l230 Service Manual

SERVICE MANUAL
L223 / L225 / L230

Tier 4A
200 Series Skid Steer Loader
L223 PIN NDM474381 and above; L225 PIN NDM461085 and above;
L230 PIN NCM449907 and above
C232 / C238
Tier 4A
200 Series Compact Track Loader
C232 PIN NDM451672 and above; C238 PIN NCM425510 and above
Part number 47540694

English
April 2014
Printed in U.S.A. Replaces part number 47465733
Copyright © 2014 CNH Industrial America LLC. All Rights Reserved. New Holland is a registered trademark of CNH Industrial America LLC.
Racine Wisconsin 53404 U.S.A.
Link Product / Engine
Product Market Product Engine

C232 TIER 4 [NDM451672 - ] North America F5HFL413H*A001
C238 TIER 4 [NCM425510 - ] North America F5HFL413L*A001
L223 TIER 4 [NDM474381 - ] North America F5HFL463A*F001
L225 TIER 4 [NDM461085 - ] North America F5HFL413H*A001
L230 TIER 4 [NCM449907 - ] North America F5HFL413L*A001
47540694 28/04/2014
Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust
treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
Front axle system ....................................................................... 25

[25.450] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
Rear axle system........................................................................ 27

[27.650] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
Hydrostatic drive......................................................................... 29
[29.202] Hydrostatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1
[29.134] Two-speed assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2
[29.200] Mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.3
[29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.4
Brakes and controls .................................................................... 33

[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.128] Auxiliary hydraulic function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.350] Safety and main relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
47540694 28/04/2014
[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.600] High flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9
[35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
[35.734] Tool quick coupler hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11
Frames and ballasting ................................................................. 39

[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
Wheels ...................................................................................... 44
[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1
[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2
Tracks and track suspension ........................................................ 48

[48.100] Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.1
[48.130] Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2
[48.134] Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.3
[48.138] Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.4
Cab climate control ..................................................................... 50

[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
Electrical systems ....................................................................... 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.031] Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
47540694 28/04/2014
[55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . 55.10
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11
[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12
[55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13
[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14
[55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16
Front loader and bucket............................................................... 82

[82.100] Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1
[82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2
Platform, cab, bodywork, and decals ............................................. 90

[90.154] Cab doors and hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
47540694 28/04/2014
47540694 28/04/2014
INTRODUCTION
47540694 28/04/2014
1
Contents
INTRODUCTION
Foreword - Important notice regarding equipment servicing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety rules (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety rules - Personal safety (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety rules - Ecology and the environment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety rules (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Torque - Minimum tightening torques for normal assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Torque - Standard torque data for hydraulics (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Basic instructions - Shop and assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic contamination – Contamination (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General specification - Left-hand instrument cluster (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General specification - Electronic Instrument Cluster (EIC) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
General specification - Advanced Instrument Cluster (AIC) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
General specification - Biodiesel fuels (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Product identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
(*) See content for specific models

47540694 28/04/2014
2
INTRODUCTION
Foreword - Important notice regarding equipment servicing

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu-
facturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for
continuous improvement. Some information could not be updated due to modifications of a technical or commercial
type, or changes to the laws and regulations of different countries.
In case of questions, refer to your NEW HOLLAND CONSTRUCTION Sales and Service Networks.
47540694 28/04/2014
3
INTRODUCTION
Safety rules
C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. These precautions are intended for the personal safety of you and those working with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
47540694 28/04/2014
4
INTRODUCTION
Safety rules - Personal safety

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Carefully study these precautions, and those included in the external attachment operators
manual, and insist that they be followed by those working with and for you.
1. Thoroughly read and understand this manual and the attachment Operator’s Manual before operating this or any
other equipment.
2. Be sure all people and pets are clear of the machine before starting. Sound the horn, if equipped, three times
before starting engine.
3. Only the operator should be on the machine when in operation. Never allow anyone to climb on to the machine
while it is in motion. If the machine is equipped with an Instructors Seat, this must only be used for training
purposes. Passengers must not be allowed to use the Instructors Seat.
4. Keep all shields in place. Never work around the machine or any of the attachments while wearing loose clothing
that might catch on moving parts.
5. Observe the following precautions whenever lubricating the machine or making adjustments.
• Disengage all clutching levers or switches.

• Lower the attachment, if equipped, to the ground or raise the attachment completely and engage the cylinder
safety locks. Completing these actions will prevent the attachment from lowering unexpectedly.
• Engage the parking brake.
• Shut off the engine and remove the key.
• Wait for all machine movement to stop before leaving the operators platform.
6. Always keep the machine in gear while travelling downhill.

7. The machine should always be equipped with sufficient front or rear axle weight for safe operation.
8. Under some field conditions, more weight may be required at the front or rear axle for adequate stability. This is
especially important when operating in hilly conditions or/when using heavy attachments.
9. Always lower the attachment, shut off the engine, set the parking brake, engage the transmission gears, remove
the key and wait for all machine movement to stop before leaving the operators platform.
10. If the attachment or machine should become obstructed or plugged; set the parking brake, shut off the engine
and remove the key, engage the transmission gears, wait for all machine or attachment motion to come to a stop,
before leaving the operators platform to removing the obstruction or plug.
11. Never disconnect or make any adjustments to the hydraulic system unless the machine and/or the attachment is
lowered to the ground or the safety lock(s) is in the engaged position.
12. Use of the flashing lights is highly recommended when operating on a public road.
13. When transporting on a road or highway, use accessory lights and devices for adequate warning to the opera-
tors of other vehicles. In this regard, check local government regulations. Various safety lights and devices are
available from your NEW HOLLAND CONSTRUCTION dealer.
14. Practice safety 365 days a year.
15. Keep all your equipment in safe operating condition.
16. Keep all guards and safety devices in place.
17. Always set the parking brake, shut off the engine and remove the key, engage the transmission gears, wait for all
machine or attachment motion to come to a stop, before leaving the operators platform to service the machine
and attachment.
18. Remember: A careful operator is the best insurance against an accident.
19. Extreme care should be taken in keeping hands and clothing away from moving parts.
47540694 28/04/2014
5
INTRODUCTION
Safety rules - Ecology and the environment

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment
of some of the substances required by advanced technology, sound judgment should govern the use and disposal of
products of a chemical and petrochemical nature.
NOTE: The following are recommendations that may be of assistance:
• Become acquainted with and ensure that you understand the relative legislation applicable to your country.
• Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning
agents, etc., with regard to their effect on man and nature and how to safely store, use, and dispose of these
substances.
• Agricultural consultants will, in many cases, be able to help you as well.
Helpful hints
• Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems that may cause considerable
spillage.
• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances that may be
harmful to your health.
• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.
• Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc.
Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper
way to comply with local legislation and available resources.
• Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not
be allowed to get into the soil, but should be collected and disposed of properly.
• Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere.
Your NEW HOLLAND CONSTRUCTION dealer or air conditioning specialist has a special extractor for this purpose
and will have to recharge the system properly.
• Repair any leaks or defects in the engine cooling or hydraulic system immediately.
• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.
• Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of
oils, coolant, etc.
47540694 28/04/2014
6
INTRODUCTION
Safety rules
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
BT09A213 1
47540694 28/04/2014
7
INTRODUCTION
Torque - Minimum tightening torques for normal assembly

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
METRIC NON-FLANGED HARDWARE

NOM. LOCKNUT LOCKNUT
SIZE CL.8 CL.10
CLASS 8.8 BOLT and CLASS 10.9 BOLT and W/CL8.8 W/CL10.9
CLASS 8 NUT CLASS 10 NUT BOLT BOLT
PLATED PLATED
UNPLATED UNPLATED
W/ZnCr W/ZnCr
2.2 N·m (19 lb 2.9 N·m (26 lb 3.2 N·m (28 lb 4.2 N·m (37 lb 2.9 N·m (26 lb
M4 2 N·m (18 lb in)
in) in) in) in) in)
4.5 N·m (40 lb 5.9 N·m (52 lb 6.4 N·m (57 lb 8.5 N·m (75 lb 5.8 N·m (51 lb
M5 4 N·m (36 lb in)
in) in) in) in) in)
7.5 N·m (66 lb 10 N·m (89 lb 11 N·m (96 lb 15 N·m (128 lb 6.8 N·m (60 lb 10 N·m (89 lb
M6
in) in) in) in) in) in)
18 N·m (163 lb 25 N·m (217 lb 26 N·m (234 lb 35 N·m (311 lb 17 N·m (151 lb 24 N·m (212 lb
M8
49 N·m (36 lb 70 N·m (51 lb 33 N·m (25 lb 48 N·m (35 lb
M10 37 N·m (27 lb ft) 52 N·m (38 lb ft)
ft) ft) ft) ft)
M12 64 N·m (47 lb ft) 91 N·m (67 lb ft)
ft) ft) ft) ft)
158 N·m (116 lb 210 N·m 225 N·m (166 lb 301 N·m (222 lb 143 N·m (106 lb 205 N·m (151 lb
M16
ft) (155 lb ft) ft) ft) ft) ft)
319 N·m (235 lb 425 N·m 440 N·m (325 lb 587 N·m (433 lb 290 N·m (214 lb 400 N·m (295 lb
M20
ft) (313 lb ft) ft) ft) ft) ft)
551 N·m (410 lb 735 N·m 762 N·m (560 lb 1016 N·m 501 N·m (370 lb 693 N·m (510 lb
M24
ft) (500 lb ft) ft) (750 lb ft) ft) ft)
NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque
specifications are shown in pound-feet.
47540694 28/04/2014
8
INTRODUCTION
METRIC FLANGED HARDWARE

NOM. CLASS 8.8 BOLT and CLASS 10.9 BOLT and LOCKNUT LOCKNUT
SIZE CLASS 8 NUT CLASS 10 NUT CL.8 CL.10
W/CL8.8 W/CL10.9
BOLT BOLT
PLATED PLATED
UNPLATED UNPLATED
W/ZnCr W/ZnCr
2.4 N·m (21 lb 3.2 N·m (28 lb 3.5 N·m (31 lb 4.6 N·m (41 lb 2.2 N·m (19 lb 3.1 N·m (27 lb
M4
4.9 N·m (43 lb 6.5 N·m (58 lb 7.0 N·m (62 lb 9.4 N·m (83 lb 4.4 N·m (39 lb 6.4 N·m (57 lb
M5
8.3 N·m (73 lb 11 N·m (96 lb 12 N·m (105 lb 16 N·m (141 lb 7.5 N·m (66 lb 11 N·m (96 lb
M6
M8
54 N·m (40 lb 77 N·m (56 lb
M10 40 N·m (30 lb ft) 57 N·m (42 lb ft) 37 N·m (27 lb ft) 53 N·m (39 lb ft)
ft) ft)
93 N·m (69 lb 100 N·m (74 lb 134 N·m (98 lb
M12 70 N·m (52 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft)
ft) ft) ft)
M16
ft) ft) ft) ft) ft) ft)
M20
ft) ft) ft) ft) ft) ft)
607 N·m (447 lb 809 N·m (597 lb 838 N·m (618 lb 1118 N·m 552 N·m (407 lb
M24
ft) ft) ft) (824 lb ft) ft)
IDENTIFICATION
Metric Hex head and carriage bolts, classes 5.6 and up
20083680 1
1. Manufacturer's Identification
2. Property Class
Metric Hex nuts and locknuts, classes 05 and up
20083681 2
47540694 28/04/2014
9
INTRODUCTION
1. Manufacturer's Identification
2. Property Class
3. Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60 ° apart indicate Class
10 properties, and marks 120 ° apart indicate Class 8.
INCH NON-FLANGED HARDWARE

LOCKNUT LOCKNUT
NOMINAL SAE GRADE 5 BOLT SAE GRADE 8 BOLT
GrB W/ Gr5 GrC W/ Gr8
SIZE and NUT and NUT
BOLT BOLT
UN-
UN-
PLATED PLATED PLATED
PLATED
or W/ZnCr W/ZnCr
or PLATED
PLATED GOLD GOLD
SILVER
SILVER
8 N·m (71 lb 11 N·m (97 lb 12 N·m 16 N·m 12.2 N·m (109 lb
1/4 8.5 N·m (75 lb in)
in) in) (106 lb in) (142 lb in) in)
17 N·m 23 N·m 24 N·m 32 N·m 17.5 N·m (155 lb 25 N·m (220 lb
5/16
(150 lb in) (204 lb in) (212 lb in) (283 lb in) in) in)
30 N·m (22 lb 40 N·m 43 N·m (31 lb 57 N·m (42 lb
3/8 31 N·m (23 lb ft) 44 N·m (33 lb ft)
ft) (30 lb ft) ft) ft)
48 N·m (36 lb 65 N·m 68 N·m (50 lb 91 N·m (67 lb
7/16 50 N·m (37 lb ft) 71 N·m (53 lb ft)
ft) (48 lb ft) ft) ft)
74 N·m (54 lb 98 N·m 104 N·m 139 N·m 108 N·m (80 lb
1/2 76 N·m (56 lb ft)
ft) (73 lb ft) (77 lb ft) (103 lb ft) ft)
107 N·m 142 N·m 150 N·m 201 N·m 156 N·m (115 lb
9/16 111 N·m (82 lb ft)
(79 lb ft) (105 lb ft) (111 lb ft) (148 lb ft) ft)
147 N·m 196 N·m 208 N·m 277 N·m 153 N·m (113 lb 215 N·m (159 lb
5/8
(108 lb ft) (145 lb ft) (153 lb ft) (204 lb ft) ft) ft)
3/4
7/8
1
NOTE: For Imperial Units, 1/4 in and 5/16 in hardware torque specifications are shown in pound-inches. 3/8 in
through 1 in hardware torque specifications are shown in pound-feet.
47540694 28/04/2014
10
INTRODUCTION
INCH FLANGED HARDWARE

NOM- LOCKNUT LOCKNUT
SAE GRADE 5 BOLT and SAE GRADE 8 BOLT and
INAL GrF W/ Gr5 GrG W/ Gr8
NUT NUT
SIZE BOLT BOLT
UNPLATED PLATED UNPLATED PLATED
or PLATED W/ZnCr or PLATED W/ZnCr
SILVER GOLD SILVER GOLD
1/4 9 N·m (80 lb in) 8 N·m (71 lb in)
in) in) in) in)
5/16
3/8 30 N·m (22 lb ft) 43 N·m (32 lb ft)
ft) ft) ft) ft)
7/16 48 N·m (35 lb ft) 68 N·m (50 lb ft)
ft) ft) ft) ft)
81 N·m (60 lb 108 N·m (80 lb 115 N·m (85 lb 153 N·m 104 N·m (77 lb
1/2 74 N·m (55 lb ft)
ft) ft) ft) (113 lb ft) ft)
117 N·m (86 lb 156 N·m 165 N·m 221 N·m 157 N·m (116 lb
9/16 106 N·m (78 lb ft)
ft) (115 lb ft) (122 lb ft) (163 lb ft) ft)
162 N·m (119 lb 216 N·m 228 N·m 304 N·m 147 N·m (108 lb 207 N·m (153 lb
5/8
ft) (159 lb ft) (168 lb ft) (225 lb ft) ft) ft)
3/4
7/8
1
IDENTIFICATION
Inch Bolts and free-spinning nuts
20083682 3
Grade Marking Examples
SAE Grade Identification

1 Grade 2 - No Marks 4 Grade 2 Nut - No Marks
2 Grade 5 - Three Marks 5 Grade 5 Nut - Marks 120 ° Apart
3 Grade 8 - Five Marks 6 Grade 8 Nut - Marks 60 ° Apart
47540694 28/04/2014
11
INTRODUCTION
Inch Lock Nuts, All Metal (Three optional methods)
20090268 4
Grade Identification
Grade Corner Marking Method (1) Flats Marking Method (2) Clock Marking Method (3)
Grade A No Notches No Mark No Marks
Grade B One Circumferential Notch Letter B Three Marks
Grade C Two Circumferential Notches Letter C Six Marks
47540694 28/04/2014
12
INTRODUCTION
Torque - Standard torque data for hydraulics

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
INSTALLATION OF ADJUSTABLE FITTINGS

IN STRAIGHT THREAD O RING BOSSES
1. Lubricate the O-ring by coating it with a light oil or

petroleum. Install the O-ring in the groove adjacent
to the metal backup washer which is assembled at the
extreme end of the groove (4).
2. Install the fitting into the SAE straight thread boss until
the metal backup washer contacts the face of the boss
(5).
NOTE: Do not over tighten and distort the metal
backup washer. 23085659 1
3. Position the fitting by turning out (counterclockwise)
up to a maximum of one turn. Holding the pad of the
fitting with a wrench, tighten the locknut and washer
against the face of the boss (6).
STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS

TUBE NUTS FOR 37° FLARED FITTINGS O-RING BOSS PLUGS
ADJUSTABLE FITTING
LOCKNUTS, SWIVEL
JIC- 37° SEATS
SIZE TUBING OD THREAD TORQUE TORQUE
SIZE
4 6.4 mm (1/4 in) 7/16-20 12 - 16 N·m (9 - 12 lb ft) 8 - 14 N·m (6 - 10 lb ft)
12 19.1 mm (3/4 in) 1-1/16-12 104 - 111 N·m (77 - 82 lb ft) 81 - 95 N·m (60 - 70 lb ft)
14 22.2 mm (7/8 in) 1-3/16-12 122 - 136 N·m (90 - 100 lb ft) 95 - 109 N·m (70 - 80 lb ft)
16 25.4 mm (1 in) 1-5/16-12 149 - 163 N·m (110 - 120 lb ft) 108 - 122 N·m (80 - 90 lb ft)
20 31.8 mm (1-1/4 in) 1-5/8-12 190 - 204 N·m (140 - 150 lb ft) 129 - 158 N·m (95 - 115 lb ft)
24 38.1 mm (1-1/2 in) 1-7/8-12 217 - 237 N·m (160 - 175 lb ft) 163 - 190 N·m (120 - 140 lb ft)
32 50.8 mm (2 in) 2-1/2-12 305 - 325 N·m (225 - 240 lb ft) 339 - 407 N·m (250 - 300 lb ft)
These torques are not recommended for tubes of 12.7 mm (1/2 in) OD and larger with wall thickness of 0.889 mm
(0.035 in) or less. The torque is specified for 0.889 mm (0.035 in) wall tubes on each application individually.
Before installing and torquing 37 ° flared fittings, clean the face of the flare and threads with a clean solvent or Loctite
cleaner and apply hydraulic sealant LOCTITE® 569 to the 37 ° flare and the threads.
Install fitting and torque to specified torque, loosen fitting and retorque to specifications.
47540694 28/04/2014
13
INTRODUCTION
PIPE THREAD FITTING TORQUE PIPE THREAD FITTING

Thread Size Torque (Maximum)
Before installing and tightening pipe fittings, clean the
threads with a clean solvent or Loctite cleaner and apply 1/8-27 13 N·m (10 lb ft)
sealant LOCTITE® 567 PST PIPE SEALANT for all fittings 1/4-18 16 N·m (12 lb ft)
including stainless steel or LOCTITE® 565 PST for most 3/8-18 22 N·m (16 lb ft)
metal fittings. For high filtration/zero contamination sys- 1/2-14 41 N·m (30 lb ft)
tems use LOCTITE® 545. 3/4-14 54 N·m (40 lb ft)
INSTALLATION OF ORFS (O-RING FLAT

