Traction Switch Bypass Kit

TX 1000 Compact Tool Carrier

Model No. 140-5879-Serial No. and Up

Model No. 140-5896-Serial No. and Up

Safety

Safety and Instructional Decals

Graphic

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing.
decal144-7365

144-7365

  1. Traction hydraulic—enable

Installation

Note: Determine the left and right sides of the machine from the normal operating position.

Preparing the Machine

  1. Park the machine on a level surface.

  2. Engage the parking brake.

  3. Lower the loader arms.

  4. Shut off the engine and remove the key.

  5. Open the hood and secure the prop rod.

  6. Turn the battery-disconnect switch to the OFF position.

Accessing Internal Components

  1. Use a nylon strap to secure the hood to a reference bar on the control panel.

  2. Remove the prop rod from the hood.

    g352716

    Figure 1

    1. Washer and hairpin cotter

  3. Open the rear-access cover and secure it open using a nylon strap.

  4. Remove the cover plate.

    g351987

    Figure 2

    1. Bolt—1/4 x 3/4 inch (3)
    2. Cover plate

  5. Remove the bolt and washer to release the rubber baffle.

    g352599

    Figure 3

    1. Washer (1/4 inch)
    2. Bolt (1/4 x 3/4 inch)

  6. Remove the bottom plate.

    g351986

    Figure 4

    1. Bottom plate
    2. Bolt—3/8 x 1 inch (2)

Replacing the Traction Valve

Model 140-5896 Only

Parts needed for this procedure:

Traction valve1
Swivel elbow fitting2
Straight fitting2

Removing the Valve

  1. If the machine has a test port, remove the test port and elbow fitting from the right side of the traction valve. Discard the elbow fitting.

    g351646

    Figure 5

    1. Test port
    2. Elbow fitting

  2. Label the traction valve hoses with their port locations.

    g355599

    Figure 6

    1. Upper left port (T)
    2. Lower left port (P)
    3. Port 1
    4. Port 2
    5. Port 3
    6. Port 4

  3. Disconnect the hose fittings from the valve.

  4. Remove the handle from traction valve.

    g355602

    Figure 7

    1. Handle (2 halves)
    2. Screw

  5. Remove the fasteners from the cover panel.

    g355600

    Figure 8

    1. Bolt (1/4 x 7/8 inch) and nut (1/4 inch)

  6. Remove the fasteners, rubber cover, and clamp plate securing the valve to the cover plate.

    g355601

    Figure 9

    1. Bolt—1/4 x 1 inch (2)
    2. Rubber cover
    3. Clamp plate
    4. Nut—1/4 inch (4)
    5. Bolt—1/4 x 7/8 inch (2)

  7. Remove the valve.

Installing the Valve

  1. Secure the new traction valve to the cover panel.

    g355601

    Figure 10

    1. Bolt—1/4 x 1 inch (2)
    2. Rubber cover
    3. Clamp plate
    4. Nut—1/4 inch (4)
    5. Bolt—1/4 x 7/8 inch (2)

  2. Secure the cover panel to the control panel.

    g355600

    Figure 11

    1. Bolt (1/4 x 7/8 inch) and nut (1/4 inch)

  3. Install the 2 handle halves to the traction valve, positioning the screw heads toward the operator position.

    g355602

    Figure 12

    1. Handle (2 halves)
    2. Screw

Installing the Traction Valve Hoses and Fittings

  1. Install the 4 lower hoses to their labeled locations; angle the fittings toward the 10 o’clock position (toward the front, left).

    g355616

    Figure 13

    1. Upper left hose (port T)
    2. Lower left hose (port P)
    3. Lower hoses

  2. Install the hoses to the upper and lower left ports; angle the lower fitting toward the 5 o’clock position.

  3. Install a straight fitting to the upper right port (T).

    g354116

    Figure 14

    1. Straight fitting (port T)
    2. Elbow fitting

  4. Install the elbow fitting to the straight fitting and point it forward.

  5. If you previously removed a test port, install the test port to a new swivel fitting and install a straight fitting and the elbow fitting to the lower right port (P).

    g351645

    Figure 15

    1. Straight fitting (port P)
    2. Swivel fitting
    3. Test port

  6. Torque the straight and 45-degree fittings to 12.2 to 14.9 N∙m (9 to 11 ft-lb).

  7. Torque the swivel fittings and test port (if applicable) to 24.4 to 29.8 N∙m (18 to 22 ft-lb).

Installing the Traction Valve Fittings

Model 140-5879 Only

Parts needed for this procedure:

Swivel fitting1
Straight fitting1

  1. Install a straight fitting and elbow fitting to the upper right port of the traction valve.

    g354116

    Figure 16

    1. Straight fitting
    2. Swivel fitting

  2. Torque the straight fitting to 12.2 to 14.9 N∙m (9 to 11 ft-lb).

  3. Torque the swivel fitting to 24.4 to 29.8 N∙m (18 to 22 ft-lb).

Installing the Solenoid Valve

Parts needed for this procedure:

Solenoid valve bracket1
Elbow fitting3
Solenoid valve1
Bolt (1/4 x 2 inches)2
Hose—26 cm (10-1/4 inch) length1
Hose—31 cm (12-1/4 inch) length1

  1. Remove the hose that extends from the tee fitting on the detent valve to the T1 port on the loader valve.

    g351744

    Figure 17

  2. Remove the radiator hose from the detent valve.

    g355849

    Figure 18

  3. Remove the locknuts securing the detent valve to the bracket.

    g351613

    Figure 19

    1. Detent valve
    2. Locknut—5/16 inch (2)

  4. Use the locknuts you removed to install the solenoid valve bracket.

    g351610

    Figure 20

    1. Locknut (2)
    2. Solenoid valve bracket

  5. Install 3 elbow fittings on the solenoid valve. Torque them to 12 to 15 N∙m (9 to 11 ft-lb).

    Note: For machines without a Low Flow Kit, rotate the fittings at ports 1 and 3 approximately 30° toward the rear.For machines with a Low Flow Kit, rotate the fittings toward the front.

    g351611

    Figure 21

  6. Loosely install hoses on ports 2 and 3.

    g353002

    Figure 22

    1. Hose—26 cm (10-1/4 inch) length
    2. Hose—31 cm (12-1/4 inch) length

  7. Loosen the upper left hose on the traction valve. Swivel it away to improve access to the charge-pressure hose.

    g352718

    Figure 23

    1. Loosen this hose.

  8. Remove the charge-pressure hose from the lower left port and install it to port 1 on the solenoid valve.

    g351743

    Figure 24

  9. Install 1 bolt (1/4 x 2 inches) to the left side of the solenoid bracket.

    g353093

    Figure 25

    1. Bolt—1/4 x 2 inches

  10. Connect the hose from port 2 on the solenoid valve to the upper right fitting on the traction-control valve.

    g351742

    Figure 26

    1. Hose from port 2
    2. Hose from port 3

  11. Connect the hose from port 3 on the solenoid valve to the lower left fitting on the traction-control valve.

  12. Torque the hoses on the valve fittings and the hose loosened in step 10 to 24.4 to 29.8 N∙m (18 to 22 ft-lb).

  13. Place the solenoid valve onto the bolt, then secure it with the second bolt.

Connecting the Hydraulic Tube

Parts needed for this procedure:

Tube1

  1. Loosen the nut on the detent valve tee fitting.

    g351741

    Figure 27

    1. Tee fitting
    2. Push down this hose.
    3. Tube at T1 port
    4. Radiator hose

  2. Loosely install the tube to the T1 port on the loader valve.

  3. Push down the hose shown in Figure 27 to rotate the tee fitting to align it with the tube.

  4. Install the tube to the fitting.

  5. Torque both ends of the tube to 50.2 to 63.7 N∙m (37 to 47 ft-lb).

  6. Torque the nut on the tee fitting to 78.6 to 97.6 N∙m (58 to 72 ft-lb).

  7. Install the radiator hose to the detent valve and tighten the hose clamp.

Cutting a Hole for the Switch

Machines without a Plug Only

If your machine does not have a plug on the control panel, you must cut a hole to install the switch.

Warning

Using a drill without wearing eye protection may allow debris to enter the eye, causing personal injury.

When drilling, always wear eye protection.

  1. Using the dimensions shown, mark a 2.1 x 3.7 cm (0.83 x 1.45 inch) rectangle on the control panel.

    g354721

    Figure 28

    1. 8.3 cm (3-1/4 inches)
    2. 2.1 cm (0.83 inch)
    3. 1.9 cm (3/4 inch)
    4. 3.7 cm (1.45 inch)

  2. Drill a 3/8 inch hole in the center of the rectangle, then use a jigsaw to cut out the rectangle.

    Important: Ensure that you do not cut through any wires or hoses beneath the control panel.

  3. Remove any burrs around the edge of the hole.

Installing the Switch and Decal

Parts needed for this procedure:

Switch1
Decal1

  1. Remove the plug (if applicable) from the control panel.

    g353380

    Figure 29

  2. Clean around the hole with alcohol and a clean rag.

  3. Remove the backing from the decal and install the decal.

    g353381

    Figure 30

    1. Decal

  4. Install the switch.

    g351859

    Figure 31

Routing the Wire Harness

Parts needed for this procedure:

Wire harness1
Self-tapping screw1
Relay1
Traction enable jumper harness1
Cable tie2

Wire Harness Overview

Note: This kit contains 2 wire harnesses. Use the wire harness that fits the key switch to your machine and discard the other wire harness.

g351814

Figure 32

Appearance of key switch connector may differ for your machine.

