Contactor Kit

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Lower the cutting units.

4. Shut off the engine and remove the key.

1. Open the hood (Figure 1).

   

   Figure 1

2. Rotate the battery disconnect switch to the OFF position, refer to the Operator’s Manual for your machine.

1. Loosen the 2 knobs that secure the left and right side panels to the machine (Figure 2).

   

   Figure 2

   Right side panel shown

   1. Side panel
   2. Knobs

2. Remove the side panels from the machine (Figure 2).

Note: Your machine may have up to 3 fuses on the fuse bracket towards the rear end of the machine. For this procedure, remove the 28-V solenoid under the fuse holder shown in Figure 3.

Figure 3

1. Open the fuse-holder cover (Figure 4).

2. Remove the 2 ring terminals from the left post of the fuse holder (Figure 4).

   

   Figure 4

   1. Fuse cover
   2. Ring terminal—28V + FUSE
   3. Ring terminal—battery cable
   4. Nut
   5. Wire connectors (labeled COIL + [28V MASTER CONTACTOR] and COIL - [28V MASTER CONTACTOR])

3. Remove the wire connectors (labeled COIL + [28V MASTER CONTACTOR] and COIL - [28V MASTER CONTACTOR]) from the solenoid (Figure 4).

4. Remove the red insulator and ring terminal (labeled SOLENOID LINE OUT [28V MASTER CONTACTOR]) from the solenoid (Figure 5).

   

   Figure 5

   1. Nut
   2. Ring terminal—SOLENOID LINE OUT [28V MASTER CONTACTOR]
   3. Red insulator

5. Remove and discard the jumper strap and insulator (Figure 6).

   

   Figure 6

   1. Nuts
   2. Jumper strap and insulator
   3. Bolt
   4. Solenoid

6. Remove the bolts and nuts that secure the solenoid to the bracket (Figure 6).

7. Remove and discard the solenoid from the bracket (Figure 6).

Parts needed for this procedure:

1. Use 2 carriage bolts and 2 nuts (1/4 inch) to secure the contactor mount to the bracket (Figure 7).

   

   Figure 7

   1. Carriage bolt
   2. Contactor mount
   3. Nut (1/4 inch)

2. Use 2 flange bolts and 2 nuts (1/4 inch) to secure the contactor to the contactor mount (Figure 8).

   

   Figure 8

   1. Contactor
   2. Flange bolt
   3. Nut (1/4 inch)

3. Use a nut (5/16 inch) to secure the end of the cable with the boot attached to the contactor (Figure 9).

   

   Figure 9

   1. Nut (5/16 inch)
   2. Cable
   3. Nut (5/16 inch)

4. Use a nut (5/16 inch) to secure the other end of the cable to the right post of the fuse holder (Figure 9).

5. Install the wire connector labeled COIL + [28V MASTER CONTACTOR] to the left post at the top of the contactor (Figure 10).

   

   Figure 10

   1. Ring terminal—28V + FUSE and ring terminal—battery cable
   2. Nut
   3. Wire connector—COIL + [28V MASTER CONTACTOR]
   4. Wire connector—COIL - [28V MASTER CONTACTOR]

6. Install the wire connector labeled COIL - [28V MASTER CONTACTOR] to the right post at the top of the contactor (Figure 10).

7. Assemble the ring terminal labeled 28V + FUSE of the machine wire harness onto the left post of the fuse holder (Figure 10).

8. Assemble the ring terminal of the battery cable onto the left post of the fuse holder and use the previously removed nut to secure the terminals to the post (Figure 10).

9. Torque the nuts that secure the connectors to the fuse-holder posts to 14 N∙m (10 ft-lbs).

10. Install the red insulator and ring terminal labeled SOLENOID LINE OUT [28V MASTER CONTACTOR] (Figure 11) to the left post of the contactor.

