighten the nut from 129 to 149 N∙m (95 to 110 ft-lb). 4. Check and adjust the axle stop bolts; refer to Adjusting Axle Stop Bolts (page 7–3). 5. Continue to tighten the slotted nut to align if necessary and install a new cotter pin. 6. Grease the outer tie rod with Mobil high-temp XHP-222 grease or equivalent until the boot swells. Do not allow the grease to purge from boot.
Front Axle g254406 Figure 121 1. Front axle 2. Flange nut (4 each) 3. 4. Socket head screw (4 each) 17. Cap screw (4 each) 10. Steering cylinder 18. Plain washer (4 each) Speed sensor 11. Cap screw (2 each) 19. Spacer (4 each) Axle drive motor 12. Flange nut (2 each) 20. Lug nut (12 each) 5. Flange head screw (2 each) 13. Retainer (2 each) 21. Wheel assembly (2 each) 6. Flange head screw (2 each) 14. Flange head screw (4 each) 22. Slotted nut 7. Cover (2 each) 15.
Removing the Front Axle 1. Raise and support the front of the machine; refer to Jacking Instructions (page 1–8). 2. Remove the front wheels. 3. Remove the front axle drive motor from the motor mount. Retrieve the coupler assembly (item 8) and support the motor. 4. Disconnect the front axle speed sensor (item 3) from the machine wire harness. 5. Disconnect and plug the hydraulic hoses at the steering cylinder and the differential lock. Cap the hydraulic fittings.
Installing the Front Axle (continued) 11. Apply anti-seize lubricant to the inner edge of the wheel and install the wheel. Tighten the lug nuts in a crossing pattern from 380 to 434 N∙m (280 to 320 ft-lb). 12. Check and adjust front tire air pressure as necessary.
Rear Axle g254526 Figure 122 1. Rear axle 2. Flange nut (8 each) 10. Axle drive motor 18. Cap screw (2 each) 3. U-bolt (4 each) 11. Cap screw (2 each) 19. Cap screw (2 each) 9. Cap screw (4 each) 17. Plain washer (4 each) 4. Tie rod assembly (2 each) 12. Gasket 20. Cylinder support (2 each) 5. Cotter pin (2 each) 13. Brake assembly 21. Lug nut (12 each) 6. Slotted nut (2 each) 14. Coupler assembly 22. Wheel assembly (2 each) 7. Dowel pin 15. Cap screw (2 each) 23.
Removing the Rear Axle (continued) 3. Remove the rear tie rods; refer to Removing the Tie Rods (page 7–5). 4. Remove the rear axle drive motor and brake assembly from the motor mount. Locate and retrieve the dowel pin (item 7) . Retrieve the coupler assembly (item 14) and support the motor and brake. 5. Disconnect the rear axle speed sensor (item 8) from the machine wire harness. 6. Disconnect and plug the hydraulic hoses at the steering cylinder and the differential lock. Cap the hydraulic fittings. 7.
Installing the Rear Axle (continued) 12. Grease the rear axle with Mobil high-temp XHP-222 grease or equivalent ; refer to the traction unit Operator’s Manual. 13. Apply anti-seize lubricant to the inner edge of the wheel and install the wheel. Tighten the lug nuts in a crossing pattern from 380 to 434 N∙m (280 to 320 ft-lb). 14. Check and adjust front tire air pressure as necessary.
Front and Rear Axle Service g267252 Figure 123 1. Front axle assembly 2. Rear axle assembly Refer to the traction unit Operator’s Manual for axle fluid change procedures. Additional axle service information can be found in the Carraro Drivetech Repair Manual for Model 26.09M.
Front PTO Gear Box g246820 Figure 124 1. Front PTO gear box 3. Coupler 2. Flange head screw (7 each 4. Dowel pin (2 each) CAUTION The front PTO gear box weighs approximately 42 kg (93 lbs). Use an appropriate lift to remove and install the gear box. Note: The front PTO gear box output shaft seal can be replaced in the machine. The PTO drive shaft must be disconnected but the gear box does not have to be removed. Removing the Front PTO Gear Box 1.
