- Articulated Truck:
- D350E (S/N: 9LR1-UP)
- D400E (S/N: 2YR1-UP)
Introduction
Reference: Operation and Maintenance Manual, SEBU6904, "D350E and D400E Articulated Trucks"
This Instruction describes the procedure to replace the P2 Pressure Switch with a Pressure Sensor and a Buffer. This instruction applies only to D350E and D400E Articulated Trucks.
When performing any procedures that are described in this instruction, refer to the machine's Operation and Maintenance Manual. The machine's Operation and Maintenance Manual describes the machine safety requirements that are not covered in this instruction.
| Special Tools Required | |
| Tool Name | Description |
| Deutsch extraction tool | Blue |
| Parts Required | ||
| Part Number | Part Description | Quantity |
| 9X-0261 | Adapter | 1 |
| 3J-1907 | O-Ring Seal | 1 |
| 3J-7354 | O-Ring Seal | 1 |
| 163-8515 | Pressure Sensor | 1 |
| 212-0386 | Buffer | 1 |
| 220-1572 | Harness (Cab) | 1 |
| 220-1571 | Harness (Chassis) | 1 |
| 155-2269 | Connector Plug | 1 |
| 155-2261 | Plug Lock Wedge | 1 |
| 8T-8737 | Seal Plug | 2 |
| 6L-7008 | Cable Strap | as needed |
| 4P-8134 | Clip | 1 |
| 9B-7237 | Bolt | 1 |
| 3E-6915 | Clip | 1 |
P2 Pressure Sensor and Buffer Installation
- Use the disconnect switch (1) to isolate the batteries.
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| Illustration 1 | g00887563 |
Disconnect switch (1) Disconnect switch | |
- Remove the four cover bolts (2). Remove the cover in order to reveal the EPTCII control and the associated wiring.
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| Illustration 2 | g00887575 |
(2) Cover bolts | |
- To gain access behind the EPTCII mounting configuration, remove the two bolts that secure the hinged cover. The hinged cover is located over the left-front tire (facing forward). After the two bolts have been removed, the hinged cover swings down. Remove the front cab pins and tilt the cab. Follow the correct procedure that is outlined in the Operation and Maintenance Manual.
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| Illustration 3 | g00887588 |
(3) Bolts that secure the hinged cover | |
- Locate the solenoid driver connector (4). The solenoid driver connector (4) is located on the rear of the plate that secures the EPTCII control ECM.
 | |
| Illustration 4 | g00887594 |
(4) Solenoid driver connector (5) 125-0946 Cab Harness As connector (Secondary Service Brake Solenoid Driver) | |
- Disconnect the cab harness connector (5) from the solenoid driver connector (4). Remove the wedge from the cab harness connector. Carefully extract the 126-PK wire (6) from the cab harness connector (pin location 1).
 | |
| Illustration 5 | g00887602 |
(4) Solenoid driver connector (5) Original 125-0946 Cab Harness As connector (Secondary Service Brake Solenoid Driver) (6) Extracted 126-PK wire | |
- Insert the 126-PK wire (removed in Step 5) into Location 2 of the supplied 155-2269 Connector Plug (7). Push the 126-PK wire into location 2 of the 155-2269 Connector Plug until a click is heard. Gently pull on the 126-PK wire to confirm a positive connection. Insert a 8T-8737 Seal Plug into location 1 of the 155-2269 Connector Plug (7). Insert a 155-2261 Plug Lock Wedge into the end of the 155-2269 Connector Plug .
 | |
| Illustration 6 | g00887605 |
(7) 155-2269 Connector Plug (with 126-PK wire installed) | |
- Install the single wire from the 220-1571 Harness (126-PK) into location 1 of the original cab harness connector (5). Mate the 220-1571 Harness two-way receptacle (cab) with the 155-2269 Connector Plug that was assembled in Step 6.
Note: The remaining loose connector of the 220-1571 Harness will mate with the 220-1572 Harness later in this procedure (Step 15).
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| Illustration 7 | g00887612 |
(8) 155-2269 Connector Plug mated with one of the 220-1571 Harness connectors | |
- Reconnect the solenoid driver connector (4) to the original cab connector (5). Use the 2U-4497 Straps to secure the connectors.
- When routing the 220-1571 Harness (10), follow the cab harness down to the transmission. Use 2U-4497 Straps (9) to secure the remainder of the 220-1571 Harness to the original cab harness.