FACED) FITTINGS
When installing ORFS fittings thoroughly clean both flat
surfaces of the fittings (1) and lubricate the O-ring (2) with
light oil. Make sure both surfaces are aligned properly.
Torque the fitting to specified torque listed throughout the
repair manual.
NOTICE: If the fitting surfaces are not properly cleaned,
the O-ring will not seal properly. If the fitting surfaces are
not properly aligned, the fittings may be damaged and will
not seal properly.
NOTICE: Always use genuine factory replacement oils
50011183 2
and filters to ensure proper lubrication and filtration of en-
gine and hydraulic system oils.
The use of proper oils, grease, and keeping the hydraulic

system clean will extend machine and component life.
47540694 28/04/2014
14
INTRODUCTION
Basic instructions - Shop and assembly

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
Shimming
For each adjustment operation, select adjusting shims and measure the adjusting shims individually using a microm-
eter, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or
the rated value shown on each shim.
Rotating shaft seals

For correct rotating shaft seal installation, proceed as follows:
1. Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.
2. Thoroughly clean the shaft and check that the working surface on the shaft is not damaged.
3. Position the sealing lip facing the fluid.
NOTE: With hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that
they will move the fluid towards the inner side of the seal.
4. Coat the sealing lip with a thin layer of lubricant (use oil rather than grease). Fill the gap between the sealing lip
and the dust lip on double lip seals with grease.
5. Insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a
hammer or mallet.
6. While you insert the seal, check that the seal is perpendicular to the seat. When the seal settles, make sure that
the seal makes contact with the thrust element, if required.
7. To prevent damage to the seal lip on the shaft, position a protective guard during installation operations.
O-ring seals
Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and
twisting, which would jeopardize sealing efficiency.
Sealing compounds
Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing
compound, prepare the surfaces as directed by the product container.
Spare parts
Only use CNH Original Parts or NEW HOLLAND CONSTRUCTION Original Parts.
Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same
parts that are assembled during standard production. Only CNH Original Parts or NEW HOLLAND CONSTRUCTION
Original Parts can offer this guarantee.
When ordering spare parts, always provide the following information:

• Machine model (commercial name) and Product Identification Number (PIN)
• Part number of the ordered part, which can be found in the parts catalog
47540694 28/04/2014
15
INTRODUCTION
Protecting the electronic and/or electrical systems during charging and welding
To avoid damage to the electronic and/or electrical systems, always observe the following practices:
1. Never make or break any of the charging circuit connections when the engine is running, including the battery
connections.
2. Never short any of the charging components to ground.
3. Always disconnect the ground cable from the battery before arc welding on the machine or on any machine at-
tachment.
• Position the welder ground clamp as close to the welding area as possible.
• If you weld in close proximity to a computer module, then you should remove the module from the machine.
• Never allow welding cables to lie on, near, or across any electrical wiring or electronic component while you
weld.
4. Always disconnect the negative cable from the battery when charging the battery in the machine with a battery
charger.
NOTICE: If you must weld on the unit, you must disconnect the battery ground cable from the machine battery.
The electronic monitoring system and charging system will be damaged if this is not done.
5. Remove the battery ground cable. Reconnect the cable when you complete welding.
Special tools
WARNING
Battery acid causes burns. Batteries contain sulfuric acid.
Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush
with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large
quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.
Failure to comply could result in death or serious injury.
W0111A
The special tools that NEW HOLLAND CONSTRUCTION suggests and illustrate in this manual have been specifically
researched and designed for use with NEW HOLLAND CONSTRUCTION machines. The special tools are essential
for reliable repair operations. The special tools are accurately built and rigorously tested to offer efficient and long-
lasting operation.
By using these tools, repair personnel will benefit from:

• Operating in optimal technical conditions
• Obtaining the best results
• Saving time and effort
• Working in safe conditions
47540694 28/04/2014
16
INTRODUCTION
Hydraulic contamination – Contamination

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination
is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways.
1. When you drain the oil or disconnect any line.
2. When you disassemble a component.
3. From normal wear of the hydraulic components.
4. From damaged or worn seals.
5. From a damaged component in the hydraulic system.
All hydraulic systems operate with some contamination. The design of the components in this hydraulic system
permits efficient operation with a small amount of contamination. An increase in this amount of contamination can
cause problems in the hydraulic system. The following list includes some of these problems.
1. Cylinder rod seals leak.
2. Control valve spools do not return to neutral.
3. Movement of control valve spools is difficult.
4. Hydraulic oil becomes too hot.
5. Pump gears, housing, and other parts wear rapidly.
6. Relief valves or check valves held open by dirt.
7. Quick failure of components that have been repaired.
8. Cycle times are slow; machine does not have enough power.
If your machine has any of these problems, check the hydraulic oil for contamination. See types of contamination
below. If you find contamination, use the Portable Filter to clean the hydraulic system.
NOTE: There are two types of contamination, microscopic and visible.
Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil.
These particles are too small to see or feel. Microscopic contamination can be found by identification of the following
problems or by testing in a laboratory. Examples of the problems:
1. Cylinder rod seal leak.
2. Control valve spools do not return to NEUTRAL.
3. The hydraulic system has a high operating temperature.
Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause
a sudden failure of components. Examples of visible contamination:
1. Particles of metal or dirt in the oil.
2. Air in the oil.
3. The oil is dark and thick.
4. The oil has an odor of burned oil.
5. Water in the oil.
47540694 28/04/2014
17
INTRODUCTION
General specification - Left-hand instrument cluster

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
(1) HVAC DIAL

Rotate this dial to adjust temperature.
(2) FAN SWITCH

Rotate this dial to activate the fan.
(3) AIR CONDITIONING SWITCH

The lamp will illuminate, to confirm the
system is operational, once the fan switch
has been activated.
(4) TURN SIGNAL INDICATOR

Indicates directional turn signal operation
when flashing.
(5) HYDRAULIC ATTACHMENT COUPLER

SWITCH
Push the unlock side of this switch to unlock
the coupler from the attachment. This switch
must be used in conjunction with hydraulic
pressure from the lift arm down, attachment
curl in or auxiliary.
To Lock: with the coupler properly inserted
in the attachment, apply hydraulic pressure
from the lift arm down, attachment curl in
or auxiliary making sure that the hydraulic
system goes over system relief to set lock
pins.
(6) 2 SPEED INDICATOR

Indicates 2 speed system is in use.
RAPH12SSL0031DA 1
(7) ROTATING BEACON SWITCH
If equipped, push the switch to activate the
rotating beacon.
(8) HAZARD FLASHER SWITCH

If equipped, push the switch to activate the
4-way flashers.
47540694 28/04/2014
18
INTRODUCTION
(9) SELF LEVELING SWITCH

If equipped, use this switch to activate the
self leveling feature.
(10) AUXILIARY HYDRAULIC SWITCH

Push the switch to the upper (HF) position
to engage the high flow auxiliary hydraulic
mode that produces 207 bar (3000 psi).
Push the switch into the lower (HP) position
to engage the enhanced high flow mode
to produce 276 bar (4000 psi) if equipped
with approved attachment. The lamp will
illuminate when activated. Keep the switch
in the neutral position to disable high flow.
(11) AUXILIARY ELECTRIC SWITCH #2

If equipped, this switch is for the front
electric connector.
(12) LOADER LOCKOUT

If equipped, push to disable loader control
while roading the unit. The bucket and
loader arm will be locked in the position
they are in when the loader lockout switch is
pressed to the ON position. This prevents
the operator from inadvertently lowering or
raising the loader arm or bucket while driving
the machine on roads. NOTE: A mechanical
machine with the loader lockout activated
will result in DTC 4952 being displayed
along with an amber lamp and buzzer. The
auxiliary override button (lower left) on the
instrument cluster can be pressed to clear
the display and silence the buzzer. The
amber lamp will remain illuminated.
(13) WINDSHIELD WIPER SWITCH

If equipped, this three position switch turns RAPH12SSL0031DA 2
the wiper ON/OFF and operates the washer
fluid spray.
(14) BLANK
This location is left open for any options you
may add in the future.
(15) 12 V POWER PORT

Supplies 12 V of power for accessories.
47540694 28/04/2014
19
INTRODUCTION
General specification - Electronic Instrument Cluster (EIC)

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
The EIC is located on the right hand cab post.
Once in the seat, the alarm sounds and selected lamps illuminate briefly. Monitor these lamps on a daily basis to
confirm that they will function in the event of a system alarm. The fuel gauge and hour meter will remain illuminated
for operator monitoring.
When started, the machine will be in park with the PARK BRAKE lamp illuminated. The PARK BRAKE lamp is
located on the instrument cluster. The PARK BRAKE button switch is located on the right-hand control handle.
The operator must be in the seat with the seat belt fastened and the restraint bar lowered. The operator must push
the OPERATE button to activate the loader arms and ground drive, after the loader is started.
A semi-hidden SETUP menu allows the user to view, select, change and customize a number of machine settings. A
security code may be entered into the Instrument Cluster. Once the security code has been entered, each user will
have to enter the code before the machine will start. Contact your dealer for detailed information on the SETUP menu
and security feature activation.
NOTE: Fault code definitions are located in the troubleshooting section. The updated fault code is visible to the
operator on the display on the right-hand column.
NOTICE: Low hydraulic charge pressure will cause engagement of the park brake. With an Electro Hydraulic (EH)
control unit, the PARK BRAKE lamp will flash and an audible alarm will sound, if this condition exists.
47540694 28/04/2014
20
INTRODUCTION
(1) KEY SWITCH

This four position key switch has AUX, OFF,
RUN and START operations.
(2) STOP
Severe warning requiring immediate shut
down, RED lamp will flash and audible alarm
will sound.
(3) ENGINE MALFUNCTION

Yellow lamp will flash when an engine fault is
detected. Use the fault code that appeared
in text display and reference it in the trouble
shooting section of this manual.
(4) HYDRAULIC SYSTEM MALFUNCTION

Yellow Lamp will flash when a hydraulic
fault is detected. Use the fault code that
appeared in text display and reference it in
the trouble shooting section of this manual.
(5) ELECTRONIC SYSTEM MALFUNCTION

This yellow lamp will flash and the alarm will
sound. Use the fault code that appeared
in text display and reference it in the
troubleshooting section of this manual.
(6) SEAT BELT

RED lamp will illuminate when the restraint
bar is raised. RED lamp will also illuminate
when the operator lifts his body off of the
operator’s seat.
93109329A 1
47540694 28/04/2014
21
INTRODUCTION
(7) PARK BRAKE LAMP:

This Red lamp illuminates to indicate the
park brake is engaged.
Under normal conditions the park brake will

be set when:
• The PARK BRAKE button switch is ac-
tivated (located on the right-hand control
handle)
• The OPERATE button is activated
• The engine is shut off
• The engine is running and the restraint bar
is raised
• The operator leaves the seat
(8) ENGINE PREHEATING LAMP:

In cold climate starting conditions, after
turning the KEY switch to RUN, this yellow
engine pre-heating lamp will illuminate,
instructing the operator that incoming air is
being preconditioned for smoother starting.
The operator must wait until the lamp goes
out before attempting to start the engine.
(9) FUNCTION BUTTON

Use this, when in the SETUP menu, as the
"enter" data key
NOTE: This button is used for user code lock
and unlock.
(10) FUNCTION BUTTON

Use this when in the SETUP menu, also
used to scroll within the setup menu.
and unlock.
(11) OPERATE
This button activates and deactivates the
hydraulic system when engine is running.
and unlock.
93109329A 2
47540694 28/04/2014
22
INTRODUCTION
(12) AUXILIARY HYDRAULIC INTERLOCK

OVERRIDE:
When an operator leaves the seat, oil flow
to an attachment will normally be halted via
direct hydraulic flow cutoff. Depress this
button and leave the seat within 30 seconds
to defeat this interlock. Small red indicator
lamp below the switch illuminates when the
interlock is defeated.
and unlock.
(13) H / ISO control pattern selector, if equipped`

This selects the drive pattern type of hand
control operation. Read the proper steps
listed in this chapter to activate.
(14) WORK LIGHTS

This knob controls the external working
lights and road lights.
(15) FUEL GAUGE:

The fuel gauge consists of a series of bars
that indicate the level of fuel in the fuel
tank. When all 8 bars are visible the fuel
tank is full. Bottom bar flashing indicates
approximately 1 gal of fuel remaining.
(16) ENGINE COOLANT TEMPERATURE BAR

GRAPH:
This bar graph indicates the relative
temperature of the engine coolant from
0 - 110 °C (32 - 230 °F). If the coolant
temperature goes above 110 °C (230 °F), all
8 bars will display, the backlighting will flash,
and the audible alarm will sound.
93109329A 3
47540694 28/04/2014
23
INTRODUCTION
(17) HYDRAULIC FLUID TEMPERATURE BAR

GRAPH:
This hydraulic oil temperature bar graph
indicates the relative temperature of the
hydraulic oil from 0 - 110 °C (32 - 230 °F). If
the temperature exceeds 110 °C (230 °F), all
8 graph segments will display, backlighting
will flash, and the audible alarm will sound.
(18) TEXT DISPLAY:

This display will show the following during
normal operation, as selected by the
operator.
• Engine hours: Engine hours will always be
displayed momentarily when the operator
initially sits in the seat. The operator may
choose to leave engine hours on display
continuously or select one of the following.
• Engine RPM
• Engine coolant temperature (degrees F or
C)
• Hydraulic oil temperature (degrees F or C)
• Cycle: If this display option is chosen, the
display will continuously cycle through all
four of the above items
The text display will also help the operator
or technician with information as the SETUP
menu is utilized.
NOTE: To change display mode "on the
go" hold the AUX OVERRIDE (3) until the
current option name is displayed, push the
AUX OVERRIDE button repeatedly until
desired option name is displayed. This
display mode value will continue to be
shown until another selection is made.
93109329A 4
47540694 28/04/2014
24
INTRODUCTION
General specification - Advanced Instrument Cluster (AIC)

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
The AIC is located on the right hand cab post.
Once in the seat, the alarm sounds and selected lamps illuminate briefly. Monitor these lamps on a daily basis to
confirm that they will function in the event of a system alarm. The fuel gauge and hour meter will remain illuminated
for operator monitoring.
When started, the machine will be in park with the PARK BRAKE lamp illuminated. This lamp and the PARK BRAKE
switch will be covered in the following pages.
The operator must be in the seat with the seat belt fastened. The operator must push the OPERATE button to activate
the loader arms and ground drive, after the loader is started.
A semi-hidden SETUP menu allows the user to view, select, change and customize a number of machine settings. A
security code may be entered into the Instrument Cluster. Once the security code has been entered, each user will
have to enter the code before the machine will start. Contact your dealer for detailed information on the SETUP menu
and security feature activation.
NOTE: Fault code definitions are located in the troubleshooting Section. The updated fault code is visible to the
operator on the display on the right-hand column.
NOTICE: Low hydraulic charge pressure will cause engagement of the park brake. With an Electro Hydraulic (EH)
control unit, the PARK BRAKE lamp will flash and an audible alarm will sound, if this condition exists.
47540694 28/04/2014
25
INTRODUCTION
(1) STOP
Severe warning requiring immediate shut
down, RED lamp will flash and audible alarm
will sound.
(2) ENGINE MALFUNCTION

Yellow Lamp will flash when an engine
appeared in text display and reference it in
the troubleshooting section of this manual.
(3) HYDRAULIC SYSTEM MALFUNCTION

Yellow Lamp will flash when a Hydraulic
appeared in the text display and reference it
in the troubleshooting section of this manual.
(4) ELECTRONIC SYSTEM MALFUNCTION

This yellow lamp will flash and the alarm will
sound. Use the fault code that appeared
in the text display and reference it in the
troubleshooting section of this manual.
(5) SEAT BELT

RED lamp will illuminate when the seat belt
is not latched. RED lamp will also illuminate
when the operator lifts his body off of the
operator’s seat.
93109330 1
47540694 28/04/2014
26
INTRODUCTION
(6) PARK BRAKE LAMP:

This Red lamp illuminates to indicate the
park brake is engaged.
Under normal conditions the Park Brake will

be set when:
• The PARK BRAKE switch is activated
• The OPERATE button is activated
• The engine is shut off
• The engine is running and the seat belt is
not latched
• The operator leaves the seat
(7) ENGINE PREHEATING LAMP:

In cold climate starting conditions, after
turning the KEY switch to RUN, this yellow
Engine Pre-Heating Lamp will illuminate,
instructing the operator that incoming air is
being preconditioned for smoother starting.
The operator must wait until the lamp goes
out before attempting to start the engine.
(8) SYSTEM POWER:

Push for Start-up power and Engine shut
down power. Use this, when in the SETUP
menu, as the "enter" Data Key.
and unlock.
(9) START:
Push to actuate the starter motor and start
the engine. Use this when in the SETUP
menu, Also used to scroll within the setup
menu.
and unlock.
93109330 2
47540694 28/04/2014
27
INTRODUCTION
(10) OPERATE
This button activates and deactivates the
hydraulic system when engine is running.
and unlock.
(11) AUXILIARY HYDRAULIC INTERLOCK

OVERRIDE:
When an operator leaves the seat, oil flow
to an attachment will normally be halted via
direct hydraulic flow cutoff. Depress this
button and leave the seat within 30 seconds
to defeat this interlock. Small red indicator
lamp below the switch illuminates when the
interlock is defeated.
and unlock.
(12) H / ISO Control Pattern Selector, if equipped

This selects the drive pattern type of hand
control operation. Read the proper steps
listed in this chapter to activate.
(13) PARK BRAKE SWITCH

Press the PARK BRAKE switch to activate
or deactivate the parking brake. The
park symbol on the instrument panel will
illuminate red when the parking brake is on.
The other hydraulic functions remain active
when the parking brake is on.
(14) WORK LIGHTS

This knob controls the external working
lights and road lights.
(15) FUEL GAUGE:

The fuel gauge consists of a series of bars
that indicate the level of fuel in the fuel
tank. When all 8 bars are visible the fuel
tank is full. Bottom bar flashing indicates
approximately 1 gal of fuel remaining.
93109330 3
47540694 28/04/2014
28
INTRODUCTION
(16) ENGINE COOLANT TEMPERATURE BAR

GRAPH:
This bar graph indicates the relative
temperature of the engine coolant from
0 - 110 °C (32 - 230 °F). If the coolant
temperature goes above 110 °C (230 °F), all
8 bars will display, the backlighting will flash,
and the audible alarm will sound.
(17) HYDRAULIC FLUID TEMPERATURE BAR

GRAPH:
This Hydraulic Oil Temperature Bar Graph
indicates the relative temperature of the
hydraulic oil from 0 - 110 °C (32 - 230 °F). If
the temperature exceeds 110 °C (230 °F), all
8 graph segments will display, backlighting
will flash, and the audible alarm will sound.
(18) TEXT DISPLAY:

This display will show the following during
normal operation, as selected by the
operator.
• Engine Hours: Engine hours will always
be displayed momentarily when the oper-
ator initially sits in the seat. The operator
may choose to leave engine hours on dis-
play continuously or select one of the fol-
lowing.
• Engine RPM
• Engine Coolant Temperature (degrees F
or C)
• Hydraulic Oil Temperature (degrees F or
C)
• Cycle: If this display option is chosen, the
display will continuously cycle through all
four of the above items
The text display will also help the operator
or technician with information as the SETUP
menu is utilized.
NOTE: To change display mode "on the go"
hold the AUX OVERRIDE button (3) until
the current option name is displayed, push
the AUX OVERRIDE button repeatedly
until desired option name is displayed.
This display mode value will continue to be
shown until another selection is made.
93109330 4
47540694 28/04/2014
29
INTRODUCTION
General specification - Biodiesel fuels

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
Biodiesel usage in NEW HOLLAND CONSTRUCTION products
Introduction to Fatty Acid Methyl Ester (FAME) biodiesel