Replacing Front Gear Box Seals g246822 Figure 125 1. Retaining ring 3. Flange head screw (4 each) 2. Hub 4. Plate (2 each) 5. Shaft seal (2 each) 1. Remove the retaining ring and the hub from the gear box output shaft. 2. Remove the flange head screws and plate to access either shaft seal. 3. Carefully remove and discard the shaft seal. 4. Clean the gear box housing bore and cover the shaft splines with tape to protect the shaft seal during installation. 5.
Disassembling the Front PTO Gear Box g244466 Figure 126 1. Cover 14. Bearing 27. Hub Plate 2. Shaft seal 15. Retaining ring 28. 3. Plate 16. Thrust washer (2 each) 29. Shaft seal 4. Flange head screw (4 each) 17. Gear – 77T 30. Plug 5. Retaining ring 18. Needle bearing 31. Plug (4 used) 6. Bearing 19. Clutch assembly 32. Bearing (2 each) 7. Retaining ring (2 each) 20. O-ring 33. retaining ring (2 each) 8. Gear – 64T 21. Dowel pin (2 each) 34. Output shaft 9.
Disassembling the Front PTO Gear Box (continued) 5. Remove the clutch shaft and the output shaft assemblies from the gear box case together. 6. Remove the plates and shaft seals. 7. Clean the gear box cover and case, removing any old sealant. Assembling the Front PTO Gear Box 1. If previously removed, fit the dowel pins into the gear box case or cover. g246912 Figure 127 1. Gear box case 4. Clutch shaft assembly 2. Stops 5. Output shaft assembly 3. Brake disc pack tabs 6. Mating surface 2.
Installing the Front PTO Gear Box (continued) 3. Apply a thin layer of anti-seize lubricant to the splines of the output shaft and the coupler, then install the coupler.
PTO Clutch g244147 Figure 128 1. Drive assembly 2. Shaft 10. Piston 18. Bearing (2 each) 3. Key (2 each) 11. Clutch disc pack 19. Clutch shaft O-ring 4. O-ring 12. Internal retaining ring 20. Retaining ring 5. Basket 13. Spring 21. Thrust washer (2 each) 6. Retaining ring 14. Washer 22. Gear – 77T 7. Gear 43T 15. Retaining ring 23. Needle bearing 8. Retaining ring 16. Brake disc pack 9. 17.
PTO Clutch Service (continued) 5. Remove the clutch piston then remove and discard the piston O-ring. 6. Remove the external retaining ring then remove and discard the entire brake disc pack. 7. Install the new brake disc pack. Install the retaining ring and align the steel tabs. Note: Do not twist, nick, cut or otherwise damage the piston O-ring during installation or assembly. 8. Lubricate the new O-ring with petroleum grease and install onto the piston, then carefully fit the piston into the basket.
Rear PTO Gear Box g246796 Figure 129 1. Rear PTO gear box 3. Breather hose 2. Flange head screw (6 each) 4. Hose clamp CAUTION The rear PTO gear box weighs approximately 38 kg (84 lbs). Use an appropriate lift to remove and install the gear box. Note: The rear PTO gear box shaft seals can be replaced in the machine. The PTO drive shaft must be disconnected but the gear box does not have to be removed. Removing the rear PTO Gear Box 1. Disconnect the breather hose from the top of the gear box. 2.
Replacing Rear Gear Box Seals g245027 Figure 130 1. Retaining ring 5. Retaining ring (2 each) 2. Hub 6. Shaft seal (2 each) 3. Flange head screw (4 each) 7. Plug 4. Plate (2 each) 8. Barb elbow 9. 10. Eyebolt Magnetic plug 1. Remove the retaining ring and the hub from the gear box input shaft. 2. Remove the flange head screws, plate and retaining ring to access either shaft seal. 3. Carefully remove and discard the shaft seal. 4.
Installing the Rear PTO Gear Box (continued) 3. Connect the breather hose to the top of the gear box. 4. Check and adjust the rear PTO gear box fluid level; refer to the traction unit Operator’s Manual. 5. Install the PTO drive shaft; refer to Installing the PTO Drive Shaft (page 7–26).