    

    Figure 11

    1. Fuse-holder cover
    2. Ring terminal (SOLENOID LINE OUT [28V MASTER CONTACTOR])

11. Torque the nuts that secure the connectors to the contactor posts to 5 to 6 N∙m (40 to 50 in-lb).

12. Close the cover of the fuse-holder (Figure 11) until the cover snaps closed securely.

Parts needed for this procedure:

1. Locate and remove the I-terminal wire (green wire) on the alternator (Figure 12).

   

   Figure 12

   1. Nut
   2. Ring terminal (I-terminal wire)
   3. I-terminal wire (green wire)
   4. Alternator post—Remote sense terminal
   5. Alternator post—I terminal
   6. Alternator post—R terminal

2. Cut off and discard the ring terminal from the wire (Figure 12).

3. Install the wire cap on the end of the cut green wire and crimp (Figure 13).

   

   Figure 13

   1. Vinyl cap
   2. Wire cap
   3. Wire label
   4. Alternator post—I terminal
   5. Nut (M5)

4. Install the wire label onto the wire (Figure 13).

5. Use a cable tie to secure the wire to the wire harness.

6. Install a nut (M5) flush with the top of the alternator post (Figure 13).

7. Install a vinyl cap over the alternator post (Figure 13).

   Note: The nut (M5) helps to secure the vinyl cap over the post.

Parts needed for this procedure:

For machines with a serial number of 403444961 or below:

1. Locate the fuse block on the right side of the machine (Figure 14).

   

   Figure 14

   1. Diode
   2. Fuse-block cover
   3. Fuse block

2. Access the fuse block by pulling the fuse block down from the cover (Figure 14).

3. Remove the diode from the fuse block (Figure 14) and discard it.

4. Install the fuse block into the cover.

For machines with a serial number of 403444962 or above:

1. Remove the molded diode from the connector labeled P103 on the right side of the machine (Figure 15).

   

   Figure 15

   1. Diode
   2. Connector—P103
   3. Molded plug

2. Discard the diode.

3. Install the molded plug into the connector (Figure 15).

Parts needed for this procedure:

Perform this procedure only if your machine is equipped with a cab or cab power supply (i.e., 2-Post ROPS Extension Kit or Power Harness Kit).

Figure 16 illustrates the fuses as seen from the rear of the machine. For this procedure, replace the existing cab power fuse (100 A) with the 60 A fuse from this kit.

Figure 16

1. 24-V-system-power fuse (100 A)
2. Cab-power fuse (100 A)
3. Platform-power fuse (60 A)

1. Open the cover of the cab power fuse (Figure 17).

2. Remove the nuts from the posts of the fuse holder (Figure 17).

   

   Figure 17

   1. Ring terminal (yellow)
   2. Nut
   3. Fuse
   4. Post (fuse holder)

3. Remove the ring terminal for the yellow wire of the machine wire harness from the left post of the fuse holder (Figure 17).

4. Remove the fuse (100 A) from the fuse holder (Figure 17) and discard it.

5. Install the fuse (60 A) to the fuse holder (Figure 17).

6. Assemble the ring terminal for the yellow wire of the machine wire harness onto the left post of the fuse holder (Figure 17).

7. Assemble the 2 nuts onto the left and right posts of the fuse-holder (Figure 17).

8. Torque the nuts to 14 N∙m (10 ft-lbs).

9. Close the cover of the fuse-holder until the cover snaps closed securely (Figure 18).

   

   Figure 18

   1. Cover (fuse holder)

Parts needed for this procedure:

1. Remove any dust and debris from the existing fuse-decal surface; refer to Figure 19 for the decal location.

   

   Figure 19

   1. Contactor
   2. Decal location

2. Install the fuse decal (Part No. 139-1031) over the existing fuse decal (Figure 19).

Rotate the battery disconnect switch to the ON position; refer to the Operator’s Manual for your machine.

1. Align the holes in side panels with the holes in the panel supports of the machine; refer to Figure 2 in Removing the Side Panels.

2. Secure the side panels to the machine with the 2 knobs that you removed in Removing the Side Panels.

3. Close the hood and secure it.

Important: Ensure that all wiring is routed away from any hot, sharp, or moving parts on the machine.

1. Ensure that the machine software is updated to the latest version (i.e., Rev K or higher).

2. Use the InfoCenter to confirm that the 28-V system and cab power (if equipped) are charging.

   Note: You can determine that these systems are charging by toggling to the voltage indicators in the startup screen; refer to the machine Software Guide.

3. Verify that the radiator and hydraulic cooler fans are functioning by performing the following steps to run the fan demo in the InfoCenter:

   1. From the Main Menu screen, select the Service option.

   2. From the Service screen, select the Fan Demo option.

   3. Follow the InfoCenter prompts to perform the fan demo.