FAME biodiesel, called biodiesel fuel in the following section, consists of a family of fuels derived from vegetable oils
treated with methyl esters.
There are two main biodiesel fuel types: Rapeseed Methyl Ester (RME) and Soybean Methyl Ester (SME). RME is a
blend of rapeseed and sunflower methyl ester, and is the preferred crop in Europe. SME is the preferred crop in the
United States.
Biodiesel fuel is a renewable alternative fuel source. Its use and development is promoted worldwide, especially in
Europe and in the United States.
NOTICE: Your Selective Catalytic Reduction (SCR) system is compatible with up to 20 % biodiesel fuel (B20). Be
aware that the use of biodiesel fuel that does not comply with the standards mentioned in this section could lead to
severe damage to the engine, fuel system or aftertreatment system of your machine. The use of non-approved fuels
may void NEW HOLLAND CONSTRUCTION Warranty coverage.
Biodiesel fuel can be used to run diesel engines as pure biodiesel fuel or when blended with standard diesel fuel:
• B5: indicates the blend of 5 % biodiesel and 95 % diesel fuels.
• B100: indicates pure biodiesel, or 100 % biodiesel fuel. Do not use.
Biodiesel fuel has several positive features in comparison with diesel fuel:
• Biodiesel fuel adds lubricity to the fuel, which is beneficial in many circumstances, particularly as sulfur and aro-
matics are removed from the fuel.
• Biodiesel has a greater cetane number and burns cleaner.
• Biodiesel produces less particulate matter and reduces smoke emissions.
• Biodiesel is fully biodegradable and non-toxic.
Diesel and biodiesel fuel specifications

Tier 4a diesel fuel specifications are covered by the following:
• ASTM D975-10, Standard Specification for Diesel Fuel Oils. (15 ppm sulfur maximum.)
Biodiesel blends are covered by:

• United States Diesel Fuel Specification ASTM D6751-09A allows up to 5 % biodiesel since 2009. United States
fuel suppliers are allowed to use up to 5 % biodiesel fuel (B5) to supply the network.
• United States Biodiesel Fuel Specification ASTM D7467-09A provides specifications for diesel and biodiesel blends
from B5 to B20.
Pure biodiesel (B100) specification is covered by the following requirements:

• ASTM D6751-09A - Standard specification for biodiesel fuel blend stock (B100) for middle distillate fuels.
NOTE: ASTM D6751 specification has been updated to improve the quality of biodiesel in the market place.
Before raw oil can be converted into usable biodiesel fuel, it must undergo transesterification to remove glycerides.
During the transesterification process, the oil reacts with an alcohol to separate the glycerine from the fat or vegetable
47540694 28/04/2014
30
INTRODUCTION
oil. This process leaves behind two products: methyl ester (the chemical name for biodiesel) and glycerine (a byprod-
uct usually sold for use in soaps or other products).
NOTICE: Biodiesel fuels approved for use in the NEW HOLLAND CONSTRUCTION equipment must be transesteri-
fied and comply with the North America Standard ASTM D6751.
NOTICE: Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined veg-
etable oils used as motor fuel, are fuels that are normally made from Rapeseed oil or similar high oil content crops.
These kinds of fuel are not transesterified, so they do not fulfil the ASTM D6751 requirements. There is no recog-
nized quality standard available for these types of fuel. Therefore the use of Cold Pressed Biodiesel, Cold Pressed
Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel are NOT APPROVED
at any blend in any NEW HOLLAND CONSTRUCTION product.
NOTICE: Any engine and fuel injection equipment fitted to a NEW HOLLAND CONSTRUCTION vehicle found to have
run with any blend of NON-APPROVED fuel (fuel not fulfilling the specification described in the requirement ASTM
D6751) will no longer be covered for Warranty by NEW HOLLAND CONSTRUCTION.
Biodiesel fuel usage conditions

You must stringently follow the biodiesel fuel usage conditions. Incorrect application of the biodiesel fuel usage con-
ditions could lead to severe damage to the engine, fuel injection equipment and aftertreatment system.
The main concerns related to operation with biodiesel fuels are:

• Filters and injector blockage caused by poor fuel quality.
• Wear and corrosion of internal components due to water content, which affects lubricity.
• Deterioration of some rubber sealing compounds in the fuel system.
• Biodiesel oxidation, which can lead to the formation of deposits that can harm the fuel injection system.
NOTICE: Any problem in the engine fuel injection equipment associated with non-compliance to the following condi-
tions for biodiesel fuel handling and maintenance will not be covered for Warranty by NEW HOLLAND CONSTRUC-
TION.
Purchase biodiesel fuel from a trusted supplier who understands the product and maintains acceptable fuel quality.
It is highly recommended that you use biodiesel from BQ 9000 accredited suppliers to maintain the quality and con-
sistency of the fuel. The BQ 9000 Quality Management Program is accredited by the National Biodiesel Board for
producers and marketers of biodiesel fuel. See the National Biodiesel Board website at www.biodiesel.org for more
information.
The use of biodiesel blends above B5 through B20 will not void the NEW HOLLAND CONSTRUCTION warranty as
long as the following conditions for biodiesel fuel handling and maintenance are stringently followed:
Biodiesel fuel must be pre-blended by the supplier. Mixing biodiesel fuels on-site can result in an incorrect mixture
that could damage the engine and/or fuel system.
For machines using Tier 4a engines with SCR aftertreatment:

1. If the biodiesel blend stock to ASTM D6751-09A is used, special precautions need to be taken to insure that it fully
complies with the following special requirements:
• Group I Metals content (Sodium + Potassium) is ≤ 5 mg/kg per EN14538 as specified in the biodiesel spec.
• Group II Metals content (Calcium + Magnesium) is ≤ 5 mg/kg per EN14538 as specified in the biodiesel spec.
• Phosphorus content lower than specified is a mandatory requirement. Phosphorus must not exceed 4 mg/kg
per ASTM D4951.
2. The resulting greater than B5 through B20 blend must not exceed 1 mg/kg for Group I Metals (Sodium + Potas-
sium) and for Group II Metals (Calcium + Magnesium).
NOTICE: For machines using Tier 4a engines with SCR aftertreatment in regions where the biodiesel blend
stock is supplied to the ASTM D6751-09A standard, it is essential that evidence of compliance to the
special limits for Group I Metals, Group II Metals and the reduced phosphorus content specified above be
obtained on every delivery of fuel from the fuel supplier. Failure to comply with this requirement can result
in damage to the SCR system which will not be covered under warranty.
47540694 28/04/2014
31
INTRODUCTION
NOTICE: NEW HOLLAND CONSTRUCTION may void your warranty if the problem is associated with poor fuel quality
due to improper blending. It is the responsibility of the fuel supplier and/or yourself to ensure the right type of fuel and
blend is delivered and used.
Maintenance intervals
For machines using the all electronic engines with a high pressure common rail fuel system, the engine oil and filter
change interval is reduced down to 50% of the standard value when using biodiesel blends greater than B5 up to B20.
Please refer to the maintenance intervals specified in the Operator Manual for all engines.
Check all hoses, connections and gaskets to ensure integrity and cleanliness every 3 months or 150 hours of oper-
ation, whichever comes first.
Regular oil sampling is highly recommended to monitor for oil and engine deterioration.
NOTE: Oil sampling kits are available from your authorized NEW HOLLAND CONSTRUCTION dealer.
When switching back from biodiesel to regular #2 diesel, all fuel filter, oil and oil filter should be changed even if this
falls between routine service intervals.
Storage
The machine should not be stored for more than three months with biodiesel in the fuel system. For longer storage
time, it is strongly suggested that only regular #2 diesel fuel is used.
NOTE: If storage for longer than 3 months is necessary, the engine must be run on regular #2 diesel for a minimum
of 20 h to flush the biodiesel fuel out of the fuel system prior to storage.
Biodiesel is highly hygroscopic and tends to collect water more than diesel fuel. This increases the risk of algae and
bacteria growth which can cause severe damage to the fuel injection system. Keep the machine fuel tanks and on-site
storage tanks as full as possible to limit the amount of air and water vapors inside the tank. Drain water from the tanks
at least once a week.
NOTICE: Do not use biocide additives on Tier 4a engines with an exhaust aftertreatment system.
47540694 28/04/2014
32
INTRODUCTION
Capacities
Fuel tank
Capacity
L213 and L216 60.5 l (16.0 US gal)
L218 and L220 75.5 l (20.0 US gal)
L230 and C238 95.5 l (25.5 US gal)
Specifications #1 or #2 Diesel ultra low sulfur
Cooling system
Capacity
L213 15.0 l (4.0 US gal)
L218, L220, and L216 15.6 l (4.2 US gal)
L230 and C238 19 l (5 US gal)
Specifications 50 % distilled water and 50 % ethylene glycol
Hydraulic system
Reservoir capacity 15.0 l (3.96 US gal)
System capacity:
L213 and L216 29.2 l (7.7 US gal)
L218 and L220 38.1 l (10.0 US gal)
L230 and C238 45.4 l (12.0 US gal)
Specifications NEW HOLLAND AMBRA SUPER GOLD 10W-30
Chain compartments
Capacity - each side
L213 and L216 6.25 l (6.6 US qt)
L218 and L220 7.4 l (7.9 US qt)
L230 22.2 l (23.5 US qt)
Specifications NEW HOLLAND AMBRA SUPER GOLD 10W-30
Grease fittings
Quantity As required
Specifications Molydisulfide grease
Engine crank case oil

Capacity - with filter change
L213, L216, L218, and L220, 7 l (7.5 US qt)
L230 and C238 8.5 l (8.9 US qt)
Specifications NEW HOLLAND AMBRA UNITEK MASTERGOLD SBL
CJ-4
Final track drive

Capacity - each side 1.0 l (1.06 US qt) +/- 0.1 l (0.1 US qt)
Specifications NEW HOLLAND GEAR 135 EP
47540694 28/04/2014
33
INTRODUCTION
Product identification
Product Identification Number (PIN).
• Outside right side of chassis - vertical lift
9310748611 1
• Inside left side lift arm tower - radial lift
931002296A 2
Roll Over Protective Structure (ROPS) certification plate.

• Front edge (lower) inside cab.
931007505A 3
Engine serial number plate location for Models L213

and L216
• On the fuel injection pump.
76075756 4
47540694 28/04/2014
34
INTRODUCTION
Engine serial number plate location for Models L218

and L220
• On the right-hand side of the engine.
RAPH12SSL0406AA 5
Engine serial number plate location for Models L221,

L223, L225, L230, L232, L238, C227, C232, and C238
• On top of the Exhaust Gas Recirculation (EGR) cooler.
• On top of the valve cover.
• The serial number is also stamped on the engine front
cover.
RCPH11SSL020AAP 6
Bucket identification plate
BT04F026-01 7
47540694 28/04/2014
35
INTRODUCTION
Product identification
C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
RAPH12SSL0057BA 1
The terms front (1), right (2), rear (3), and left (4) are used in this manual to indicate the direction as seen
from the operator's seat.
47540694 28/04/2014
36
SERVICE MANUAL
Engine
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
10
Contents
Engine - 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment 10.6
47540694 28/04/2014
10
Engine - 10
Engine and crankcase - 001
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
10.1 [10.001] / 1
Contents
Engine - 10
SERVICE
Engine
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
47540694 28/04/2014
10.1 [10.001] / 2
Engine - Engine and crankcase
Engine - Remove
C232 TIER 4 [NDM451672 - ] NA Mechanical hydraulic controls
C238 TIER 4 [NCM425510 - ] NA Mechanical hydraulic controls
L225 TIER 4 [NDM461085 - ] NA Mechanical hydraulic controls
L230 TIER 4 [NCM449907 - ] NA Mechanical hydraulic controls
WARNING
Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine.
1. Disengage all drives.
2. Engage parking brake.
3. Lower all attachments to the ground, or raise and engage all safety locks.
4. Shut off engine.
5. Remove key from key switch.
6. Switch off battery key, if installed.
7. Wait for all machine movement to stop.
W0047A
WARNING
Fire hazard!
When handling diesel fuel, observe the following precautions:
1. Do not smoke.
2. Never fill the tank when the engine is running.
3. Wipe up spilled fuel immediately.
W0099A
WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or
other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or per-
forming work on the hydraulic system. Before applying pressure, make sure all connections are tight
and all components are in good condition. Never use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your
doctor immediately.
W0178A
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
W0398A
Prior operation:
Tilt the ROPS.
Prior operation:
Disconnect the battery. See Battery - Disconnect (55.302).
Prior operation:
Drain the coolant. See Radiator - Drain fluid (10.400).
Prior operation:
Drain the engine oil.
Prior operation:
Remove the rear engine access door. See Engine inspection door - Remove (90.102).
Prior operation:
Evacuate the A/C system (if equipped). See Air conditioning - Evacuate (50.200).
47540694 28/04/2014
10.1 [10.001] / 3
1. Remove engine oil pan access plate (1).
RAPH12SSL0233AA 1
2. Disconnect the remote engine oil filter line (1) from the
engine oil pan.
RAPH12SSL0232AA 2
3. Disconnect the tail lights (3) and disconnect the tail light
electrical harness (4) from the engine hood. If equipped
with A/C, disconnect the A/C lines (1) from the con-
denser. Disconnect the fan motor electrical connector
(2).
RAPH12SSL0237AA 3
47540694 28/04/2014
10.1 [10.001] / 4
4. Support the engine hood with a suitable lifting device.

Disconnect the engine hood strut (1).
RAPH12SSL0236AA 4
5. Remove the mounting hardware (2), and remove the

engine hood (1).
RAPH12SSL0236AA 5
6. Remove the fenders (1).
RAPH12SSL0235AA 6
47540694 28/04/2014
10.1 [10.001] / 5
7. Remove the engine cover (1).
RAPH12SSL0234AA 7
8. Remove the air cooler. See Aftercooler - Remove

(10.310).
9. Remove the radiator. See Radiator - Remove
(10.400).
10. Remove the radiator fan (1).
RAPH12SSL0062AA 8
11. Disconnect the dipstick tube (1) from the cooling pack-
age bracket assembly.
RAPH12SSL0276AA 9
47540694 28/04/2014
10.1 [10.001] / 6
12. Disconnect the intake tube for the air cooler (1).
RAPH12SSL0265AA 10
13. Disconnect the lower radiator hose retainers (1) from

the cooling package bracket assembly.
RAPH12SSL0060AA 11
14. Remove the hydraulic oil filter (1).
RAPH12SSL0227AA 12
47540694 28/04/2014
10.1 [10.001] / 7
15. Unbolt and remove the cooling package bracket as-

sembly (1).
RAPH12SSL0228AA 13
16. Disconnect the overflow hose (1) from the lower radi-
ator hose.
RAPH12SSL0059AA 14
17. Remove the deaeration tank cap (1), and disconnect

the overflow hose (2) and return hose (3). Remove
the deaeration tank assembly (4).
RAPH12SSL0225AA 15
47540694 28/04/2014
10.1 [10.001] / 8
18. Remove the U bolt (1) on the exhaust pipe.
RAPH12SSL0226AA 16
19. Disconnect the following sensors:

• Diesel particulate filter (DPF) inlet temperature sen-
sor (exhaust gas temp sensor #2) (1)
• Diesel oxidation catalyst (DOC) inlet temperature
sensor (exhaust gas temp sensor #1) (2)
• Heated exhaust gas oxygen sensor (lambda sen-
sor) (4)
• DPF pressure sensor (5)
20. Remove the exhaust clamp (3).
RAPH12SSL0071AA 17
21. Support the DPF assembly (2) with a suitable lifting

device. Remove the mounting bolts (1), and remove
the DPF assembly (2).
RAPH12SSL0070AA 18
47540694 28/04/2014
10.1 [10.001] / 9
22. Disconnect the air restriction sensor (1) and the air
temperature sensor (2).
RAPH12SSL0263AA 19
23. Disconnect the fuel temperature sensor (2) and fuel

lines (3), (4).
24. Disconnect the air cleaner tubes and remove the air
cleaner/fuel filter bracket assembly (1).
RAPH12SSL0224AA 20
25. Remove the cotter pin (2) on the left boom lock pin
link (3). Unbolt the boom lock bellcrank (1) and place
away from engine area.
RAPH12SSL0223AA 21
47540694 28/04/2014
10.1 [10.001] / 10
26. Remove the oil filler neck (1). If equipped with A/C,
disconnect the low pressure line (2) on the A/C com-
pressor.
RAPH12SSL0266AA 22
27. Disconnect the fuel return line (1) at the tank.
RAPH12SSL0053AA 23
28. Disconnect the two main engine harness electrical

connectors (1).
RAPH12SSL0052AA 24
47540694 28/04/2014
10.1 [10.001] / 11
29. Place a suitable container under the remote engine

oil filter lines (1). Label and disconnect the remove
engine oil filter lines (1).
931001923 25
30. Disconnect the following:

• Alternator positive (+) battery cable (1)
• Voltage regulator connector (2)
• Starter solenoid exciter wire connector (3)
• Starter positive (+) battery cable (4)
NOTE: Alternator may need to be adjusted to disconnect
the positive (+) battery cable and voltage regulator connec-
tor.
RAPH12SSL0049AA 26
31. Disconnect the ground cable (1) located below the

starter.
931001910 27
32. Disconnect the heater hose (1).

33. Disconnect the P clamp (2) on the gear pump feed
hose.
34. Disconnect the hydraulic line P clamp (3) on the bell
housing.
NOTE: Electro-hydraulic (EH) pump shown. Mechanical
pump is similar.
RAPH12SSL0058AA 28
47540694 28/04/2014
10.1 [10.001] / 12
35. Support the drive train with a suitable lifting device (1).
RAPH12SSL0221AA 29
36. Support the engine with a suitable lifting device (1).

Remove the bell housing bolts (2) and disengage the
drive train assembly from the engine.
RAPH12SSL0222AA 30
37. Remove the engine mount hardware (1).

NOTE: Pump side engine mount hardware not shown.
RAPH12SSL0050AA 31
38. Carefully remove the engine from the chassis.
47540694 28/04/2014
10.1 [10.001] / 13
Engine - Install
WARNING
Fire hazard!
1. Do not smoke.
W0099A
WARNING
Heavy objects!
W0398A
1. Carefully lower the engine into the chassis.

2. Install the engine mount hardware (1). Apply LOCTITE®
243 to the threads of the engine mount hardware (1).
Tighten the engine mount hardware (1) to a torque of
133 - 144 N·m (98 - 106 lb ft).
RAPH12SSL0050AA 1
3. Engage the drive train assembly to the engine. Apply

LOCTITE® 243 to the threads of the bell housing bolts
(2). Install the bell housing bolts (2) and tighten to a
torque of 56 - 60 N·m (41 - 44 lb ft). Remove the lifting
device (1).
RAPH12SSL0222AA 2
47540694 28/04/2014
10.1 [10.001] / 14
4. Remove the lifting device (1).
RAPH12SSL0221AA 3
5. Connect the heater hose (1).