PTO Drive Shaft g246761 Figure 131 1. PTO drive shaft 4. Shaft guard (2 each) 7. Shaft cover 2. Flange head screw (8 each) 5. Flange nut (4 each) 8. Cap screw (2 each) 3. Cap screw (2 each) 6. Flange head screw (3 each) Removing the PTO Drive Shaft CAUTION It may be necessary to raise the operator platform to remove the PTO drive shaft. If so, block the operator platform to prevent it from lowering accidently. 1. Remove the bed. 2. Remove the PTO shaft cover. 3. Remove the 2 shaft guards.
Servicing the PTO Drive Shaft Cross Bearings g244467 Figure 132 1. Tube yoke 5. Retaining ring (8 each) 2. Boot 6. Cross bearing 3. Slip yoke 7. Flange yoke 4. Grease fitting IMPORTANT When placing yoke in vise, clamp lightly on the solid part of the yoke to prevent damage. The use of a vise with soft jaws is recommended. 1. Lightly clamp each yoke in a vise and remove the snap rings that secure the bearings to the yoke. 2.
Servicing the PTO Drive Shaft Cross Bearings (continued) assembly. Make sure that all the bearing rollers are properly seated in the bearing cage. B. Press one bearing partially into the yoke. IMPORTANT Take care when installing the cross into the bearing to avoid damaging the bearing seal. C. Carefully insert the cross into the bearing and yoke. D. Hold the cross in alignment and press the bearing in until it hits the yoke. E. Carefully place the second bearing into the yoke bore and onto the cross shaft.
Chapter 8 Chassis Table of Contents General Information .............................................................................................................................. 8–2 Traction Unit Operator’s Manual and Accessory Installation Instructions............................................ 8–2 Service and Repairs ............................................................................................................................. 8–3 Front Screen .........................................
General Information Traction Unit Operator’s Manual and Accessory Installation Instructions The traction unit Operator’s Manual and accessory Installation Instructions provide information regarding the operation, general maintenance and maintenance intervals for the machine and its accessories. Refer to the traction unit Operator’s Manual and accessory Installation Instructions for additional information.
Service and Repairs Front Screen g250124 Figure 133 1. 2. Front screen Bulb seal 8. 9. Tether Cap screw 3. Bulb seal (2 each) 10. Bumper (2 each) 4. Flange head screw (2 each) 11. Bulb seal 5. Flat washer (2 each) 12. Shoulder screw 6. Spacer 13. Lock nut 7. Flange nut (3 each) Removing and Installing the Front Screen 1. Park the machine on a level surface, lower any attachments, shut off the engine and remove the key from the key switch. 2.
Hood g249481 Figure 134 1. Lynch pin (2 each) 5. lock nut 9. 2. 3. Hood skin Hood prop 6. 7. Lock nut Washer 10. 11. 4. Shoulder screw 8.
Removing and Installing the Hood 1. Park the machine on a level surface, lower any attachments, shut off the engine and remove the key from the key switch. 2. Release the hood latches and raise the hood. 3. Disconnect the hood from the platform wire harness. 4. Support the hood and remove the fasteners at either end of the hood prop. CAUTION The hood assembly is bulky. The hood assembly can safely be removed by two technicians, one on each side of the machine. 5.
Operator Platform g255499 Figure 135 1. Operator platform 4. Front cowl 2. Front lift point (2 each) 5. Plug (2 each) 8. Front fender (2 each) 3. Rear lift point (2 each) 6. Flange nut (4 each) 9. Cap screw (4 each) 7. Snubbing washer (4 each) Removing the Operator’s Platform 1. Remove the front loader if equipped. 2. Remove the bed; refer to Standard Bed (page 8–21), or the optional cargo bed Installation Instructions . 3. Remove the front cowl. 4.
Removing the Operator’s Platform (continued) IMPORTANT To prevent damage to the electrical wire harnesses, coolant hoses, and refrigerant hoses, numerous cable ties and clamps are used to secure these items to the machine. Record the location of all cable ties and clamps that are removed from the machine during operator platform removal so that they can be properly replaced during installation. g255047 Figure 136 1. Access panel 4. Hydraulic manifold ST port 2. Battery negative (-) cable 5.
