873F Aux hyd and AHC issue

[shotym2]

1998 873F BICS, AHC no BOSS
1-The aux hyd lights were alternating flashing so started some troubleshooting. After a couple hours with the handy DVM traced the problem to the wiring from the right hand control. All work if the handle is held toward center, (most of the time) momentary and detent are fine. Release handle or push toward outside and nothing. There are no breaks in the insulation and wires appear good but if they are twisted or bent back just a bit they lose continuity.Can the bad portion of the wires be cut out and new pieces soldered back in? As the proportional control works off resistance will this add more than is allowed? I would even like to extend the wires a bit to loosen it up a bit under the cab. Looks like about a 2-3” section where it loops over the AHC pivot is where the bad spot is and also looks like all 5 wires are bad. Don't want to buy a new handle if it is just a couple of bad wires.
2- Aux male FF connector was stuck and would not connect, used a hammer and punch to get plunger to go in. Got it loose but now will not come all of the way out. Will try some emery cloth to get rid of rust but might be better off buying a new one. What is the thread type for this? I am thinking 3/4“ ORB but not experienced enough to know the difference from looking. I didn't get the numbers off of it, will try later in the week, but remembered it is a faster coupler. This machine does not have a coupler 'block'.
Sorry for the long post.
Dwight

 

[shotym2]

I checked the wires and started replacing a section of each wire and then re testing. Finally found the broken wire on the fourth try. Auxillary works perfect and all it cost was an hour of my time rather than the $500 BC wanted for the handle assembly.
Also took off the coupler and touched up the plunger with a bit of emery cloth, flushed it out and now it seats nice and tight.

 

[Tazza]

I checked the wires and started replacing a section of each wire and then re testing. Finally found the broken wire on the fourth try. Auxillary works perfect and all it cost was an hour of my time rather than the $500 BC wanted for the handle assembly.
Also took off the coupler and touched up the plunger with a bit of emery cloth, flushed it out and now it seats nice and tight.

Wow, its not often you hear of a member working out an AHC fault without taking the machine to the dealer, well done!
Its always a good feeling to have a win, shame the wires are so fragile to cause this issue in the first place.

 

[shotym2]

Wow, its not often you hear of a member working out an AHC fault without taking the machine to the dealer, well done!
Its always a good feeling to have a win, shame the wires are so fragile to cause this issue in the first place.

Actually, its not that the wires were fragile, they were 18 ga , more that each strand might have been a little too thick, and just could not flex. A straighter wire path would be better even with lighter wire.
The machine has lots of hours and with the AHC there is alot of repetitive bending. I added some heavy wire loom over the wire bundle and straightened the routing a bit. Might take a bit of the strain off the wires and make the location of the bend more of an arc as opposed to a tight bend. I guess we will see.