6. Connect the P clamp (2) on the gear pump feed hose.
7. Connect the hydraulic line P clamp (3) on the bell hous-
ing.
NOTE: Electro-hydraulic (EH) pump shown. Mechanical
pump is similar.
RAPH12SSL0058AA 4
8. Connect the ground cable (1) located below the starter.
931001910 5
47540694 28/04/2014
10.1 [10.001] / 15
9. Connect the following:

• Alternator positive (+) battery cable (1). Tighten the
alternator positive (+) battery cable nut to a torque of
8 N·m (71 lb in).
NOTE: Alternator may need to be adjusted to connect the
positive (+) battery cable and voltage regulator connector.
RAPH12SSL0049AA 6
10. Connect the remote engine oil filter lines (1).
931001923 7
11. Connect the two main engine harness electrical con-

nectors (1).
RAPH12SSL0052AA 8
47540694 28/04/2014
10.1 [10.001] / 16
12. Connect the fuel return line (1) at the tank.
RAPH12SSL0053AA 9
13. Attach the oil filler neck (1). Tighten the oil filler neck
mounting bolts to a torque of 11 - 15 N·m (97 - 133 lb
in). If equipped with A/C, lubricate the low pressure
line O-ring with CNH PAG OIL. Connect the low pres-
sure line (2) on the A/C compressor.
RAPH12SSL0266AA 10
14. Attach the boom lock bellcrank (1).Connect the left

boom lock pin link (3) and attach the cotter pin (2).
RAPH12SSL0223AA 11
47540694 28/04/2014
10.1 [10.001] / 17
15. Install the air cleaner/fuel filter bracket assembly (1)

and connect the air cleaner tubes.
16. Connect the fuel temperature sensor (2) and fuel lines
(3), (4).
RAPH12SSL0224AA 12
17. Connect the air restriction sensor (1) and the air tem-
perature sensor (2).
RAPH12SSL0263AA 13
18. Support the diesel particulate filter (DPF) assembly (2)

with a suitable lifting device. Center the DPF assem-
bly, and install the mounting bolts (1).
RAPH12SSL0070AA 14
47540694 28/04/2014
10.1 [10.001] / 18
19. Connect the following sensors:

• DPF inlet temperature sensor (exhaust gas temp
sensor #2) (1)
sor) (4)
20. Center the exhaust pipe, and install the exhaust clamp
(3).
RAPH12SSL0071AA 15
21. Center the exhaust pipe, and install the U bolt (1).
RAPH12SSL0226AA 16
22. Install the deaeration tank assembly (4). Install the

deaeration tank cap (1), and connect the overflow
hose (2) and return hose (3).
RAPH12SSL0225AA 17
47540694 28/04/2014
10.1 [10.001] / 19
23. Connect the overflow hose (1) to the lower radiator

hose.
RAPH12SSL0059AA 18
24. Center and attach the cooling package bracket as-

sembly (1). Tighten the cooling package bracket as-
sembly mounting bolts to a torque of 54 - 73 N·m (40
- 54 lb ft).
RAPH12SSL0228AA 19
25. Install the hydraulic oil filter (1).
RAPH12SSL0227AA 20
47540694 28/04/2014
10.1 [10.001] / 20
26. Connect the lower radiator hose retainers (1) to the

cooling package bracket assembly.
RAPH12SSL0060AA 21
27. Connect the intake tube for the air cooler. Tighten the
clamp (1) to a torque of 3 - 4 N·m (27 - 35 lb in).
RAPH12SSL0265AA 22
28. Connect the dipstick tube (1) to the cooling package

bracket assembly.
RAPH12SSL0276AA 23
47540694 28/04/2014
10.1 [10.001] / 21
29. Install the radiator fan (1). Tighten the retaining bolts
(2) to a torque of 52 - 61 N·m (38 - 45 lb ft).
RAPH12SSL0062AA 24
30. Install the radiator. See Radiator - Install (10.400).

31. Install the air cooler. See Aftercooler - Install
(10.310).
32. Install the engine cover (1).
RAPH12SSL0234AA 25
33. Install the fenders (1).
RAPH12SSL0235AA 26
47540694 28/04/2014
10.1 [10.001] / 22
34. Center the engine hood (1), and install the mounting
hardware (2).
RAPH12SSL0236AA 27
35. Connect the engine hood strut (1).
RAPH12SSL0236AA 28
36. If equipped with A/C, lubricate the condenser line

O-rings with CNH PAG OIL. Connect the A/C lines
(1) to the condenser. Connect the tail lights (3) and
connect the tail light electrical harness (4) to the
engine hood.
37. Connect the fan motor electrical connector (2).
RAPH12SSL0237AA 29
47540694 28/04/2014
10.1 [10.001] / 23
38. Connect the remote engine oil filter line (1) to the en-
gine oil pan.
RAPH12SSL0232AA 30
39. Center and attach the engine oil pan access plate (1).
Tighten the engine oil pan access plate mounting bolts
RAPH12SSL0233AA 31
47540694 28/04/2014
10.1 [10.001] / 24
Engine - Remove
C232 TIER 4 [NDM451672 - ] NA Electro hydraulic controls
C238 TIER 4 [NCM425510 - ] NA Electro hydraulic controls
L225 TIER 4 [NDM461085 - ] NA Electro hydraulic controls
L230 TIER 4 [NCM449907 - ] NA Electro hydraulic controls
WARNING
4. Shut off engine.
W0047A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Heavy objects!
W0398A
Prior operation:
Tilt the ROPS.
Prior operation:
Disconnect the battery. See Battery - Disconnect (55.302).
Prior operation:
Drain the coolant. See Radiator - Drain fluid (10.400).
Prior operation:
Drain the engine oil.
Prior operation:
Remove the rear engine access door. See Engine inspection door - Remove (90.102).
Prior operation:
Evacuate the A/C system (if equipped). See Air conditioning - Evacuate (50.200).
47540694 28/04/2014
10.1 [10.001] / 25
1. Remove engine oil pan access plate (1).
RAPH12SSL0233AA 1
2. Disconnect the remote engine oil filter line (1) from the
engine oil pan.
RAPH12SSL0232AA 2
3. Disconnect the tail lights (3) and disconnect the tail light
electrical harness (4) from the engine hood. If equipped
with A/C, disconnect the A/C lines (1) from the con-
denser. Disconnect the fan motor electrical connector
(2).
RAPH12SSL0237AA 3
47540694 28/04/2014
10.1 [10.001] / 26
4. Support the engine hood with a suitable lifting device.

Disconnect the engine hood strut (1).
RAPH12SSL0236AA 4
5. Remove the mounting hardware (2), and remove the

engine hood (1).
RAPH12SSL0236AA 5
6. Remove the fenders (1).
RAPH12SSL0235AA 6
47540694 28/04/2014
10.1 [10.001] / 27
7. Remove the engine cover (1).
RAPH12SSL0234AA 7
8. Remove the air cooler. See Aftercooler - Remove

(10.310).
9. Remove the radiator. See Radiator - Remove
(10.400).
10. Remove the radiator fan (1).
RAPH12SSL0062AA 8
11. Disconnect the dipstick tube (1) from the cooling pack-
age bracket assembly.
RAPH12SSL0276AA 9
47540694 28/04/2014
10.1 [10.001] / 28
12. Disconnect the intake tube for the air cooler (1).
RAPH12SSL0265AA 10
13. Disconnect the lower radiator hose retainers (1) from

the cooling package bracket assembly.
RAPH12SSL0060AA 11
14. Remove the hydraulic oil filter (1).
RAPH12SSL0227AA 12
47540694 28/04/2014
10.1 [10.001] / 29
15. Unbolt and remove the cooling package bracket as-

sembly (1).
RAPH12SSL0228AA 13
16. Disconnect the overflow hose (1) from the lower radi-
ator hose.
RAPH12SSL0059AA 14
17. Remove the deaeration tank cap (1), and disconnect

the overflow hose (2) and return hose (3). Remove
the deaeration tank assembly (4).
RAPH12SSL0225AA 15
47540694 28/04/2014
10.1 [10.001] / 30
18. Remove the U bolt (1) on the exhaust pipe.
RAPH12SSL0226AA 16

sor) (4)
RAPH12SSL0071AA 17
21. Support the DPF assembly (2) with a suitable lifting

device. Remove the mounting bolts (1), and remove
the DPF assembly (2).
RAPH12SSL0070AA 18
47540694 28/04/2014
10.1 [10.001] / 31
22. Disconnect the air restriction sensor (1) and the air
temperature sensor (2).
RAPH12SSL0263AA 19
23. Disconnect the fuel temperature sensor (2) and fuel

lines (3), (4).
24. Disconnect the air cleaner tubes and remove the air
cleaner/fuel filter bracket assembly (1).
RAPH12SSL0224AA 20
25. Remove the cotter pin (2) on the lock pin link (3) for
the left boom. Unbolt the boom lock bellcrank (1) and
place it away from the engine area.
RAPH12SSL0223AA 21
47540694 28/04/2014
10.1 [10.001] / 32
26. Remove the oil filler neck (1). If equipped with A/C,
disconnect the low pressure line (2) on the A/C com-
pressor.
RAPH12SSL0266AA 22
27. Disconnect the fuel return line (1) at the tank.
RAPH12SSL0053AA 23
28. Disconnect the two main engine harness electrical

connectors (1).
RAPH12SSL0052AA 24
47540694 28/04/2014
10.1 [10.001] / 33
29. Place a suitable container under the remote engine

oil filter lines (1). Label and disconnect the remove
engine oil filter lines (1).
931001923 25
30. Disconnect the following:

• Alternator positive (+) battery cable (1)
NOTE: Alternator may need to be adjusted to disconnect
the positive (+) battery cable and voltage regulator connec-
tor.
RAPH12SSL0049AA 26
31. Disconnect the ground cable (1) located below the

starter.
931001910 27
32. Disconnect the heater hose (1).

33. Disconnect the P clamp (2) on the gear pump feed
hose.
34. Disconnect the hydraulic line P clamp (3) on the bell
housing.
RAPH12SSL0058AA 28
47540694 28/04/2014
10.1 [10.001] / 34
35. Disconnect the right-hand reverse control solenoid

connector (1).
RAPH12SSL0077AA 29
36. Support the drive train with a suitable lifting device (1).
RAPH12SSL0057AA 30
37. Remove the drive train mounting bolts (1).
931001928 31
38. Disengage the drive train assembly (2) from the en-
gine bell housing (1).
931001936 32
47540694 28/04/2014
10.1 [10.001] / 35
39. Support the engine with a suitable lifting device (1).
RAPH12SSL0051AA 33
40. Remove the engine mount hardware (1).

RAPH12SSL0050AA 34
41. Carefully remove the engine from the chassis.
47540694 28/04/2014
10.1 [10.001] / 36
Engine - Install
WARNING
Fire hazard!
1. Do not smoke.
W0099A
WARNING
Heavy objects!
W0398A
1. Carefully lower the engine into the chassis.

2. Install the engine mount hardware (1). Apply LOCTITE®
243 to the threads of the engine mount hardware (1).
Tighten the engine mount hardware (1) to a torque of
133 - 144 N·m (98 - 106 lb ft).
RAPH12SSL0050AA 1
RAPH12SSL0051AA 2
47540694 28/04/2014
10.1 [10.001] / 37
4. Engage the drive train assembly (2) to the engine bell

housing (1).
931001936 3
5. Apply LOCTITE® 243 to the threads of the drive train

mounting bolts (1). Install the drive train mounting bolts
(1). Tighten the drive train mounting bolts (1) to a
torque of 87 - 117 N·m (64 - 86 lb ft).
931001928 4
RAPH12SSL0057AA 5
7. Connect the right-hand reverse control solenoid con-

nector (1).
RAPH12SSL0077AA 6
47540694 28/04/2014
10.1 [10.001] / 38
8. Connect the heater hose (1).

9. Connect the P clamp (2) on the gear pump feed hose.
10. Connect the hydraulic line P clamp (3) on the bell
housing.
RAPH12SSL0058AA 7
11. Connect the ground cable (1) located below the

starter.
931001910 8
12. Connect the following:

• Alternator positive (+) battery cable (1). Tighten the
alternator positive (+) battery cable nut to a torque
of 8 N·m (71 lb in).
NOTE: Alternator may need to be adjusted to connect the
positive (+) battery cable and voltage regulator connector.
RAPH12SSL0049AA 9
13. Connect the remote engine oil filter lines (1).
931001923 10
47540694 28/04/2014
10.1 [10.001] / 39
14. Connect the two main engine harness electrical con-

nectors (1).
RAPH12SSL0052AA 11
15. Connect the fuel return line (1) at the tank.
RAPH12SSL0053AA 12
16. Attach the oil filler neck (1). Tighten the oil filler neck
mounting bolts to a torque of 11 - 15 N·m (97 - 133 lb
in). If equipped with A/C, lubricate the low pressure
line O-ring with CNH PAG OIL. Connect the low pres-
sure line (2) on the A/C compressor.
RAPH12SSL0266AA 13
47540694 28/04/2014
10.1 [10.001] / 40
17. Attach the boom lock bellcrank (1).Connect the left

boom lock pin link (3) and attach the cotter pin (2).
RAPH12SSL0223AA 14
18. Install the air cleaner/fuel filter bracket assembly (1)

and connect the air cleaner tubes.
19. Connect the fuel temperature sensor (2) and fuel lines
(3), (4).
RAPH12SSL0224AA 15
20. Connect the air restriction sensor (1) and the air tem-
perature sensor (2).
RAPH12SSL0263AA 16
47540694 28/04/2014
10.1 [10.001] / 41
21. Support the diesel particulate filter (DPF) assembly (2)

with a suitable lifting device. Center the DPF assem-
bly, and install the mounting bolts (1).
RAPH12SSL0070AA 17

• DPF inlet temperature sensor (exhaust gas temp
sensor #2) (1)
sor) (4)
(3).
RAPH12SSL0071AA 18
24. Center the exhaust pipe, and install the U bolt (1).
RAPH12SSL0226AA 19
47540694 28/04/2014
10.1 [10.001] / 42
25. Install the deaeration tank assembly (4). Install the

deaeration tank cap (1), and connect the overflow
hose (2) and return hose (3).
RAPH12SSL0225AA 20
26. Connect the overflow hose (1) to the lower radiator

hose.
RAPH12SSL0059AA 21
27. Center and attach the cooling package bracket as-

sembly (1). Tighten the cooling package bracket as-
sembly mounting bolts to a torque of 54 - 73 N·m (40
- 54 lb ft).
RAPH12SSL0228AA 22
47540694 28/04/2014
10.1 [10.001] / 43
28. Install the hydraulic oil filter (1).
RAPH12SSL0227AA 23
29. Connect the lower radiator hose retainers (1) to the

cooling package bracket assembly.
RAPH12SSL0060AA 24
30. Connect the intake tube for the air cooler. Tighten the
clamp (1) to a torque of 3 - 4 N·m (27 - 35 lb in).
RAPH12SSL0265AA 25
47540694 28/04/2014
10.1 [10.001] / 44
31. Connect the dipstick tube (1) to the cooling package

bracket assembly.
RAPH12SSL0276AA 26
32. Install the radiator fan (1). Tighten the retaining bolts
RAPH12SSL0062AA 27
33. Install the radiator. See Radiator - Install (10.400).

34. Install the air cooler. See Aftercooler - Install
(10.310).
35. Install the engine cover (1).
RAPH12SSL0234AA 28
47540694 28/04/2014
10.1 [10.001] / 45
36. Install the fenders (1).
RAPH12SSL0235AA 29
37. Center the engine hood (1), and install the mounting
hardware (2).
RAPH12SSL0236AA 30
38. Connect the engine hood strut (1).
RAPH12SSL0236AA 31
47540694 28/04/2014
10.1 [10.001] / 46
39. If equipped with A/C, lubricate the condenser line

O-rings with CNH PAG OIL. Connect the A/C lines
(1) to the condenser. Connect the tail lights (3) and
connect the tail light electrical harness (4) to the
engine hood.
40. Connect the fan motor electrical connector (2).
RAPH12SSL0237AA 32
41. Connect the remote engine oil filter line (1) to the en-
gine oil pan.
RAPH12SSL0232AA 33
42. Center and attach the engine oil pan access plate (1).
Tighten the engine oil pan access plate mounting bolts
RAPH12SSL0233AA 34
47540694 28/04/2014
10.1 [10.001] / 47
Index
Engine - 10

Engine - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
47540694 28/04/2014
10.1 [10.001] / 48
Engine - 10
Fuel tanks - 216
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
10.2 [10.216] / 1
Contents
Engine - 10
Fuel tanks - 216
SERVICE
Fuel tank
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
47540694 28/04/2014
10.2 [10.216] / 2
Engine - Fuel tanks
Fuel tank - Remove

C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L223 NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
WARNING
Fire hazard!
1. Do not smoke.
W0099A
Prior operation:
Remove the engine. See Engine - Remove (10.001)
Prior operation:
Remove the oil cooler. See Oil cooler/Heat exchanger - Remove (35.300)
1. Drain the tank.
RAPH12SSL0344AA 1
2. Disconnect the fuel level sensor (1).

3. Disconnect the fuel outlet line (2).
RAPH12SSL0042AA 2
47540694 28/04/2014
10.2 [10.216] / 3
Engine - Fuel tanks
4. Remove the right hand side fuel tank bracket (1).
931002100B 3
5. Remove the left hand side fuel tank bracket (1).
RAPH12SSL0345AA 4
6. Carefully remove the fuel tank.
931002102B 5
47540694 28/04/2014
10.2 [10.216] / 4
Engine - Fuel tanks
Fuel tank - Install

C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L223 NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
WARNING
Fire hazard!
1. Do not smoke.
W0099A
1. Carefully install the fuel tank.
931002102B 1
2. Install the left hand side fuel tank bracket (1).
RAPH12SSL0345AA 2
47540694 28/04/2014
10.2 [10.216] / 5
Engine - Fuel tanks
3. Install the right hand side fuel tank bracket (1).
931002100B 3
4. Connect the fuel level sensor (1).

5. Connect the fuel outlet line (2).
RAPH12SSL0042AA 4
47540694 28/04/2014
10.2 [10.216] / 6
Index
Engine - 10
Fuel tanks - 216

Fuel tank - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel tank - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
10.2 [10.216] / 7
47540694 28/04/2014
10.2 [10.216] / 8
Engine - 10
Aftercooler - 310
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
10.3 [10.310] / 1
Contents
Engine - 10
Aftercooler - 310
SERVICE
Aftercooler
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47540694 28/04/2014
10.3 [10.310] / 2
Engine - Aftercooler
Aftercooler - Remove
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
1. Open rear access door and lift engine hood.

2. Disconnect the air cooler tubes (1) and (2). NOTE:
Engine hood removed for picture clarity.
RAPH12SSL0231AA 1
3. Remove the air cooler mounting bolts (1), and remove

the air cooler (2).
RAPH12SSL0230AA 2
47540694 28/04/2014
10.3 [10.310] / 3
Engine - Aftercooler
Aftercooler - Install
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
1. Place the air cooler (2) above the radiator, and install
the air cooler mounting bolts (1). Tighten the mounting
bolts (1) to a torque of 27 - 37 N·m (20 - 27 lb ft).
RAPH12SSL0230AA 1
2. Connect the air cooler tubes (1) and (2). Tighten the
hose clamps to a torque of 3 - 4 N·m (27 - 35 lb in).
NOTE: Engine hood removed for picture clarity.
RAPH12SSL0231AA 2
47540694 28/04/2014
10.3 [10.310] / 4
Index
Engine - 10
Aftercooler - 310
Aftercooler - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Aftercooler - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
10.3 [10.310] / 5
47540694 28/04/2014
10.3 [10.310] / 6
Engine - 10
Engine cooling system - 400
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
10.4 [10.400] / 1
Contents
Engine - 10
SERVICE
Radiator
Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
47540694 28/04/2014
10.4 [10.400] / 2
Engine - Engine cooling system
Radiator - Drain fluid

C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
WARNING
Burn hazard!
Be very careful to avoid contact with hot fluids. If fluid is extremely hot, allow it to cool to a moderately
warm temperature before proceeding.
W0362A
1. If engine is HOT do not drain cooling system. Allow the

system to cool before draining the radiator.
2. Open the rear access door.
3. Loosen the cap (1) on the deaeration tank.
RAPH12SSL0072AA 1
4. Drain the engine coolant system by loosening the drain

valve (1), and drain the coolant into a suitable con-
tainer. When the radiator is empty, tighten the drain
valve
NOTE: Rear access door removed for picture clarity.
RAPH12SSL0083AA 2
47540694 28/04/2014
10.4 [10.400] / 3
Radiator - Filling
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
CAUTION
Burn hazard!
Take care if removing the filler cap while the system is hot. Before removing the cap: completely cover
the cap using a thick cloth, and slowly open the filler cap to allow the pressure to escape. Do not add
cold water to a hot coolant reservoir.
Failure to comply could result in minor or moderate injury.
C0031A
1. Open the rear access door and engine hood after the
engine has cooled.
2. Remove the cap (1) on the deaeration tank. Slowly
fill the coolant system with a 50% mixture of ethylene
glycol engine coolant and 50% water mixture.
RAPH12SSL0072AA 1
3. Start and run the engine until it reaches operating tem-

perature. Stop the engine and check the level of the
coolant in the deaeration tank (2). Fill the deaera-
tion tank with a 50% mixture of ethylene glycol engine
coolant and 50% water mixture to the full level marked
on the tank. Once the level is good, tighten the cap (1)
on the deaeration tank.
RAPH12SSL0072AA 2
47540694 28/04/2014
10.4 [10.400] / 4
Radiator - Remove
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
WARNING
Burn hazard!
Be very careful to avoid contact with hot fluids. If fluid is extremely hot, allow it to cool to a moderately
warm temperature before proceeding.
W0362A
Prior operation:
Drain the coolant system. See Radiator - Drain fluid (10.400)
Prior operation:
Remove the air cooler.
1. Disconnect the upper radiator hose (1).
RAPH12SSL0065AA 1
2. Disconnect the lower radiator hose (1).