Removing the Operator’s Platform (continued) g255072 Figure 137 1. Engine ECU 4. Frame wire harness connector (green ring) 2. Engine wire harness connector 5. 3–pin engine harness connector P63 3. Frame wire harness connector (blue ring) 6. 7–pin engine harness connector P18 9. Disconnect the engine wire harness from the engine ECU. 10. Separate the operator platform wire harness from the frame wire harness at the 2 connectors (under the right side of the dash cover). 11.
Removing the Operator’s Platform (continued) g255593 Figure 138 1. 2. Cap screw Relay assembly 13. Remove the main instrument panel mounting screws and lift the panel to access the glow, start and EGR relays. Remove the cap screw securing the relay bracket to the frame and pass the assembly out of the operator platform.
Removing the Operator’s Platform (continued) g255177 Figure 139 1. Hydraulic hose (rear steering cylinder, right 3. fitting) 2. Hydraulic hose (front steering cylinder, left fitting) Hydraulic hose (hydraulic tube) 14. Label and disconnect the 3 hoses at the rear bulkhead. Cap the fittings and plug the hoses to prevent contamination from entering the hydraulic system.
Removing the Operator’s Platform (continued) g255229 Figure 140 1. Coolant hose (from heater core) 2. Coolant hose (to heat valve) 15. For machines equipped with a cab heater, label and disconnect the coolant hoses at the front of the engine. Cap the fittings and plug the hoses to prevent contamination from entering the engine or coolant lines. IMPORTANT Important: Do not allow refrigerant to discharge into the atmosphere.
Removing the Operator’s Platform (continued) g255201 Figure 141 1. Compressor 2. Refrigerant hose (pressure) 3. Refrigerant hose (return) 16. For machines equipped with air conditioning, discharge the refrigerant hoses in accordance with local regulations and disconnect the hoses at the compressor. Cap the fittings and plug the hoses to prevent contamination from entering the air conditioning system. 17. Remove the rubber boot from the auxiliary load valve. 18.
Removing the Operator’s Platform (continued) IMPORTANT The operator’s platform assembly can rest on the right and left steps. Support the front and rear of the platform assembly with blocks or jack stands to prevent it from tipping. 21. Raise the operator platform clear of the machine, then lower the platform assembly to the floor. Installing the Operator’s Platform 1. Using the 4 lift points provided, lower the operator platform over the machine chassis.
Installing the Operator’s Platform (continued) 20. For machines equipped with a cab heater, operate the heater and adjust the coolant level as required; refer to the traction unit Operator’s Manual. 21. For machines equipped with air conditioning, have a certified refrigeration technician fill/recharge and test the air conditioning system. 22. Operate the machine carefully at first to allow the hydraulic system to refill with fluid. Check for and correct any hydraulic leaks.
Steering Wheel, Instrument Panels and Dash Cover g248962 Figure 142 1. Dash cover 7. Instrument panel – main 2. Button head screw (5 each) 8. Button head screw (3 each) 14. Steering wheel cover 3. Washer (2 each) 9. Flange head screw (2 each) 15. Button head screw (4 each) 16. Instrument panel – console 4. Steering column cover 10. Flange nut (2 each) 5. Button head screw (4 each) 11. Steering wheel 6. Instrument panel – steering 12.
Removing the Steering Wheel, Instrument Panels and Dash Cover 1. Park the machine on a level surface, lower any attachments, shut off the engine and remove the key from the key switch. 2. Disconnect the battery; refer to Removing the Battery (page 6–81). 3. Remove the steering wheel. If necessary, use a suitable puller to remove the steering wheel from the steering column.
Operator’s Console g249199 Figure 143 1. Console 6. Button head screw (4 each) 2. Button head screw (4 each) 7. Flange nut (2 each) 3. Instrument panel – console 8. Flange head screw (2 each) 4. Access panel 9. Instrument panel – main 5. Knob (3 each) Removing and Installing the Operator’s Console 1. Park the machine on a level surface, lower any attachments, shut off the engine and remove the key from the key switch. 2. Disconnect the battery; refer to Removing the Battery (page 6–81).