  1. Solenoid valve (P05)
  2. Traction-enable switch (P08)
  3. Auxiliary output (P07)
  4. Auxiliary input (P06)
  5. Key switch input (P03)
  6. Key switch output (P04)
  7. Traction relay (P10)
  8. Diode (P11)
  9. Parking brake output (P02)
  10. Parking brake input (P01)

Installing the Upper Connectors

  1. Route the upper portion of the wire harness between the rubber baffle and frame and behind the detent valve hydraulic hose.

    g352653

    Figure 33

  2. Disconnect the machine wire harness from the key switch.

    g351811

    Figure 34

    1. Key switch
    2. Key switch connector

  3. Connect the key switch connector to the key switch input (P03) on the kit wire harness.

    g351813

    Figure 35

    1. Key switch output connector (P04)
    2. Key switch input connector (P03)
    3. Key switch connector from machine wire harness

  4. Connect the key switch output (P04) to the key switch.

  5. Locate the auxiliary connector on the machine wire harness and remove the cap.

    Note: The connector is secured underneath the machine wire harness using a cable tie, near the key switch connector. If another connector is already plugged into it, unplug the connector and plug it into the auxiliary output connector (P07).

    g351812

    Figure 36

    1. Auxiliary connector from machine wire harness
    2. Auxiliary input connector (P06)
    3. Auxiliary output connector (P07)

  6. Connect the auxiliary input connector (P06) to the auxiliary connector on the machine wire harness.

  7. Disconnect the wire harness from the audio alarm.

    g352862

    Figure 37

    1. Audio alarm

  8. If the Low Flow Kit is installed on the machine, remove the audio alarm.

  9. Route the traction relay, switch, and solenoid connectors under the alarm bracket.

  10. Secure the wire harness for the traction relay connector to the solenoid bracket using the attached push-mount cable tie.

    g351957

    Figure 38

    1. Traction relay connector (P10)
    2. Self-tapping screw
    3. Push-mount cable tie

  11. Secure the traction relay connector (P10) to the solenoid bracket using a self-tapping screw.

  12. Install the relay.

    g351958

    Figure 39

    1. Relay

  13. Route the traction switch and solenoid valve connectors under the relay connector and between the solenoid bracket and valve fitting.

  14. Connect the traction switch connector (P08) to the traction switch.

    g351956

    Figure 40

    1. Traction switch connector (P08)
    2. Solenoid valve connector (P05)

  15. Connect the solenoid valve connector (P05) to the solenoid valve.

  16. If the Low Flow Kit is installed on the machine, install the audio alarm.

  17. Connect the machine wire harness to the audio alarm (Figure 37).

  18. Disconnect the traction valve connectors from the machine wire harness and move them out of the way.

    Note: The traction valve connectors will remain disconnected after installing this kit.

    g353108

    Figure 41

    1. Traction valve connector (2)

  19. Install the jumper harness to the 2 machine wire harness connectors.

    g354777

    Figure 42

    1. Jumper harness

Installing the Lower Connectors

  1. Raise the rear of the machine so that you can access beneath it. Support it using jackstands.

    Note: Use jack stands rated for your machine. Refer to the Operator’s Manual for your machine to determine the weight.

    Warning

    Mechanical or hydraulic jacks may fail to support the machine and cause serious injury.

    Use jack stands when supporting the machine.

  2. Route the parking brake connectors from the rubber baffle, behind the hydraulic filter, through the existing cable tie for the hydraulic hoses, and down to the left traction motor, following the hydraulic hoses.

    g352654

    Figure 43

    1. Existing cable tie

  3. Disconnect the parking brake switch from the machine wire harness.

    g351985

    Figure 44

    1. Machine wire harness
    2. Parking brake switch

  4. Plug the parking brake switch into the parking brake output (P02) on the kit wire harness.

    g354775

    Figure 45

    1. Machine wire harness
    2. Parking brake input connector (P02)
    3. Parking brake switch
    4. Parking brake output connector (P02)

  5. Plug the parking-brake switch connector on the machine wire harness to the parking brake input (P02) on the kit wire harness.

Securing the Wire Harness

Use cable ties to secure the wire harness above and below the left traction motor as shown.

g353267

Figure 46

  1. Cable tie (2)
  2. Left traction motor

Completing the Installation

  1. Install the bottom plate.

    g351986

    Figure 47

    1. Bottom plate
    2. Bolt—3/8 x 1 inch (2)

  2. Remove the jackstands and lower the machine to the ground.

  3. Secure the rubber baffle.

    g352599

    Figure 48

    1. Washer (1/4 inch)
    2. Bolt (1/4 x 3/4 inch)

  4. Install the cover plate.

    g351987

    Figure 49

    1. Bolt—1/4 x 3/4 inch (3)
    2. Cover plate

  5. Install the prop rod.

    g352716

    Figure 50

    1. Washer and hairpin cotter

  6. Remove the strap and close the rear access cover.

  7. Turn the battery-disconnect switch to the ON position.

  8. Remove the strap and close the hood.

Operation

Using the Traction-Enable Switch

The traction control is automatically disabled when starting the machine. Toggle the traction-enable switch after starting the machine to use the traction control.