NOTE: Rear access door removed for picture clarity.
RAPH12SSL0083AA 2
47540694 28/04/2014
10.4 [10.400] / 5
3. Remove the 45 ° overflow hose elbow (1).

4. Remove the radiator hold-down bolts (3), and remove
the radiator (2).
RAPH12SSL0066AA 3
47540694 28/04/2014
10.4 [10.400] / 6
Radiator - Install
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
1. Place the radiator (2) above the hydraulic oil cooler. In-
stall the radiator hold-down bolts (3). Tighten the bolts
to a torque of 27 - 37 N·m (20 - 27 lb ft).
NOTE: Engine hood and rear access door removed for pic-
ture clarity.
2. Apply LOCTITE® 567 PST PIPE SEALANT to the treads of
the 45 ° overflow hose elbow (1) and install the elbow
into the side of the radiator. Tighten the 45 ° overflow
hose elbow (1) two to three turns past finger tight.
NOTE: 45 ° overflow hose elbow (1) is to be positioned with
the spout facing downward.
RAPH12SSL0066AA 1
3. Connect the lower radiator hose (1). Tighten the clamp

to a torque of 3 - 4 N·m (27 - 35 lb in).
RAPH12SSL0083AA 2
4. Connect the upper radiator hose (1). Tighten the clamp

to a torque of 3 - 4 N·m (27 - 35 lb in).
RAPH12SSL0065AA 3
47540694 28/04/2014
10.4 [10.400] / 7
Index
Engine - 10

Radiator - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Radiator - Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Radiator - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Radiator - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
47540694 28/04/2014
10.4 [10.400] / 8
Engine - 10
Fan and drive - 414
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
10.5 [10.414] / 1
Contents
Engine - 10
Fan and drive - 414
SERVICE
Belt
Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
10.5 [10.414] / 2
Engine - Fan and drive
Belt - Tension adjust

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
NOTE: The engine serpentine belt does not have a tensioning procedure. The alternator is adjusted all the way to
the stop.
Use the following procedure to set the alternator adjust-
ment out to the stop.
1. Loosen the upper and lower mounting bolts (1)on
the alternator.
2. Loosen the adjusting bracket bolt (2).
3. Loosen the adjusting bolt jam nut (3), and adjust
the adjusting bolt (4) until bracket (5) is adjusted to
the stop (all the way out as shown).
4. Tighten the adjusting bracket bolt (2).
5. Tighten the adjusting bolt jam nut (3).
6. Tighten the alternator mounting bolts (1).
RCPH11SSL038AAP 1
47540694 28/04/2014
10.5 [10.414] / 3
Index
Engine - 10
Fan and drive - 414

Belt - Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
10.5 [10.414] / 4
Engine - 10
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF)

exhaust treatment - 501
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
10.6 [10.501] / 1
Contents
Engine - 10
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust

treatment - 501
FUNCTIONAL DATA
Diesel Particulate Filters (DPF)

Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Diesel Oxidation Catalyst (DOC)
SERVICE
Diesel Particulate Filters (DPF)

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
47540694 28/04/2014
10.6 [10.501] / 2
Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment
Diesel Particulate Filters (DPF) - Dynamic description

C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
During normal operation, the diesel engine generates certain pollutants. Federal law regulates the levels of exhaust
pollutants that a vehicle is allowed to emit. Pollutants generated during the normal operation of these engines require
after-treatment. The Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) system controls these pol-
lutants.
The DPF system uses a heated exhaust gas oxygen sensor (1) which provides information about combustion ef-
ficiency to the Engine Control Unit (ECU) (3). The ECU (3) uses this information to determine the fuel injection
requirements. The system also uses a Diesel Oxidation Catalyst (DOC) (6) which converts carbon monoxide and
hydrocarbons into carbon dioxide and water. During normal operation, lower combustion temperature created by the
Exhaust Gas Recirculation (EGR) system lowers the NOx levels, but also creates particulate matter. The DPF (4)
traps this particulate matter. Restriction of the DPF (4) is monitored by the DPF differential pressure sensor (2), which
measures the inlet and outlet pressure of the DPF (4). When the pressure at the inlet side differs from the pressure
at the outlet side, the DPF (4) is cleaned of particulate matter by elevating the exhaust temperature. This process
is called regeneration. Normally, the ECU (3) controls regeneration while the machine is operating under normal
conditions, but if the operator inhibits regeneration too many times, the ECU (3) will request a forced regeneration,
which demands that the machine be parked and idling. During regeneration, the ECU (3) closes the throttle valve to
restrict air flow into the engine. Then the ECU (3) injects fuel into the exhaust by spraying the fuel injectors during the
exhaust stroke of the cylinder. The high temperature combined with the fuel creates the heat needed to regenerate
the DPF (4). The ECU (3) monitors the DOC inlet temperature sensor (7) and the DPF inlet temperature sensor (5)
during regeneration. The DOC (6) outlet temperature will be higher than the DOC (6) inlet temperature because of
the chemical reactions occurring inside the DOC (6). Extreme temperatures will damage the DOC (6) and DPF (4).
The DPF requires replacement after four thousand hours of usage. After replacement of the DPF, the technician
needs to reset the DPF data in the ECU. The technician can reset the data by following the directions located within
the diagnostic software associated with this machine’s engine.
RAPH14SSL0022FA 1
DOC/DPF system
47540694 28/04/2014
10.6 [10.501] / 3
DOC/DPF components
(1) Heated exhaust gas, (3) ECU (5) DPF inlet temperature (7) DOC inlet temperature
oxygen sensor sensor sensor
(2) DPF differential pressure (4) DPF (6) DOC
sensor
There are four kinds of regenerations: passive, active, forced, and service
• During a passive regeneration, the ECU calibrates the machine’s fuel injection, EGR, and throttle valve without the
operator being aware. During a passive regeneration, the operating temperature is between 280 - 500 °C (536 -
932 °F).
• During an active regeneration, dPF ON or REGEN ACTIVE is displayed on the instrument cluster. Again, the
ECU calibrates the machine’s fuel injection, EGR, and throttle valve. During an active regeneration, the operating
temperature is between 400 - 600 °C (752 - 1112 °F). The operator may notice an increase in engine noise and
may smell a burning or “hot” odor, but may continue to use the machine as it is designed during this process. When
active regeneration is completed, dPF OFF or REGEN OFF is displayed on the instrument cluster.
• During a forced regeneration, the instrument cluster displays dPF PARK or REGEN PARK. The operator must
park the idling machine, and wait for IDLE to appear on the instrument cluster. The instrument cluster then tells
the operator to press the AUX OVERRIDE button on the instrument cluster. During a forced regeneration, the
operating temperature is between 250 - 700 °C (482 - 1292 °F). The operator can not use the machine during a
forced regeneration.
• During a service regeneration, the technician performs a regeneration of the DPF by using the regeneration option in
the Electronic Service Tool (EST). The technician can perform a regeneration of the system at any time, regardless
of the ECU’s recorded information, and does not need to reset the DPF data after performing a service regeneration.
During a service regeneration, the operating temperature is between 250 - 700 °C (482 - 1292 °F). The technician
can not use the machine during a service regeneration.
The regeneration process will last approximately five to twenty minutes. Do not shut the machine off during any
observable regeneration. The DPF will need to be serviced or replaced after four thousand hours of usage.
Inhibit regeneration
Under certain conditions, the operator may want to delay the regeneration process. Continuing to delay the auto
regeneration process will result in a forced regeneration, because of a buildup of particulate matter in the DPF.
The instrument cluster can inhibit the regeneration process by entering the SETUP menu on the instrument cluster.
When inside the SETUP menu, press START on the instrument cluster until dPF or REGEN displays. Then press
POWER on the instrument cluster until INHIb displays. Press START to toggle between the choices, and press
POWER on the instrument cluster to save your choice.
The default setting of the instrument cluster allows the DPF system to auto regenerate any time it is commanded by
the ECU.
After-treatment System ( ATS) Failure

When the DPF and/or EGR system detect a malfunction,
the ECU will derate the engine output and prompt the op-
erator to seek service for the machine by displaying ATS
FAIL on the instrument cluster. The display warning will RAPH13SSL0576AA 2
also be accompanied by a red, flashing light and an au-
dible alarm. An ATS failure will trigger one or more fault
codes. Please use the EST to diagnose the fault(s). Once
the fault is corrected and the code is cleared, ATS FAIL,
the alarm, and warning light will disappear from the instru-
ment cluster and the machine will return to normal opera-
tions.
47540694 28/04/2014
10.6 [10.501] / 4
Diesel Oxidation Catalyst (DOC) - Dynamic description

L223 TIER 4 [NDM474381 - ] NA
During normal operation, the diesel engine generates certain pollutants. Federal law regulates the levels of exhaust
pollutants that a vehicle is allowed to emit. Pollutants generated in the normal operation of these engines require
after-treatment. The Diesel Oxidant Catalyst (DOC) and a Particulate Matter Catalyst (PM-Catalyst) emissions system
controls these pollutants.
The DOC and PM-Catalyst system is an opened passage, non-serviceable, particulate filter system that allow exhaust
gasses to freely flow, thus decreasing exhaust pressure and increasing engine performance. The DOC oxidizes car-
bon monoxide and hydrocarbons into carbon dioxide and water, and the PM-Catalyst traps particulate matter. The
Engine Control Unit (ECU) monitors the inlet temperature sensor (2) and the outlet temperature sensor (3) to deter-
mine DOC efficiency. During normal operations, the DOC outlet temperature is higher than the DOC inlet temperature
because of the chemical reactions inside the DOC. The ECU estimates soot accumulation in the PM-Catalyst by mon-
itoring and recording the lambda sensor (1). The ECU also monitors the outlet temperature sensor (3) during PM-Cat-
alyst regeneration; extreme temperatures will damage the PM-Catalyst. As soot content and exhaust temperature
information are being observed and recorded, the ECU calibrates machine operation to regenerate the PM-Catalyst.
Nothing is needed from the operator to perform a regeneration to the PM-Catalyst. To effectively regenerate the
PM-Catalyst, the ECU must calculate a NOx to particulate matter ratio of twelve to one or higher and the exhaust
temperature at the inlet of the DOC must be between 250.0 - 400.0 °C (482 - 752 °F).
The PM-Catalyst does not require replacement or service after four thousand hours of usage unlike the Diesel Par-
ticulate Filter (DPF) system. The DOC and PM-Catalyst needs to be replaced when the customer notices excessive
regenerations of the PM-Catalyst as well as a decrease in fuel economy.
RAPH14SSL0016FA 1
DOC/PM-Catalyst
DOC/PM-Catalyst components
(1) DOC (3) DOC outlet temperature sensor (5) Lambda sensor
(2) PM-Catalyst (4) DOC inlet temperature sensor
dPF ON or REGEN ACTIVE notification on the instrument cluster

The DOC and PM-Catalyst emissions system does not have a DPF. Fiat Power Train (FPT) added an observable re-
generation process to the PM-Catalyst system to improve PM-Catalyst performance. Like other tier four, New Holland
models, the operator is notified by a single audible beep and dPF ON or REGEN ACTIVE appears on the instrument
cluster when the regeneration process has started. The audible beep and the dPF ON or REGEN ACTIVE notifica-
tion disappears and reappears during this process. When the regeneration process is complete, dPF OFF or REGEN
OFF will appear on the instrument cluster.
47540694 28/04/2014
10.6 [10.501] / 5
After Treatment System (ATS) Failure

If the DOC and PM-Catalyst and/or Exhaust Gas Recir-
culation (EGR) system detects a malfunction, the ECU
derates the engine output and prompts the operator to
seek service for the machine by displaying ATS FAIL on RAPH13SSL0576AA 2
the instrument cluster. The instrument cluster warning is
also accompanied by a red, flashing light and an audible
alarm. An ATS failure triggers one or more fault codes.
Please use the Electronic Service Tool (EST) to diagnose
the fault(s). Once the fault is corrected and the code is
cleared, ATS FAIL, the alarm, and warning light will dis-
appear from the instrument cluster and the machine will
return to normal operations.
47540694 28/04/2014
10.6 [10.501] / 6
Diesel Particulate Filters (DPF) - Remove

C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
CAUTION
Burn hazard!
During the Diesel Particular Filter (DPF) regeneration process the exhaust stack and fixed hood area
becomes extremely hot. Allow area to cool before servicing or working near the exhaust system com-
ponents.
C0102A
1. Remove the rear deck panel (1).
931001899 1
2. Remove the U-bolt (1).
RAPH12SSL0085AA 2

• Heated exhaust gas oxygen sensor (lambda sensor)
(4)
RAPH12SSL0071AA 3
47540694 28/04/2014
10.6 [10.501] / 7
5. Remove the DPF mounting bolts (1) , and carefully re-

move the DPF assembly (2) from the unit.
RAPH12SSL0070AA 4
47540694 28/04/2014
10.6 [10.501] / 8
Diesel Particulate Filters (DPF) - Disassemble

C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
1. Mark the Diesel Particulate Filter (DPF) assembly and

the hold-down strap as shown in picture 1.
RAPH12SSL0082AA 1
2. Remove the hold-down straps bolts (2) and straps (1).
RAPH12SSL0078AA 2
3. Disconnect the DPF differential pressure sensor tube

(1).
RAPH12SSL0079AA 3
47540694 28/04/2014
10.6 [10.501] / 9
4. Remove the DPF clamps (1).
RAPH12SSL0080AA 4
5. Separate the DPF (1) from the DPF exhaust assembly.
RAPH12SSL0081AA 5
47540694 28/04/2014
10.6 [10.501] / 10
Diesel Particulate Filters (DPF) - Assemble

C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
1. Place the Diesel Particulate Filter (DPF) (1) into the

DPF exhaust assembly.
RAPH12SSL0081AA 1
2. Assemble the DPF assembly. Install the DPF clamps

(1).
RAPH12SSL0080AA 2
3. Connect the DPF differential pressure sensor tube (1).
RAPH12SSL0079AA 3
47540694 28/04/2014
10.6 [10.501] / 11
4. Install the hold-down straps (2) and bolts (1), but do

not tighten. Align the previously marked DPF assembly
with the previously marked hold-down strap as shown
in picture 4.
RAPH12SSL0082AA 4
5. Tighten the bolts (1) to a torque of 32 - 44 N·m (24 -

33 lb ft).
RAPH12SSL0078AA 5
47540694 28/04/2014
10.6 [10.501] / 12
Diesel Particulate Filters (DPF) - Install

C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
1. Carefully place the DPF assembly (2) into the unit. In-
stall the DPF mounting bolts (1).
RAPH12SSL0070AA 1

• Heated exhaust gas oxygen sensor (lambda sensor)
(4)
(3).
RAPH12SSL0071AA 2
4. Install the U-bolt (1).
RAPH12SSL0085AA 3
47540694 28/04/2014
10.6 [10.501] / 13
5. Install the rear deck panel (1).
931001899 4
Next operation:
Reset the Engine Control Unit (ECU) data for the DPF. Please connect the Electronic Service Tool (EST) to the ma-
chine, load your machine, click on the configuration menu on the EST screen, and follow the steps for resetting the
ECU data about the DPF.
47540694 28/04/2014
10.6 [10.501] / 14
Index
Engine - 10
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust

treatment - 501
Diesel Oxidation Catalyst (DOC) - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diesel Particulate Filters (DPF) - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Diesel Particulate Filters (DPF) - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Diesel Particulate Filters (DPF) - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Diesel Particulate Filters (DPF) - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Diesel Particulate Filters (DPF) - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
47540694 28/04/2014
10.6 [10.501] / 15
CNH - Main 700 State Street Racine, Wisconsin United States 53404
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 2014 CNH Industrial America LLC.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
NEW HOLLAND CONSTRUCTION policy is one of continuous improvement and the right to change prices,
specification or equipment at any time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your NEW HOLLAND CONSTRUCTION Dealer.
47540694 28/04/2014
EN
SERVICE MANUAL
Front axle system
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
25
Contents
Front axle system - 25
[25.450] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
47540694 28/04/2014
25
Chain drive system - 450
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
25.1 [25.450] / 1
Contents
SERVICE
Axle
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chain drive
Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Measure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
47540694 28/04/2014
25.1 [25.450] / 2
Front axle system - Chain drive system
Axle - Remove
L223 NA
L225 NA
L230 NA
WARNING
Jack stands can slip or fall over. Dropping, tipping, or slipping of machine or its components is pos-
sible.
DO NOT work under a vehicle supported by jack stands only. Park machine on a level surface. Block
wheels. Support machine with safety stands.
W0069A
NOTE: The following procedure has been performed on the right, front axle. All axles are similar.
1. Drain the chain tank.
RAIL13SSL0382BA 1
2. Lift the of the machine off of the ground, and support

the machine with adequate equipment.
3. Remove the tire.
RAIL13SSL0383BA 2
47540694 28/04/2014
25.1 [25.450] / 3
4. Support the axle with suitable lifting device. Remove

the nuts (1).
RAIL13SSL0562BA 3
5. Disconnect the axle from the sprocket.
RAIL13SSL0384BA 4
47540694 28/04/2014
25.1 [25.450] / 4
Axle - Disassemble
L223 NA
L225 NA
L230 NA
1. Remove the snap ring.
RAIL13SSL0388BA 1
2. Remove the shim.
RAIL13SSL0387BA 2
3. Remove the spacer.
RAIL13SSL0386BA 3
47540694 28/04/2014
25.1 [25.450] / 5
4. Press the axle shaft out of the axle housing.
RAIL13SSL0389BA 4
5. Remove the inner bearing.
RAIL13SSL0391BA 5
6. Remove the outer bearing.
RAIL13SSL0392BA 6
47540694 28/04/2014
25.1 [25.450] / 6
7. Remove the seal.
RAIL13SSL0393BA 7
47540694 28/04/2014
25.1 [25.450] / 7
Axle - Assemble
L223 NA
L225 NA
L230 NA
CAUTION
Burn hazard!
Always wear heat-resistant protective gloves when handling heated parts.
C0047A
NOTE: Properly grease all bearings before beginning this procedure.

1. Heat the outer bearing to 60 °C (140 °F).
RAIL13SSL0396BA 1
2. Carefully place the outer bearing in the bearing race.
RAIL13SSL0394BA 2
47540694 28/04/2014
25.1 [25.450] / 8
3. Install the seal.
RAIL13SSL0395BA 3
4. Slowly drop the axle shaft into the axle housing.