Seats g246573 Figure 144 1. Passenger seat 7. Flat washer (4 each) 2. Operator seat 8. Retractable seat belt (2 each) 3. Seat belt bracket 9. Flange head screw (4 each) 4. Cap screw (4 each) 10. Flange nut (4 each) 5. Seat belt buckle (2 each) 11. Spacer (2 each) 6. Lock nut (2 each) 12. Cap screw (4 each) Apply medium strength thread locking compound and tighten the seat belt mounting screws from 68 to 81 N∙m (50 to 60 ft-lb).
Servicing the Operator Seat g246535 Figure 145 1. Backrest cushion 13. Cap screw (2 each) 25. Torx screw 2. Seat cushion 14. Seat frame 26. Torx screw (3 each) 3. RH support cover 15. Nut 27. Washer (3 each) 4. LH armrest 16. Spring (2 each) 28. Handle 5. RH support cover 17. Magnet 29. Flat head screw (3 each) 6. Bushing (2 each) 18. Seat switch 30. Adaptor plate 7. Backrest 19. Rivet (4 each) 31. Screw 8. Plug (2 each) 20. Mounting plate 32. Lever 9.
Servicing the Operator Seat Suspension g246547 Figure 146 1. Cover assembly 6. Wire harness 11. Air control valve 2. Upper suspension 7. Air spring 12. Cover 3. Thrust limiter 8. Shock absorber 13. Compressor 4. Control lever 9. Air tube assembly 14. Bellows 5. Tether Handle 15. Lower suspension 10. Remove the operator seat to gain access the seat suspension assembly.
Standard Bed g246519 Figure 147 1. Standard bed 3. 2. Flange head screw (4 each) Flange nut (4 each) CAUTION The standard bed weighs approximately 107 kg (235 lbs). Make sure the hoist, lift or stands used to remove the bed can properly support the weight.
Front Loader Attachment g271048 Figure 148 1. Front loader arm assembly 3. Shim 2. Support assembly 4. Female coupler assembly 5. Front loader control valve Refer to General Precautions for Removing and Installing the Hydraulic System Components (page 5–49) prior to removing hydraulic system components. CAUTION The front loader arm assembly weighs approximately 218 kg (480 lbs).
Chapter 9 Operator Cab Table of Contents General Information .............................................................................................................................. 9–2 Traction Unit Operator’s Manual and Accessory Installation Instructions............................................ 9–2 Electrical Components, Schematics and Wire Harness Drawings ...................................................... 9–2 Air Conditioning System.........................................................
General Information Traction Unit Operator’s Manual and Accessory Installation Instructions The traction unit Operator’s Manual and accessory Installation Instructions provide information regarding the operation, general maintenance and maintenance intervals for the machine and its accessories. Refer to the traction unit Operator’s Manual and accessory Installation Instructions for additional information.
Air Conditioning System Air Conditioning Components The air conditioning system used in the machine operator cab consists of the following components: • A compressor mounted on the left side of the engine driven by 2 poly V−belts. • A condenser assembly with two (2) condenser fans located outside the rear of the cab roof assembly. • An evaporator, a drier−receiver and an expansion valve mounted in the headliner of the cab.
Cab Heater System The cab heater system used in the machine operator cab consists of the following components: • A heater core in the mixing box mounted in the headliner of the cab. • Hoses to allow a circuit for engine coolant to circulate through the heater core. • A blower fan motor that provides air movement through the heater core and into the cab. The fan motor is a component of the mixing box located in the cab headliner. The fan motor is also used for the air conditioning system.
Adjustments Adjusting the Compressor Belt Tension g267502 Figure 149 1. Compressor 2. Nut 3. Tensioner plate Compressor belt(s) tension = 19 mm (0.75 inch) deflection when 6.8 kg (15 lb) is applied half way between the engine and compressor pulleys. 1. Loosen nut at bottom of tensioner plate and lift or gently pry compressor upward to decrease belt(s) deflection. 2. Tighten nut and recheck belt tension.
Adjusting the Doors g271001 Figure 150 1. 2. Striker stud Shim (as required) 4. 5. Lock nut Striker guard 3. Adjuster 6. Frame 7. 8. Door seal Door panel 1. Use shims under the striker stud if necessary for proper door latch engagement. 2. Check the door adjustment to ensure proper sealing at the 3 points indicated. The distance between the sealing surface of the frame and the outer edge of the door trim when the door is fully latched should be from 19 to 25 mm (0.8 to 1.0 inch). 3.