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| Illustration 8 | g00887626 |
(9) 2U-4497 Straps (10) 220-1571 Harness | |
- Swing up the rear stone guard to reveal the top of the transmission. Remove the original bolt (11) from the left-hand hydraulics module.
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| Illustration 9 | g00887636 |
Left-hand hydraulics module (11) Original bolt (12) Original clip | |
- Install the 212-0386 Buffer and the 3E-6915 Clip (14) as shown in Illustration 10. Replace the original bolt (11) with a 9B-7237 Bolt (15) .
Note: Ensure that the three-way plug (male connector) of the buffer is installed toward the rear of the machine.
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| Illustration 10 | g00887645 |
(13) 212-0386 Buffer (14) 3E-6915 Clip (15) 9B-7237 Bolt | |
- The P2 pressure switch (17) is located on the top of the transmission. Disconnect the P2 pressure switch from the transmission harness. Remove the P2 pressure switch and the adapter (16) .
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| Illustration 11 | g00887714 |
(16) Adapter (17) P2 pressure switch | |
- Install the 3J-1907 O-Ring Seal and the 3J-7354 O-Ring Seal onto the 9X-0261 Adapter . Install the 9X-0261 Adapter (18) and the 163-8515 Pressure Sensor (19) into the location that the P2 pressure switch was removed from.
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| Illustration 12 | g00887723 |
(18) 9X-0261 Adapter (19) 163-8515 Pressure Sensor | |
- Route the 220-1572 Harness (20) under the bracket (21) on the transmission. Connect the 220-1572 Harness (sensor - plug) (25) to the 163-8515 Pressure Sensor . From the connector that was originally connected to the P2 pressure switch, remove the wire from Location A. DO NOT remove the wire from Location C.
Note: In order to remove a wire from the connector, first remove the connector wedge.
Show/hide tableTable 3 220-1572 Harness Wire Routing Table Termination A Circuit Identifier
Gauge Length (mm) Color
Circuit Identifier Termination B Harness As. -P2 (Cab) 126A
16 3260 PK
126B Harness As. -P2 (Chassis) Harness As. - Frame 126C
16 1300 PK
126D P2 Buffer Harness As. - Frame 202A
16 1300 BK
202B P2 Buffer P2 Buffer 202C
16 840 BK
202D P2 Sensor Harness As. - Frame 815A
16 1300 WH
815B P2 Buffer P2 Buffer 815C
16 840 WH
815D P2 Sensor P2 Buffer R997A
16 840 OR
R997B P2 Sensor
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| Illustration 13 | g00887728 |
(20) 220-1572 Harness (21) Bracket | |
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| Illustration 14 | g00894299 |
220-1572 Harness wiring diagram. For wire routing information, refer to Table 3. (22) Harness As. - P2 (Chassis) (23) P2 Buffers (two) (24) Harness As. - Frame (25) P2 Sensor (26) Harness As. - P2 (Cab) | |
- The connector that was originally connected to the P2 pressure switch should be populated as follows:
Location A - Harness As. - P2 (Chassis) (22) - loose wire from the 220-1572 Harness
Location B - Black wire (originally in Location A, removed in Step 14)
Location C - White wire (original)
Reinstall the wedge in order to secure the connections. Mate this connector with the 220-1572 Harness connector (frame - receptacle) (24) .
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| Illustration 15 | g00887733 |
(27) Connector that was originally connected to the P2 pressure switch | |
- Use the original bolt to install a 4P-8134 Clip (28). Refer to Illustration 16 and Illustration 18.
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| Illustration 16 | g00887746 |
(28) 4P-8134 Clip | |
- Following the original transmission harness, route the 220-1572 Harness to the buffer. Secure the 220-1572 Harness to the original transmission harness and the 4P-8134 Clip . Use 2U-4497 Straps to secure the harness and connectors.
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| Illustration 17 | g00887755 |
(28) 4P-8134 Clip (29) Mated connectors | |
- Connect each of the buffer connectors to the two buffer connectors on the 220-1572 Harness (P2 Buffer) (23). Secure the connections and the 220-1572 Harness .
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| Illustration 18 | g00887764 |
(30) 212-0386 Buffer (31) 220-1572 Harness (32) 163-8515 Sensor | |