NOTE: The axle will easily slide through the bearing if the
bearing has been heated to 60 °C (140 °F).
RAIL13SSL0397BA 4
5. Install the inner bearing.
RAIL13SSL0385BA 5
47540694 28/04/2014
25.1 [25.450] / 9
6. Install the spacer.
RAIL13SSL0386BA 6
7. Install the shim.
RAIL13SSL0387BA 7
8. Install the snap ring.
RAIL13SSL0388BA 8
47540694 28/04/2014
25.1 [25.450] / 10
Axle - Install
L223 NA
L225 NA
L230 NA
WARNING
sible.
W0069A
1. Insert the axle shaft into the sprocket, and position the
axle assembly on the mounting bolts.
RAIL13SSL0384BA 1
2. Install the nuts (1), but do not tighten.
RAIL13SSL0562BA 2
3. Remove the lifting equipment.
47540694 28/04/2014
25.1 [25.450] / 11
4. The drive chain will need adjustment. Either remove

the chain tank cover and proceed to step 5 or see
Chain drive - Check (25.450) for alternative adjust-
ment procedures.
RAIL13SSL0561BA 3
5. Adjust the axle so the chain has 10 - 15.0 mm (13/32 -

19/32 in) of slack at the center (1) of the chain.
96091469 4
6. Apply a bead of LOCTITE® RTV SILICONE CLEAR to the

bolt holes and to the chain tank opening. Install the
chain tank cover (1).
RAPH13SSL0563BA 5
47540694 28/04/2014
25.1 [25.450] / 12
7. After adjusting the chain play, torque the nuts (1) to 224
- 264 N·m (165 - 195 lb ft).
RAIL13SSL0562BA 6
8. Install the tire.

For flange nuts, torque the nuts (1) to 203.5 N·m
(150 lb ft)
For tapered nuts, torque the nuts (1) to 169.5 N·m
(125 lb ft).
RAIL13SSL0383BA 7
9. Fill the chain tank by remove the fill plug (1). Apply
LOCTITE® 545 to the threads of the fill plug (1) before
reinstalling the fill plug (1).
RAIL13SSL0560AA 8
47540694 28/04/2014
25.1 [25.450] / 13
Chain drive - Check

L223 NA
L225 NA
L230 NA
WARNING
sible.
W0069A
Check the tension of the four drive chains after the first 250 hours of operation on a new machine or if new chains
have been installed and every 500 hours of operation.
1. With the machine blocked up, rotate each tire and

check for allowable movement. 0.5 - 1.5 ° or 6 - 12 mm
(15/64 - 15/32 in) of movement is the acceptable
range.
63107489 1
Drive chain adjustment

2. To adjust the final drive chains, jack up and block the
complete skid steer securely off the ground.
931002280 2
3. Each axle drive chain is adjustable by loosening the

retaining nuts (1) (left front shown) and sliding the axle-
hub assembly to remove the excessive slack.
To tighten the chains slide the front axle-hubs forward
and rear axle-hubs rearward.
Torque the axle retaining hardware to 224 - 264 N·m
(165 - 195 lb ft).
93109317 3
4. Repeat step 1.
47540694 28/04/2014
25.1 [25.450] / 14
Chain drive - Measure

L223 NA
L225 NA
L230 NA
1. The individual joints in a roller chain articulate as they

enter and leave the sprockets. This articulation results
in wear on the pins and bushings. Material that is worn
away from these surfaces will cause the chain to grad-
ually elongate. Chains do not stretch. Material is worn
from pin and bushing.
Critical dimensions of the chain are as follows:
1. 2X pitch
2. Wear plus 2X pitch
3. Elongation due to pin and bushing wear
96091478 1
Elongation is normal and may be minimized by proper lu-

brication and drive maintenance. The rate of wear is de-
pendent upon: the relationship between the load and the
amount of bearing area between pin and bushing, the ma-
terial and surface condition of the bearing surfaces, the
adequacy of lubrication, and the frequency and degree of
articulation between pins and bushings. The latter is de-
termined by the quantity of sprockets in the drive, their
speeds, the number of teeth and the length of the chain
in pitches.
An accurate wear measurement (1) can be made by us-
ing the above illustration. Measure as closely as possible
from the center of one pin to the center of another. The
more pitches (pins) contained within the measurement in-
crease the accuracy. If the measured value exceeds the
nominal by more than the allowable percentage the chain
should be replaced. The maximum allowable wear elonga-
tion is approximately 3 % for most industrial applications,
based upon sprocket design. The allowable chain wear in
percent can be calculated using the relationship: 200/ (N),
where (N) is the number of teeth in the large sprocket. This
relationship is often useful since the normal maximum al-
lowable chain wear elongation of 3 % is valid only up to
67 teeth in the large sprocket. In drives having fixed center
distances, chains running in parallel or where smoother op- 96091469 2
eration is required, wear should be limited to approximately
1.5 %.
For example, if 12 pitches (12 pins) of a #80 chain were
measured and the result was 313.944 mm (12.360 in) or
greater (using 3 % as the maximum allowable wear), the
chain should be replaced. Anything less than 313.944 mm
(12.360 in) would still be acceptable by most industrial
standards.
47540694 28/04/2014
25.1 [25.450] / 15
Index

Axle - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Axle - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chain drive - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chain drive - Measure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
47540694 28/04/2014
25.1 [25.450] / 16
47540694 28/04/2014
25.1 [25.450] / 17
PRINTED IN U.S.A.
47540694 28/04/2014
EN
SERVICE MANUAL
Rear axle system
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
27
Contents
Rear axle system - 27
[27.650] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
47540694 28/04/2014
27
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
27.1 [27.650] / 1
Contents
SERVICE
Axle
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chain drive
Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Measure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
47540694 28/04/2014
27.1 [27.650] / 2
Rear axle system - Chain drive system
Axle - Remove
L223 NA
L225 NA
L230 NA
WARNING
sible.
W0069A
1. Drain the chain tank.
RAIL13SSL0382BA 1
2. Lift the of the machine off of the ground, and support

the machine with adequate equipment.
3. Remove the tire.
RAIL13SSL0383BA 2
47540694 28/04/2014
27.1 [27.650] / 3
4. Support the axle with suitable lifting device. Remove

the nuts (1).
RAIL13SSL0562BA 3
5. Disconnect the axle from the sprocket.
RAIL13SSL0384BA 4
47540694 28/04/2014
27.1 [27.650] / 4
Axle - Install
L223 NA
L225 NA
L230 NA
WARNING
sible.
W0069A
1. Insert the axle shaft into the sprocket, and position the
axle assembly on the mounting bolts.
RAIL13SSL0384BA 1
2. Install the nuts (1), but do not tighten.
RAIL13SSL0562BA 2
3. Remove the lifting equipment.
47540694 28/04/2014
27.1 [27.650] / 5
4. The drive chain will need adjustment. Either remove

the chain tank cover and proceed to step 5 or see
Chain drive - Check (25.450) for alternative adjust-
ment procedures.
RAIL13SSL0561BA 3
5. Adjust the axle so the chain has 10 - 15.0 mm (13/32 -

19/32 in) of slack at the center (1) of the chain.
96091469 4
6. Apply a bead of LOCTITE® RTV SILICONE CLEAR to the

bolt holes and to the chain tank opening. Install the
chain tank cover (1).
RAPH13SSL0563BA 5
47540694 28/04/2014
27.1 [27.650] / 6
7. After adjusting the chain play, torque the nuts (1) to 224
- 264 N·m (165 - 195 lb ft).
RAIL13SSL0562BA 6
8. Install the tire.

For flange nuts, torque the nuts (1) to 203.5 N·m
(150 lb ft)
For tapered nuts, torque the nuts (1) to 169.5 N·m
(125 lb ft).
RAIL13SSL0383BA 7
9. Fill the chain tank by remove the fill plug (1). Apply
LOCTITE® 545 to the threads of the fill plug (1) before
reinstalling the fill plug (1).
RAIL13SSL0560AA 8
47540694 28/04/2014
27.1 [27.650] / 7
Axle - Disassemble
L223 NA
L225 NA
L230 NA
RAIL13SSL0388BA 1
2. Remove the shim.
RAIL13SSL0387BA 2
3. Remove the spacer.
RAIL13SSL0386BA 3
47540694 28/04/2014
27.1 [27.650] / 8
4. Press the axle shaft out of the axle housing.
RAIL13SSL0389BA 4
5. Remove the inner bearing.
RAIL13SSL0391BA 5
6. Remove the outer bearing.
RAIL13SSL0392BA 6
47540694 28/04/2014
27.1 [27.650] / 9
7. Remove the seal.
RAIL13SSL0393BA 7
47540694 28/04/2014
27.1 [27.650] / 10
Axle - Assemble
L223 NA
L225 NA
L230 NA
CAUTION
Burn hazard!
Always wear heat-resistant protective gloves when handling heated parts.
C0047A
NOTE: Properly grease all bearings before beginning this procedure.

1. Heat the outer bearing to 60 °C (140 °F).
RAIL13SSL0396BA 1
2. Carefully place the outer bearing in the bearing race.
RAIL13SSL0394BA 2
47540694 28/04/2014
27.1 [27.650] / 11
3. Install the seal.
RAIL13SSL0395BA 3
4. Slowly drop the axle shaft into the axle housing.

NOTE: The axle will easily slide through the bearing if the
bearing has been heated to 60 °C (140 °F).
RAIL13SSL0397BA 4
5. Install the inner bearing.
RAIL13SSL0385BA 5
47540694 28/04/2014
27.1 [27.650] / 12
6. Install the spacer.
RAIL13SSL0386BA 6
7. Install the shim.
RAIL13SSL0387BA 7
RAIL13SSL0388BA 8
47540694 28/04/2014
27.1 [27.650] / 13
Chain drive - Check

L223 NA
L225 NA
L230 NA
WARNING
sible.
W0069A
Check the tension of the four drive chains after the first 250 hours of operation on a new machine or if new chains
have been installed and every 500 hours of operation.
1. With the machine blocked up, rotate each tire and

check for allowable movement. 0.5 - 1.5 ° or 6 - 12 mm
(15/64 - 15/32 in) of movement is the acceptable
range.
63107489 1
Drive chain adjustment

2. To adjust the final drive chains, jack up and block the
complete skid steer securely off the ground.
931002280 2
3. Each axle drive chain is adjustable by loosening the

retaining nuts (1) (left front shown) and sliding the axle-
hub assembly to remove the excessive slack.
To tighten the chains slide the front axle-hubs forward
and rear axle-hubs rearward.
Torque the axle retaining hardware to 224 - 264 N·m
(165 - 195 lb ft).
93109317 3
4. Repeat step 1.
47540694 28/04/2014
27.1 [27.650] / 14
Chain drive - Measure

L223 NA
L225 NA
L230 NA
1. The individual joints in a roller chain articulate as they

enter and leave the sprockets. This articulation results
in wear on the pins and bushings. Material that is worn
away from these surfaces will cause the chain to grad-
ually elongate. Chains do not stretch. Material is worn
from pin and bushing.
Critical dimensions of the chain are as follows:
1. 2X pitch
2. Wear plus 2X pitch
3. Elongation due to pin and bushing wear
96091478 1
Elongation is normal and may be minimized by proper lu-

brication and drive maintenance. The rate of wear is de-
pendent upon: the relationship between the load and the
amount of bearing area between pin and bushing, the ma-
terial and surface condition of the bearing surfaces, the
adequacy of lubrication, and the frequency and degree of
articulation between pins and bushings. The latter is de-
termined by the quantity of sprockets in the drive, their
speeds, the number of teeth and the length of the chain
in pitches.
An accurate wear measurement (1) can be made by us-
ing the above illustration. Measure as closely as possible
from the center of one pin to the center of another. The
more pitches (pins) contained within the measurement in-
crease the accuracy. If the measured value exceeds the
nominal by more than the allowable percentage the chain
should be replaced. The maximum allowable wear elonga-
tion is approximately 3 % for most industrial applications,
based upon sprocket design. The allowable chain wear in
percent can be calculated using the relationship: 200/ (N),
where (N) is the number of teeth in the large sprocket. This
relationship is often useful since the normal maximum al-
lowable chain wear elongation of 3 % is valid only up to
67 teeth in the large sprocket. In drives having fixed center
distances, chains running in parallel or where smoother op- 96091469 2
eration is required, wear should be limited to approximately
1.5 %.
For example, if 12 pitches (12 pins) of a #80 chain were
measured and the result was 313.944 mm (12.360 in) or
greater (using 3 % as the maximum allowable wear), the
chain should be replaced. Anything less than 313.944 mm
(12.360 in) would still be acceptable by most industrial
standards.
47540694 28/04/2014
27.1 [27.650] / 15
Index

Axle - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Axle - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chain drive - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chain drive - Measure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
47540694 28/04/2014
27.1 [27.650] / 16
47540694 28/04/2014
27.1 [27.650] / 17
PRINTED IN U.S.A.
47540694 28/04/2014
EN
SERVICE MANUAL
Hydrostatic drive
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
29
Contents
Hydrostatic drive - 29
[29.202] Hydrostatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1
[29.134] Two-speed assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2
[29.200] Mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.3
[29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.4
47540694 28/04/2014
29
Hydrostatic transmission - 202
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
29.1 [29.202] / 1
Contents
FUNCTIONAL DATA
Hydrostatic transmission
47540694 28/04/2014
29.1 [29.202] / 2
Hydrostatic drive - Hydrostatic transmission
Hydrostatic transmission - Dynamic description

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
In a closed loop, hydrostatic transmission, the engine provides power to a tandem, hydrostatic pump assembly that
sends hydraulic oil to the drive motors. Each hydrostatic pump drives a corresponding drive motor. The drive motor
turns a pair of chains by use of a dual sprocket, and the two chains turn the front and rear axles. In a hydrostatic,
closed loop system, the hydrostatic pump and the drive motor are directly connected; the hydrostatic pump sends oil
to the drive motor and the drive motor returns the oil back to the hydrostatic pump.
RAPH14SSL0013AA 1
Basic, hydrostatic, closed loop system
Hydrostatic system components

(1) Hydrostatic pump (3) Drive motor (5) Check valve
(2) Charge relief valve (4) Main relief valve (6) Charge pump
Because of the high pressures required to move the machine, some of the oil in the hydrostatic, closed loop system
leaks into the case drain and flushing valve of the components. This lost oil must be resupplied to keep the closed
loop system working as designed. A charge pump (6) is used to supply this lost oil. Located on the hydrostatic pump
assembly (1), the charge pump (6) supplies cooled, filtered oil from the reservoir to the closed loop system.
When the machine is traveling, the drive side of the closed loop has pressures too high to allow flow from the charge
pump (6), but the return side of the closed loop has pressures similar to the charge pump’s pressure. The return side
of the closed loop is where fresh, charge pump oil will enter into the closed loop from the charge pump (6). Charge
pump oil also enters the closed loop when the machine is in neutral, because pressure inside the closed loop while in
neutral is less-than-or-equal-to the charge pump’s pressure. To prevent closed loop oil from escaping back into the
charge side of the system, a check valve (5) is placed between the supply of charge pump oil and each side of the
closed loop.
While the machine is traveling, the load on the drive motor (3) can increase which causes the pressure in the closed
loop to become excessive. A main relief valve (4) is installed on each side of the closed loop to limit the maximum
pressure. These main relief valves (4) are nonadjustable and operate in only one direction.
47540694 28/04/2014
29.1 [29.202] / 3
Index

Hydrostatic transmission - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
29.1 [29.202] / 4
Two-speed assembly - 134
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
29.2 [29.134] / 1
Contents
TECHNICAL DATA
Control valve
General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Control valve
Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
47540694 28/04/2014
29.2 [29.134] / 2
Hydrostatic drive - Two-speed assembly
Control valve - General specification

L225 NA Mechanical hydraulic controls
RAPH13SSL0967EA 1
Brake, two speed valve
Hydraulic requirements: Charge pressure = 24 - 25.5 bar (350 - 370 psi)

Brake release pressure = 15 bar (218 psi)
Sequence valve setting 12 bar (174 psi)
Filter rating 40 – 50 microns
Port identification P - Supply inlet
T - Tank return
2SPD - Two speed shift
B1 - Brake motor 1
B2 - Brake motor 2
PS2 - Brake pressure switch

L225 NA Electro hydraulic controls
47540694 28/04/2014
29.2 [29.134] / 3
RAPH14SSL0006FA 1
Loader pilot interlock, brake, two speed valve
Hydraulic requirements Charge pressure = 24 - 25.5 bar (350 - 370 psi)

T - Tank return
B1 - Brake motor 1
B2 - Brake motor 2
LV - Electrohydraulic pilot pressure

C232 NA Mechanical hydraulic controls
47540694 28/04/2014
29.2 [29.134] / 4
RAPH14SSL0011FA 1

T - Tank return
B1 - Brake motor 1
B2 - Brake motor 2

C232 NA Electro hydraulic controls
47540694 28/04/2014
29.2 [29.134] / 5
RAPH12SSL0381EA 1

T - Tank return
B1 - Brake motor 1
B2 - Brake motor 2
47540694 28/04/2014
29.2 [29.134] / 6
Control valve - Component localisation

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
RAIL13SSL1004FA 1
Valve location
Valve identification
(1) Ride control valve (3) Loader pilot interlock, (5) Accumulator (7) Self level valve
brake, two speed valve
(2) Hydraulic coupler valve (4) Second auxiliary valve (6) High flow valve
47540694 28/04/2014
29.2 [29.134] / 7
Index

Control valve - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
29.2 [29.134] / 8
Mechanical control - 200
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
29.3 [29.200] / 1
Contents
SERVICE
Mechanical control
Adjust - Machines with only hand controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adjust - Machines with foot controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
47540694 28/04/2014
29.3 [29.200] / 2
Hydrostatic drive - Mechanical control
Mechanical control - Adjust - Machines with only hand controls

NOTE: Inspect the linkage and linkage components for wear and damage before performing the following steps.
Replace all worn and/or damaged parts.
1. Loosen the bolts (1) that attach the self centering damp-
eners
2. Loosen the jam nuts (3), (4). Rotate the rod (2) until the
handles are in the correct position of 75 ° (see image
2), then tighten the jam nuts (2), (3).
3. Tighten the bolts (1) that attach the self centering
dampeners.
4. Repeat for other pump.
23112921 1
23112922 2
Adjust the stop bolts

NOTE: The following images may or may not represent your exact machine configuration. This procedure is the same
for all mechanically operated machines in any configuration.
47540694 28/04/2014
29.3 [29.200] / 3
5. Turn the stop bolt (1) out several turns.