Service and Repairs General Precautions for Removing and Installing Air Conditioning System Components WARNING The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified air conditioning service technician. CAUTION Always wear safety goggles or a face shield when working with air conditioning system components.
General Precautions for Removing and Installing Air Conditioning System Components (continued) 9. The air conditioning system uses R134a refrigerant. DO NOT use other refrigerants in the system. air conditioning system capacity is approximately 1.4 kg (40 oz or 2.53 lbs) of R134a refrigerant. 10. Refrigerant containers (either full or empty) are under pressure that will increase if the containers are heated. DO NOT expose refrigerant containers to high heat sources or flame. 11.
Air Conditioning Compressor g255887 Figure 151 1. Cap screw 7. Tensioner plate 2. Shim (as required) 8. Compressor 3. Lock nut (4 each) 9. Bracket – front left 4. Refrigerant hose (pressure) 10. V-belt (2 each) 5. Refrigerant hose (return) 11. Pulley 6. Carriage bolt (3 each) 12. Cap screw (3 each) The air conditioning compressor used on the Outcross 9060 is a Sanden model SD7H15. For air conditioning compressor repair procedures; refer to the Sanden SD Compressor Service Guide.
Removing and Installing the Compressor (continued) IMPORTANT To prevent compressor oil from filling the compressor cylinders, keep compressor in the same orientation as the installed position. 4. Remove the compressor from the bracket. Locate and retrieve any shims (item 2). 5. Remove the tensioner plate from the compressor if necessary. Note: Use shims as needed to minimize the gap between the compressor and the bracket before tightening fasteners. 6.
Heating and Air Conditioning Components g256120 Figure 152 (shown with roof removed) 1. Refrigerant hoses 2. Expansion valve 3. 4. 5. Thermostat – resistor Blower Heat valve 6. 7. 8. 9. 10. Evaporator 11. Fresh air intake (2 each) Heater core 12. Condenser fans Pressure switch Drier – receiver Heater (engine coolant) hoses 13. Condenser Remove the roof to access the heating and air conditioning components. Inspect and repair damaged roof seals as necessary before installing the roof.
Control Panel and Windshield Wiper Assembly g256094 Figure 153 1. Flange nut (2 each) 2. Wiper arm – LH 3. Wiper arm – RH Lock nut (4 each) 17. Wiper motor 10. Control panel wire harness 18. Bracket – LH 11. Bracket – RH 19. Roof wire harness 9. 4. Boot (2 each) 12. Cap screw (12 each) 20. Cup (2 each) 5. Lock nut (4 each) 13. Control panel assembly 21. Rubber washer (2 each) 22. Roof panel 6. Cap screw (3 each) 14. Control panel cover assembly 7. Cap screw 15.
Removing the Control Panel and Windshield Wiper Assembly (continued) control panel wire harness from the roof harness. Remove the control panel assembly. 5. Continue to disassemble the control panel as necessary. Installing the Control Panel and Windshield Wiper Assembly 1. Install all components previously removed from the control panel. 2. If the wiper motor or wiper linkage assembly was removed: g256105 Figure 154 (view from outside cab) 1. Wiper arm – RH (passenger side) 4.
Installing the Control Panel and Windshield Wiper Assembly (continued) 7. Test wiper and washer operation before returning the machine to service.
Doors g270967 Figure 155 1. Door assembly (LH shown) 7. Lanyard (2 each) 13. Shim (as required) 2. Washer (6 each) 8. Ball stud (4 each) 14. Adjuster (2 each) 3. Flange nut (14 each) 4. Acorn nut (8 each) 9. 10. Retainer (8 each) 15. Hex nut (2 each) Flange head screw (8 each) 16. Striker guard (2 each) 17. Shoulder bolt (2 each) 5. Door mount (LH shown) 11. Washer (4 each) 6. Door spring (2 each) 12.
Doors (continued) Install the gas spring (item 6) as shown, with the barrel end at the door and the rod end at the frame. Adjust the door fit against the frame as necessary; refer to Adjusting the Doors (page 9–6).
Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations.........................................................................................................A–2 Hydraulic Schematic ..........................................................................................................................A–3 Electrical Schematic (part 1 of 3)........................................................................................................A–4 Electrical Schematic (part 2 of 3)...
Electrical Drawing Designations Note: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g., SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
Hydraulic Schematic g259663 Outcross 9060, Drawing 133-7829 Rev A, Sheet 1 of 1 18234SL Rev D Page A–3
Electrical Schematic (part 1 of 3) g264053 Page A–4 18234SL Rev D Outcross 9060, Drawing 122-1360 Rev 1, Sheet 1 of 3
Electrical Schematic (part 2 of 3) g264054 Outcross 9060, Drawing 122-1360 Rev 1, Sheet 2 of 3 18234SL Rev D Page A–5
Electrical Schematic (part 3 of 3) g267771 Page A–6 18234SL Rev D Outcross 9060, Drawing 122-1063 Rev A, Sheet 3 of 3
Wire Harness Drawing – Frame g256296 Outcross 9060, Drawing 122-0923 Rev A, Sheet 1 of 1 18234SL Rev D Page A–7
Wire Harness Diagram – Frame g256295 Page A–8 18234SL Rev D Outcross 9060, Drawing 122-0923 Rev A, Sheet
Wire Harness Drawing – Platform g256443 Outcross 9060, Drawing 122-0922 Rev A, Sheet 18234SL Rev D Page A–9
Wire Harness Diagram – Platform g256441 Page A–10 18234SL Rev D Outcross 9060, Drawing 122-0922 Rev A, Sheet
Wire Harness Diagram – Platform (continued) g256442 Outcross 9060, Drawing 122-0922 Rev A, Sheet 18234SL Rev D Page A–11
Wire Harness Drawing – Engine g256294 Page A–12 18234SL Rev D Outcross 9060, Drawing 122-0921 Rev A, Sheet 1 of 1
Wire Harness Diagram – Engine g256293 Outcross 9060, Drawing 122-0921 Rev A, Sheet 1 of 1 18234SL Rev D Page A–13
Wire Harness – Headlights g259593 Page A–14 18234SL Rev D Outcross 9060, Drawing 122-1045/122-1046 Rev A/A, Sheet 1 of 1
Wire Harness – Cab Rooftop g256477 Outcross 9060, Drawing 122-1245 Rev D, Sheet 1 of 1 18234SL Rev D Page A–15
Wire Harness – Cab Control Panel g256479 Page A–16 18234SL Rev D Outcross 9060, Drawing 122-1260 Rev A, Sheet 1 of 1
Wire Harness – Cab Heat/Air Conditioning g256480 Outcross 9060, Drawing 122-1166 Rev A, Sheet 1 of 1 18234SL Rev D Page A–17
Wire Harness – InchMode (optional) g259592 Page A–18 18234SL Rev D Outcross 9060, Drawing 122-1385 Rev A, Sheet 1 of 1
Wire Harness – Loader Selector Control Valve (SCV) Switch (optional) g260279 Outcross 9060, Drawing 122-1382 Rev A, Sheet 1 of 1 18234SL Rev D Page A–19
Wire Harness – Loader Selector Control Valve (SCV) Valve (optional) g260280 Page A–20 18234SL Rev D Outcross 9060, Drawing 122-1383 Rev A, Sheet 1 of 1
Wire Harness – Rear Selector Control Valve (SCV) Kit (optional) g260281 Outcross 9060, Drawing 122-1384 Rev A, Sheet 1 of 1 18234SL Rev D Page A–21
Wire Harness – Cab Work Light Kit (optional) g260313 Page A–22 18234SL Rev D Outcross 9060, Drawing 122-1248 Rev B, Sheet 1 of 1
Wire Harness – Domestic Road Light Kit (optional) g259650 Outcross 9060, Drawing 122-1387 Rev A, Sheet 1 of 1 18234SL Rev D Page A–23
Wire Harness – Turn Signal/Hazard Lights (optional) g260339 Page A–24 18234SL Rev D Outcross 9060, Drawing 122-1249 Rev A, Sheet 1 of 1
Wire Harness – International Road Light Kit (optional) g259651 Outcross 9060, Drawing 122-1386 Rev A, Sheet 1 of 1 18234SL Rev D Page A–25