6. Push the handle (2) forward until the pump is fully
stroked. Hold the handle in this position and turn stop
bolt in until it touches the casting.
7. Repeat steps 5 and 6 for the other side
23112915 3
23112916 4
8. Lower the machine by remove the lifting equipment

from the machine. Lower the Roller Over Protection
Structure (ROPS). Start the machine, and test drive.
Record the drift
NOTE: The machine should not steer in either direction
more than 1.8 m (6 ft) from the centerline after traveling
30.5 m (100 ft) forward or 15.2 m (50 ft) backward.
9. To make the machine travel in a straight line at full lever
travel, adjust the stop bolts.
NOTE: The stop bolt should touch the casting when the pump is at full stroke.
47540694 28/04/2014
29.3 [29.200] / 4
Mechanical control - Adjust - Machines with foot controls

NOTE: Inspect the linkage and linkage components for wear and damage before performing the following steps.
Replace all worn and/or damaged parts.
1. Remove the tag along the springs (1) (both sides).
23112920 1
2. Loosen the jam nuts (2), (3). Rotate the control rods
(6) until the handles are in the correct position of 75 °
(see image 3), then tighten the jam nuts (2), (3).
23112919A 2
23112922 3
47540694 28/04/2014
29.3 [29.200] / 5
3. Loosen the roller (4) and position the roller (4) in the
center of the cam (5). Tighten the roller (4).
4. Reinstall the tag along springs that was removed in step
1.
5. Repeat steps 2, 3 for the other pump.
23112920 4
Adjust the stop bolts

NOTE: The following images may or may not represent your exact machine configuration. This procedure is the same
for all mechanically operated machines in any configuration.
6. Turn the stop bolt (1) out several turns.
7. Push the handle (2) forward until the pump is fully
stroked. Hold the handle in this position and turn stop
bolt in until it touches the casting.
8. Repeat steps 6 and 7 for the other side
23112915 5
23112916 6
9. Lower the machine by remove the lifting equipment

from the machine. Lower the Roller Over Protection
Structure (ROPS). Start the machine, and test drive.
Record the drift
NOTE: The machine should not steer in either direction
more than 1.8 m (6 ft) from the centerline after traveling
30.5 m (100 ft) forward or 15.2 m (50 ft) backward.
10. To make the machine travel in a straight line at full
lever travel, adjust the stop bolts.
NOTE: The stop bolt should touch the casting when the pump is at full stroke.
47540694 28/04/2014
29.3 [29.200] / 6
Index

Mechanical control - Adjust - Machines with foot controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mechanical control - Adjust - Machines with only hand controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
29.3 [29.200] / 7
47540694 28/04/2014
29.3 [29.200] / 8
Pump and motor components - 218
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
29.4 [29.218] / 1
Contents
TECHNICAL DATA
Pump
Motor
General specification – Single speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General specification – Two-speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUNCTIONAL DATA
Pump
Motor
SERVICE
Pump and motor components

Pressure test – Charge pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure test – Main relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remove – Charge pressure relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install – Charge pressure relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Remove – Main relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install – Main relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Remove – Drive shaft seal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install – Drive shaft seal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Remove – Charge pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Install – Charge pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Pump
Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Measure – Piston travel (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
47540694 28/04/2014
29.4 [29.218] / 2
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Servo control
Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Motor
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Disassemble – Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Assemble – Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Disassemble – Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Assemble – Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
DIAGNOSTIC
Pump
Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
47540694 28/04/2014
29.4 [29.218] / 3
Hydrostatic drive - Pump and motor components
Pump - General specification

RAPH12SSL0359GA 1
Hydrostatic pump
Manufacturer Sauer-Danfoss
Pump displacement 46 cm³ (2.8 in³)
Charge pump displacement 22.9 cm³ (1.4 in³)
Charge pressure relief (2) at 1800 RPM 24 - 25 bar (350 - 370 psi)
Main relief (1) 360 - 378 bar (5220 - 5481 psi)
Charge pump flow at 1800 RPM 30 l (8 US gal)
Port identification A - Service line
B - Service line
T - Case drain
X1 - Control Pressure, before the orifice
R - Air bleed
Ma - Pressure gauge operating pressure A
Mb - Pressure Gauge Operating pressure B
G - Pressure for auxiliary circuit
G2 - Pressure for auxiliary circuit
S - Boost suction
Mg - Pressure gauge operating pressure G
Yst - Control pressure gauge
47540694 28/04/2014
29.4 [29.218] / 4
Pump - General specification

RAPH13SSL0964FA 1
Hydrostatic pump
Manufacturer Bosch Rexroth

Pump displacement 45 cm³ (3 in³)
Charge pump displacement 14.9 cm³ (0.9 in³)
Charge pressure relief (1) 24 - 26 bar (350 - 380 psi)
Main relief (2) 350 - 370 bar (5075 - 5365 psi)
Charge pump flow 40 l (10.5 US gal)
Port identification A - Service line
B - Service line
T - Case drain
X1 - Control pressure, before the orifice
R - Air bleed
Ma - Pressure gauge operating pressure A
Mb - Pressure gauge operating pressure B
G - Pressure for auxiliary circuit
G2 - Pressure for auxiliary circuit
S - Boost suction
Mg - Pressure gauge operating pressure G
Yst - Control pressure gauge
47540694 28/04/2014
29.4 [29.218] / 5
Motor - General specification – Single speed motor

L223 NA
L225 NA
L230 NA
RAPH14SSL0040FA 1
Motor
Manufacturer Bosch-Rexroth
Displacement 470 cm³ (29 in³)
Brake release pressure 11 - 15 bar (160 - 218 psi)
Flushing valve setting 19.0 - 21.0 bar (276 - 305 psi)
Port identification A - Main port
B - Main port
L - Case drain
Z - Brake release
Motor - General specification – Two-speed motor

L223 NA
L225 NA
L230 NA
RAPH14SSL0042FA 1
Motor
Manufacturer Bosch-Rexroth
Displacement 282 - 470 cm³ (17.2 - 28.7 in³) .
Brake release pressure 11 - 15 bar (160 - 218 psi)
Flushing valve setting 19.0 - 21.0 bar (276 - 305 psi)
47540694 28/04/2014
29.4 [29.218] / 6
Port identification A - Main port

B - Main port
L - Case drain
Z - Brake release
X - Two-speed port
Motor - General specification

C232 NA
C238 NA
RAPH14SSL0033EA 1
Motor
Manufacturer Bonfiglioli
Displacement 33.1 - 50.8 cm³ (2.0 - 3.1 in³)
Brake release pressure 13 bar (189 psi)
Fluid specification for the planetary gear case 1.3 L (1.4 US qt) of API GL-5 85W140 oil
Port identification 1 – Oil filling and draining plug
2 – Oil level plug
P1 – Service
P2 – Service
Ps – Two-speed control
Pp – Mechanical brake pilot
Dr – Drain
47540694 28/04/2014
29.4 [29.218] / 7
Pump - Dynamic description

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
The hydrostatic pump is an axial piston pump with the abil-

ity to vary the rate and the direction of the oil flow. The
change of flow is accomplished by changing the position
of the hydrostatic pump's swash plate (2). The angle of
the swash plate (2) causes the pistons (1) to stroke in and
out of the cylinder block bores as the swash plate (2) ro-
tates. Changing the angle of the swash plate (2) varies
the piston stroke and the amount of oil being pumped to
the drive motor. Tilting the swash plate (2) in the oppo-
site direction reverses the flow to the drive motor which
changes the direction of drive motor’s rotation.
RAIL14SSL0010BA 1
47540694 28/04/2014
29.4 [29.218] / 8
Motor - Dynamic description

L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
The drive motor is a radial piston motor. There are two

main parts within a radial piston motor: The rollers (A)
and the stationary cam ring (B). As displayed in image 1,
high pressure oil from the hydrostatic pump enters port 1
of the motor. This oil enters a cavity above the rollers. As
the cavities fill with oil, the rollers are forced to move down
the cam ring. The rollers are connected to an assembly,
and this roller assembly is attached to the output shaft, so
spinning the roller assembly spins the output shaft.
As the rollers travel up the cam ring, oil is sent back to the
hydrostatic pump though port 2. Changing the direction
of the oil being sent to the motor, i.e., sending oil to port
2 instead of port 1 changes the rotational direction of the
roller assembly, which changes the direction of the output
shaft.
RAPH14SSL0034BA 1
The radial piston motor is available in one-speed or two-

speed. Image 2 is an example of the two-speed function-
ality. In image 1, the high pressure oil from the hydrostatic
pump enters every roller, giving that motor a low speed
and maximum torque. In image 2, the high pressure oil
enters every other roller.
Because the hydrostatic pump sends the same amount
of oil to half of the rollers during two-speed travel, the
roller assembly spins twice as fast, but because half of
the rollers are receiving oil, the motor also has half of the
torque.
RAPH14SSL0035AA 2
47540694 28/04/2014
29.4 [29.218] / 9
Pump and motor components - Pressure test – Charge pump

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.
Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can
result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately.
W0358A
DANGER
Crushing hazard!
Always install the safety lock before working under the raised attachment.
Failure to comply will result in death or serious injury.
D0075A
Prior operation:
See Hydraulic systems - Depressurising (35.000) to depressurize the hydraulic system.
NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic
system.
NOTE: You will need two people to perform this test.
NOTE: An error code may appear on the Instrument Cluster during this test. When the unit is shut down and all
connections are returned to normal, the fault code will be stored as inactive. This fault can be cleared using the
Electronic Service Tool (EST).
1. Raise the machine off of the floor until the tires/tracks
are not touching. Support the machine with proper lift-
ing equipment.
NOTICE: This is a safety precaution if the parking brakes
fail to hold.
2. Disconnect and cap the brake lines and fittings.
NOTE: Image 1 may not match your machine. Please
see Parking brake control valve - General specifica-
tion (33.110) for specifications on the parking brake control
valve.
RAPH12SSL0392AA 1
47540694 28/04/2014
29.4 [29.218] / 10
3. Connect a 41 bar (600 psi) pressure gauge to the test

port for charge pressure, or connect a T-fitting (1) to
an outlet hose of the charge pump and attach a 41 bar
(600 psi) pressure gauge to the T-fitting. Please see
the table below for recommended testing areas or see
Pump - General specification (29.218) for specifica-
tions about the pumps.
Recommended testing areas for charge pressure

Models (mechanically controlled): L213, L215, L216,
218, L220, L221
RAPH12SSL0420AA 2
Models (mechanically controlled): L223, L225, L230,
C227, C232, C238
RAPH12SSL0421AA 3
Models (electrohydraulically controlled): L213, L215,
L216, L218, L220, L221, L223, L225, L230, C227, C232,
C238
RAPH12SSL0424AA 4
47540694 28/04/2014
29.4 [29.218] / 11
4. Start the machine and run at high idle. Read the pres-
sure gauge and record the charge pressure reading.
Stop the engine.
NOTE: Image 5 is an example of a pressure reading. Im-
age 5 may not match your reading.
5. The pressure reading must be a minimum of 24 bar
(350 psi). If the pressure reading does not meet the
specifications, repair/replace the relief valve for the
charge pressure. Please see Pump - General spec-
ification (29.218) for general specifications about the
hydrostatic pumps.
RAPH12SSL0422AA 5
47540694 28/04/2014
29.4 [29.218] / 12
Pump and motor components - Pressure test – Main relief valve

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
W0358A
DANGER
Crushing hazard!
D0075A
Prior operation:
system.
NOTE: An error code may appear on the instrument cluster during this test. When the unit is shut down and all
1. Raise the machine off of the floor until the tires/tracks
are not touching. Support the machine with proper lift-
ing equipment.
fail to hold.
2. Connect a 690 bar (10000 psi) pressure gauge to the
test port of the circuit you wish to test. Please see
the chart below for port identification, or see Pump -
General specification (29.218) for specifications on
the hydrostatic pumps.
NOTE: Not all pressure test ports on the hydrostatic pump
assembly are easily accessible. Remember, you can test
all four main relief valves by plugging a pressure gauge
into the most available main relief, pressure test port and
exchanging main relief valves.
47540694 28/04/2014
29.4 [29.218] / 13
Test port identification for the main relief valves

Mechanical controls
Models: L213, L215, L216, L218, L220, L221
Pressure port M3 (1) for port C
Pressure port M2 (2) for port B
NOTE: Port M2 located under the pump assembly.
Pressure port M4 (3) for port D
Pressure port M1 (4) for port A
RAPH12SSL0357HA 1
Mechanical controls
Models: L223, L225, L230, C227, C232, C238
Pressure port (1) for port C
Pressure port (2) for port D
Pressure port (3) for port A
Pressure port (4) for port B
RAPH12SSL0359GA 2
Electro Hydraulic (EH) controls
Models: All models
Pressure port MB (1) for port B
Pressure port MB (1) for port B
Pressure port MA (2) for port A
Pressure port MA (2) for port A
NOTE: Ports MA located under the pump assembly.
RAPH12SSL0358GA 3

valve.
RAPH12SSL0392AA 4
47540694 28/04/2014
29.4 [29.218] / 14
4. Start the machine and adjust the throttle to high idle.

NOTE: If equipped with two speed drive motors, press and
hold the two speed button.
5. Slowly move the correct control lever for the corre-
sponding hydrostatic pump in the correct position.
6. Watch the pressure gauge until the pressure stops in-
creasing. When the pressure gauge stops increasing,
record the value on the pressure gauge and move the
control lever to neutral.
NOTE: To prevent overheating, do not pressurize the sys-
tem for an extended period of time.
RAPH12SSL0407AA 5
7. Refer to Pump - General specification (29.218) for

specifications on the hydrostatic pumps. If the pressure
is not correct, repair or replace the main relief valve.
8. Retest the circuit after repair.
47540694 28/04/2014
29.4 [29.218] / 15
Pump and motor components - Remove – Charge pressure relief

valve
WARNING
W0358A
DANGER
Crushing hazard!
D0075A
Prior operation:
To depressurize the system, refer to Hydraulic systems - Depressurising (35.000).
NOTICE: The pictures below may vary from the pump you are working on. The removal procedure is the same.
1. Locate the low pressure relief valve (1).
20115485 1
2. Remove the low pressure relief valve (1).
20115786 2
47540694 28/04/2014
29.4 [29.218] / 16
3. Remove the spring collar (1).
83115530 3
4. Remove the pressure spring (1).
83115531 4
47540694 28/04/2014
29.4 [29.218] / 17
Pump and motor components - Install – Charge pressure relief valve

NOTICE: The pictures below may vary from the pump you are working on. The install procedure is the same.
1. Place the collar (1) and pressure spring (2) onto the low
pressure relief valve.
20115786 1
47540694 28/04/2014
29.4 [29.218] / 18
Pump and motor components - Remove – Main relief valve

WARNING
W0358A
DANGER
Crushing hazard!
D0075A
Prior operation:
To depressurize the system, refer to Hydraulic systems - Depressurising (35.000).
1. Locate the high pressure relief valve(s) (1).
20115485 1
47540694 28/04/2014
29.4 [29.218] / 19
2. Remove the high pressure relief valve(s) (1).
20115785 2
47540694 28/04/2014
29.4 [29.218] / 20
Pump and motor components - Install – Main relief valve

1. Lubricate the threads (1) and support surface (2).
20115785 1
2. Thread the high pressure relief valve(s) (1) into the

pump housing. Torque to 250 N·m (184.4 lb ft).
20115485 2
47540694 28/04/2014
29.4 [29.218] / 21
Pump and motor components - Remove – Drive shaft seal

NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts.
1. Locate the drive shaft seal (1).
20115485 1
2. Remove snap ring (1).
20115783 2
3. Screw in self tapping screw(s) (1) into the holes (2)

fitted with rubber. Pull out shaft seal with pliers.
20115784 3
47540694 28/04/2014
29.4 [29.218] / 22
Pump and motor components - Install – Drive shaft seal

NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts.
1. Lubricate the lip of the seal (1) with clean oil.
20115827 1
2. Carefully press the new seal, with the lip down, into the
cover.
NOTE: Be careful not to press the seal too far.
83115476 2
3. Insert the snap ring (1).
20115783 3
47540694 28/04/2014
29.4 [29.218] / 23
Pump and motor components - Remove – Charge pump

Prior operation:
To remove the hydrostatic pump, refer to Pump - Remove (29.218).
NOTE: Some of the pictures in the following procedure may vary from the pump you are repairing. The procedure is
the same.
1. Remove the mounting flange bolts (1).
83115502 1
2. Remove the flange (1).
83115503 2
3. Apply reference mark (1) on pump housing and charge

pump housing.
83115510 3
47540694 28/04/2014
29.4 [29.218] / 24
4. Remove the charge pump housing (1).
83115511 4
5. Remove o-ring (1) from charge pump housing.
83115512 5
6. Remove the outer gear (1).
83115513 6
7. Remove the inner gear (1).
83115514 7
47540694 28/04/2014
29.4 [29.218] / 25
8. Remove the coupler (1).
83115515 8
9. Apply reference mark (1) on wear plate.
83115516 9
10. Remove the wear plate (1).
83115517 10
47540694 28/04/2014
29.4 [29.218] / 26
Pump and motor components - Install – Charge pump

NOTE: Some of the pictures in the following procedure may vary from the pump you are repairing. The procedure is
the same.
1. Install the wear plate (1).
83115517 1
2. Check that the locating pin (1) and channels (2) are
correct (direction of rotation Clockwise looking on the
drive shaft).
20115828 2
3. Install the coupler (1).
83115515 3
47540694 28/04/2014
29.4 [29.218] / 27
4. Install the inner gear (1) with the chamfered side of

the gear facing the outside (facing away from the wear
plate). Align the shaft key on the coupling (2) with the
notch (3) on the inner gear.
83115514 4
5. Install the outer gear (1) with chamfered side facing

outward.
83115513 5
6. Replace the o-ring (1) on charge pump housing.
83115512 6
7. Install charge pump housing (1) using reference mark

from removal procedure.
83115510 7
47540694 28/04/2014
29.4 [29.218] / 28
8. Install the flange (1).
83115503 8
9. Install and tighten the mounting flange bolts (1).
83115502 9
47540694 28/04/2014
29.4 [29.218] / 29
Pump - Test
WARNING
W0358A
DANGER
Crushing hazard!
D0075A
Prior operation:
Checking the charge pressure

system.
NOTE: An error code may appear on the Instrument Cluster during this test. When the unit is shut down and all
1. Raise the machine off of the floor until the tires are
not touching. Support the machine with proper lifting
equipment.
fail to hold.
valve.
RAPH12SSL0392AA 1
47540694 28/04/2014
29.4 [29.218] / 30
3. Install a T-fitting (1) at the charge pump outlet.

4. Disconnect and cap the servo inlet line.
5. Connect a hose with a 41 bar (600 psi) pressure gauge
(2) from the T-fitting outlet (1) to the servo inlet (3).
RAPH12SSL0423AA 2
6. Start the machine and run at high idle.

NOTE: If equipped with two-speed drive motors, press and
hold the two-speed button.
7. Record the charge pressure with the control levers in
the neutral position on the data collection sheet located
on the following page.
8. Gently move one control lever in the forward position.
Watch for the pressure drop on the pressure gauge.
Record the pressure drop on the data collection sheet
located on the following page. Return the control lever
to the neutral position.
NOTE: Always maintain the engine RPM for this test. Do
not move the control levers to a point where a load is put
on the engine. A load on the engine will lower the engine
speed and create a difference in pump flow. A difference
RAPH12SSL0422AA 3
in pump flow will effect your readings and the accuracy of
this test.
9. Gently move the same control lever in the reverse po-
sition. Watch for the pressure drop on the pressure
gauge. Record the pressure drop on the data collec-
tion sheet located on the following page. Return the
control lever to the neutral position.
10. Repeat steps 8 and 9 on the other pump and control
lever.
Results
Review the recorded results on the data collection sheet
located on the following page. With the engine speed set
and maintained at a high idle, the maximum pressure drop
between the system in neutral and the system in forward
or reverse must be 2.1 bar (30 psi) or less. Any pressure
drop greater than 2.1 bar (30 psi) could indicate an exces-
sive leak in the hydrostatic system, which will require more
diagnosis of the hydrostatic system.
47540694 28/04/2014
29.4 [29.218] / 31
Data collection sheet
Front pump bar (psi) Neutral ___________
Forward __________
Reverse __________
Rear pump bar (psi) Neutral ___________
Forward __________
Reverse __________
Notes:
47540694 28/04/2014
29.4 [29.218] / 32
Pump - Cleaning
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
The hydrostatic system is a closed loop made up of the charging pump, piston pump, drive motors and the hoses
between these components. The hydraulic cooler and reservoir are also part of the closed loop system. Any con-
tamination in the hydrostatic system will stay in the closed loop, and probably cause damage. If the piston pump or a
motor in the hydrostatic system is removed for repair or replacement, you must clean the hydrostatic system. If any
contamination is left in the closed loop, the contamination will damage the remaining components of the hydrostatic
system.
1. Remove the piston pumps and at least the motor in the

circuit that failed. If there is a quantity of contamination
present, removal of the opposite pump and motor is
also required.
2. Disassemble, clean, and inspect the piston pumps and
motor(s).
3. Clean all hoses and tubes in the hydrostatic system.
Remove each hose and tube from the machine. Flush
and clean the hoses and tubes with hot soapy water.
Hang and allow them to air dry. Hoses and tubes must
be dry before installing.
4. Install, inspected and repaired, or new piston pumps
and motors.
5. Change the hydraulic filter.
6. Make sure that the hydraulic system is clean so that the
charge pump will not cause new contamination in the
closed loop. Remember that the oil cooler may have
internal passages that can trap and hold contamination
that can be dislodged later and cause a repeat failure.
NOTE: THE FOLLOWING PROCEDURE SHOULD BE
USED FOR CLEANING HOSES, TUBES, AND FITTINGS.
It is recommended that hoses, tubes and fittings be cleaned
with a steam cleaner and dried with compressed air.
7. Fasten the parts to a rack in a position as near to ver-
tical as possible. This will allow water to drain as you
flush parts.
8. Clean the exterior surfaces of the parts thoroughly.
9. Clean the interior surfaces of the parts. Use hot water
and soap first. Then use clean hot water to rinse.
NOTE: If the steam cleaner does not have a soap injection
system, spray an oil solvent into the parts. This will dissolve
the oil film that holds contaminants inside the parts. Then
use clean hot water to rinse.
10. Fasten the parts in the rack so that the parts can be
flushed from opposite ends. Repeat steps 8 an 9.
11. Use compressed air to dry the inside of each part. Dry
the parts from both ends to make sure all of the water
is removed.
47540694 28/04/2014
29.4 [29.218] / 33
12. Install caps or plugs in the ends of each hose, tube or

fitting as soon as the parts are dry. This will prevent
entry of contaminants. Remove the caps or plugs from
the part only when the part is in position in the machine
and you are ready to make the connection.
47540694 28/04/2014
29.4 [29.218] / 34
Pump - Visual inspection

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Inspect the face of the cylinder block for wear, scoring,

and other damage. Use a new cylinder assembly as
necessary.
2. Inspect the cylinder bores for wear, scoring, and other
damage. Use new cylinder assembly as necessary.
3. Inspect the bronze surface of the wear plate. Use a
new wear plate as necessary.
4. Inspect the parts of the charging pump for wear and
damage. Use a new pump as necessary.
5. Inspect the pistons for wear and damage, use new
parts as necessary.
6. Inspect the shaft for damage to the splines and wear at
the seal surfaces.
7. Inspect the bearings. Replace any damaged bearings.
8. Inspect the circular relief valve seats in the housings.
47540694 28/04/2014
29.4 [29.218] / 35
Pump - Measure – Piston travel

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
NOTE: This procedure is for all M46 Sauer Danfoss hydrostatic pumps.
1. Measure the free travel between the shoes and the pis-
tons. If all the measurements are not equal to within
0.13 mm ( 0.005 in), use a new cylinder assembly.
83115462 1
2. Measure the thickness of each shoe. If the measure-

ments are not equal to within 0.02 mm ( 0.0001 in), use
a new cylinder assembly.
83115463 2
3. Check the fit of the pistons in the bores. The piston

must move freely with minimum clearance. Use a new
cylinder assembly as necessary.
4. Measure the gear tip clearance between the inner gear
and the outer gear. Clearance must not be more than
0.13 mm ( 0.005 in).
5. Measure the width of the inner gear and the outer gear.
The width of each gear must be equal to within 0.05 -
0.06 mm ( 0.002 - 0.003 in).
47540694 28/04/2014
29.4 [29.218] / 36
Pump - Disassemble
Some types of failures will require the disassembly of the tandem pump for cleaning and inspection. If there is failure
in the drive motors or tandem pump, disassemble both the rear and front pumps, the drive motors, and all hoses
between the pumps and drive motors.
1. Remove the bolts that fasten the pumps together.
83111565 1
2. Remove the nut and bracket from the stud.
83111566 2
3. Separate the pumps (1).
83111567 3
47540694 28/04/2014
29.4 [29.218] / 37
4. Remove the two O-rings (1) and back-up ring (2).
83111568 4
5. Remove the charge pump cover. Note the position of

the charge pump cover pin (1) for use during assembly.
83111569 5
6. Remove the coupling from the inner gear.
83111570 6
7. Remove the inner gear from the outer gear.
83111571 7
47540694 28/04/2014
29.4 [29.218] / 38
8. Remove the outer gear from the charge pump cover.
83111572 8
9. Remove the bolt stud.
83111573 9
10. Remove the special bolts from the cover.
83111574 10
11. Remove the cover, the gasket, and the shaft assem-
bly.
83111575 11
47540694 28/04/2014
29.4 [29.218] / 39
12. Remove the swash plate.
83111576 12
13. Remove the retainer and the pistons.
83111577 13
14. Remove the guide.
83111578 14
15. Remove the cylinder block.

NOTE: Do not disassemble the cylinder block.
83111579 15
47540694 28/04/2014
29.4 [29.218] / 40
16. Do not lose the three pins (1) that are inserted into the
cylinder block. They must stay in position.
83111580 16
17. Remove the wear plate.
83111581 17
18. Remove the gasket.
83111582 18
19. Remove the snap ring from the seal.
83111583 19
47540694 28/04/2014
29.4 [29.218] / 41
20. Fasten the cover in a vise with soft jaws. Use a prybar
to remove the seal.
83111584 20
21. Remove the snap ring from the groove, just above the
ball bearing.
83111585 21
22. Push the shaft out of the cover. Inspect the bearing
on the shaft. Replace if necessary.
83111586 22
23. Inspect the bearings (1) on the cover. If the tan sur-
face has worn through to the dark base, use new bear-
ings.
83111587 23
47540694 28/04/2014
29.4 [29.218] / 42
24. Remove the screws from the cover.
83111588 24
25. Pull out the piston assembly from the housing.
83111589 25
26. Remove and discard the gasket.
83111590 26
27. Fasten the piston assembly in a vise with soft jaws.

Hold the special bolt in place. Remove the special
nut. Ensure that the special bolt does not turn while
removing the special nut.
83111591 27
47540694 28/04/2014
29.4 [29.218] / 43
28. Measure the distance between the top of the special

bolt and the cover. Record that measurement.
83111592 28
29. Thread the cover counterclockwise until it is removed

from the special bolt.
30. Fasten the piston in a vise with soft jaws. Hold the
adjusting nut in place. Loosen the jam nut.
83111593 29
31. Hold the special bolt in place. Tighten the adjusting

nut to push the outer spring guide down, and away
from the retaining ring.
83111594 30
32. Remove the retaining ring.

NOTE: The retaining ring will be difficult to remove.
83111595 31
47540694 28/04/2014
29.4 [29.218] / 44
33. Hold onto the end of the special bolt and pull out the
spring assembly.
83111596 32
34. Thread the jam nut (1) and the adjusting nut (2) coun-
terclockwise until they are removed from the special
bolt. Separate the outer spring guide (3), spring (4),
sleeve, and inner spring guide (5) from the special
bolt.
83111597 33
35. Remove the piston from the housing. Remove and

discard the O-rings, and the piston rings from each
end of the piston (1).
83111598 34
36. Remove the screws from the cover.
83111599 35
47540694 28/04/2014
29.4 [29.218] / 45
37. Remove the cover and discard the gasket.
83111600 36
38. Go to the spool assembly. Mark the position of where

the stop bracket is bolted. Repeat for the other side.
83111601 37
39. Remove the bolts and the spool assembly from the
housing.
83111602 38
40. Remove the sleeve from the housing.
83111603A 39
47540694 28/04/2014
29.4 [29.218] / 46
41. Remove the lock nut and washer from the spool.
83111604 40
42. Remove and discard the backup ring (1) and O-ring
(2) from the spool.
83111605 41
43. Remove and discard the backup ring (1) and O-ring
(2) from the sleeve.
83111606 42
44. Remove the hex plug and shims for the charge pres-
sure relief valve.
83111607 43
47540694 28/04/2014
29.4 [29.218] / 47
45. Remove the shims from the hex plug. Save the shims
for later use.
83111608 44
46. Remove the spring.
83111609 45
47. Remove the valve poppet with a slide hammer.
83111610 46
48. Mark the hex plug that is used for the circuit relief-
check valve.
83111611 47
47540694 28/04/2014
29.4 [29.218] / 48
49. Remove the hex plug.
83445485 48
83111612A 49
51. Remove the circuit relief-check valve.
83111613A 50
52. Loosen the bypass valve.
83111614B 51
47540694 28/04/2014
29.4 [29.218] / 49
53. Thread the bypass valve counterclockwise until it is

removed.
83111615C 52
54. Remove and discard the O-ring (1) and backup ring
(2).
83115460 53
55. Remove the plug.
83115461 54
47540694 28/04/2014
29.4 [29.218] / 50
Pump - Assemble
NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing.
The procedure is the same.
1. Install the plug. Tighten the plug to a torque of 0.9 -
1.3 Nm (8 - 12 lb in).
83115461Z 1
2. Slide a new backup ring (2) and O-ring (1) into the
grooves of the bypass valve.
83115460Z 2
3. Thread the bypass valve into the housing.
83111615L 3
47540694 28/04/2014
29.4 [29.218] / 51
4. Tighten the bypass valve to a torque of 9 - 13 Nm (84

- 120 lb in)
83111614Q 4
5. Thread the circuit relief-check valve into the housing.
83111613H 5
6. Insert the spring on top of the circuit relief-check valve.
83111612T 6
7. Thread the plug on top of the spring. Tighten the plug

to a torque of 115 - 230 Nm ( 85 - 170 lb ft).
83445485V 7
47540694 28/04/2014
29.4 [29.218] / 52
8. Use a slide hammer to insert the valve poppet into the

housing for the charge pressure relief valve.
83111610T 8
9. Insert the spring on top of the valve poppet.
83111609S 9
10. Insert the necessary quantity of shims into the hex

plug. Thread the hex plug on top of the spring. Tighten
but do not overtighten.
83111607- 10
11. Slide a new O-ring (2) and backup ring (1) into the
grooves of the sleeve.
83111606H 11
47540694 28/04/2014
29.4 [29.218] / 53
12. Slide a new O-ring (2) and backup ring (1) into the
grooves of the spool.
83111605S 12
13. Insert the spool into and through the stop bracket.
83115464G 13
14. Slide the washer and nut onto the protruding threads
of the spool. Hold the spool assembly in place.
Tighten the nut, but do not overtighten.
83111604P 14
15. Lubricate the sleeve. Insert the sleeve into the hous-
ing. Ensure that the notch on the end of the sleeve is
properly aligned with the notch inside housing.
83111603PNA55 15
47540694 28/04/2014
29.4 [29.218] / 54
16. Lubricate the spool. Insert the spool inside the sleeve.
83115465H0 16
17. Ensure the marks are in alignment. Secure the spool

assembly with two bolts.
83111602AS 17
18. Place the new gasket and cover onto the rim of the
housing.
83111600HJ 18
19. Secure the cover with screws.
83111599FUG 19
47540694 28/04/2014
29.4 [29.218] / 55
20. Slide the inner spring guide (5), sleeve, spring (4),
outer spring guide (3), the adjusting nut (2), and the
jam nut (1) onto the special bolt.
83111597I 20
21. Hold the bolt assembly in place. Tighten the adjusting

nut to begin compression of the spring.
83115466GH 21
22. Insert one new ring (2) and one O-ring (1) into the
grooves on each end of the piston.
83111598P 22
23. Fasten the piston in a vise with soft jaws. Hold onto
the end of the of the special bolt to insert the spring
assembly into the piston.
83111596RQWE 23
47540694 28/04/2014
29.4 [29.218] / 56
24. Hold the special bolt in place. Tighten the adjusting

nut until the outer spring guide is below the groove.
This will allow space for the retaining ring.
83111594FHJ 24
25. Install the retaining ring onto the spring assembly.
83115467DB 25
26. Slightly loosen the special bolt. Ensure that the spring
and adjusting nut do not become loose.
83111594G 26
27. Hold the adjusting nut and special bolt in place.

Tighten the jam nut. Recheck the special bolt and
spring. Verify that the spring did not become loose.
83115468KIJ 27
47540694 28/04/2014
29.4 [29.218] / 57
28. Lubricate the piston with clean oil. Slide the piston into
the housing.
83115469HY 28
29. Slide a new gasket and cover onto the special bolt.
83115470TRY 29
30. During disassembly, the measured distance between

the top of the special bolt and cover. Thread the cover
up or down the special bolt until the distance is equal
to that recorded measurement.
83115471GH 30
31. Secure the cover with four screws. Tighten the screws
to the torque of 11 - 15 Nm ( 96 - 132 lb in).
83111588SD 31
47540694 28/04/2014
29.4 [29.218] / 58
32. Hold the special bolt in place. Slide the special nut
(with the sealing surface side down) onto the special
bolt. Tighten the special nut, but do not overtighten.
83115472DFH 32
33. During disassembly, the bearings on the cover were

inspected. If one of the bearings need to be replaced,
align and insert the cover roll pin into the hole of the
bearing. This will ensure proper placement.
NOTE: If a new cover is being used, install new roll pins so
the distance between the tops of the roll pins and the face
cover are 2.3 - 2.8 mm ( 0.090 - 0.110 in).
83115473MIO 33
34. During disassembly, the ball bearing for the shaft was
inspected. If the ball bearing for the shaft has been
replaced, install one snap ring on each side of the ball
bearing.
83115474KO 34
35. Fasten the cover in a vice with soft jaws. Firmly press
the ball bearing and the shaft into the cover.
83115475DR 35
47540694 28/04/2014
29.4 [29.218] / 59
36. Install the snap ring into the groove, just above the ball
bearing.
83111585DFDFHFH 36
37. Lubricate the lip of the seal with clean oil. Carefully
press the new seal with the lip down, into the cover.
83115476ASDFG 37
38. Install the snap ring into the seal.
83111583F 38
39. Lubricate the wear plate with clean oil. Align the notch
on the wear plate with the roll pin that is located inside
the cylinder port. Insert the wear plate with the bronze
surface side up, into the cylinder port.
83111581DFF 39
47540694 28/04/2014
29.4 [29.218] / 60
40. Ensure that the three pins are still inserted in the cylin-
der block.
83111580DFFG 40
41. Hook the retaining collar and slide it up the splines

until it reaches the top.
83115477WEED 41
42. Insert the cylinder block into the pump.
83111579CVBNJ 42
43. Align and install the guide on top of the pins.
83115480SDF 43
47540694 28/04/2014
29.4 [29.218] / 61
44. Slide the retainer on top the guide. Ensure that the
holes of the retainer are properly aligned with the
holes of the cylinder block
83115479ASD 44
45. Lubricate the pistons with clean oil. Insert one pis-
ton into each aligned hole of the retainer and cylinder
block. Ensure that the guide is still properly positioned
on top of the three pins.
83115480SDF 45
46. If a new swash plate or pin is being used, go to the un-

derside of the swash plate. Insert the pin into the top,
center slot. Press down on the pin until the distance
between the top of the pin and the swash plate is 8.4
- 8.9 mm ( 0.33 - 0.35 in).
83115481X 46
47. Slide the guide (1) onto the pin located on the side of
the swash plate.
83115482MKP 47
47540694 28/04/2014
29.4 [29.218] / 62
48. Install the swash plate. The pin must engage the slot
in the body of the control valve. The retainer must
engage the groove in the piston.
83111576CV 48
49. Place a new gasket on the outside rim.
83115483FN 49
50. Carefully place the cover and the shaft assembly onto
the gasket. Rotate the shaft to align the support with
the cylinder block.
83115484I 50
51. Secure the cover with special bolts. Use the bolts to
evenly draw the cover to the housing. Tighten the
3/8 in special bolt to a torque of 53 - 64 Nm 39 - 47 lb
ft. Tighten the 7/16 in special bolts to a torque of 81 -
100 Nm ( 60 - 74 lb ft).
83111574WER 51
47540694 28/04/2014
29.4 [29.218] / 63
52. Insert the bolt stud into the housing.
83111573CFF 52
53. Slide the outer gear into the charge pump cover.
83111572HJU 53
54. Slide the inner gear into the outer gear.
83111571BL 54
55. Align the coupling pin with the inner gear slot. Slide
the coupling into the inner gear.
83111570DF 55
47540694 28/04/2014
29.4 [29.218] / 64
56. Lubricate the charge pump cover with clean oil. Align
the cover pin (1) with the hole found at the top of the
housing. Slide the cover onto the cylinder block and
into the housing.
83111569FTR 56
57. Install new O-rings and back-up ring.
83111568 57
58. Install bracket and nut. Connect the front and rear
pump together.
83111567 58
59. Torque the retaining nut to 102 N·m (75.2 lb ft)
83111566 59
47540694 28/04/2014
29.4 [29.218] / 65
60. Install the bolts that fasten the front and rear pumps
together. Torque the bolts to 91 - 111 Nm ( 67 - 82 lb
ft
83111565 60
47540694 28/04/2014
29.4 [29.218] / 66
Pump - Remove
WARNING
Heavy objects!
W0398A
Prior operation:
Tilt the ROPS
1. Label and disconnect control wires (1) on bottom of
pumps
931001961 1
NOTE: See Hydraulic systems - Depressurising (35.000) to depressurize the hydraulic system.
2. Label and disconnect the two front (1) and two rear (2)
pump control connections.
20111248 2
47540694 28/04/2014
29.4 [29.218] / 67
3. Label and disconnect the hydraulic oil temperature

sender (1).
931001963 3
4. Label and disconnect the right hand side hydraulic hose

(1).
931001964 4
5. Label and disconnect the oil supply hose (1) by loosen-

ing the hose clamp and cap ports.
931001965 5
6. Label and disconnect the top hydraulic tube (1) and cap
open ports.
931001966 6
47540694 28/04/2014
29.4 [29.218] / 68
7. Label and disconnect right hand side drive motor hoses

(1) and cap open ports.
931001970 7
8. Label and disconnect left hand side drive motor hoses

931001971 8
9. Label and disconnect hydraulic hose (1) and cap open

ports.
931001972 9
10. Label and disconnect case drain hose (1) and cap
open ports.
931001963 10
47540694 28/04/2014
29.4 [29.218] / 69
11. Label and disconnect gear pump supply hose (1) and
cap open ports.
931001955 11
12. Label and disconnect gear pump hydraulic tubes (1)

and cap open ports.
931001956 12
13. WARNING
Heavy objects!
Lift and handle all heavy components us-
ing lifting equipment with adequate capacity.
Always support units or parts with suitable
slings or hooks. Make sure the work area is
clear of all bystanders.
Failure to comply could result in death or seri-
ous injury.
W0398A
Place a lifting strap around the pump and using a hoist

support the pump, as shown.
931001974 13
14. Remove the two mounting bolts and washers (1) from
the pump.
931001928 14
47540694 28/04/2014
29.4 [29.218] / 70
15. Using the hoist, carefully remove pumps.
931001976 15
Next operation:
Pump - Install (29.218)
47540694 28/04/2014
29.4 [29.218] / 71
Pump - Install
WARNING
Heavy objects!
W0398A
Prior operation:
Inspect the O-ring on the hydrostatic pump, and replace if necessary.
Prior operation:
Lubricate the O-ring with clean hydraulic oil.
Prior operation:
Fill the hydrostatic pump with clean hydraulic oil.
Prior operation:
Apply NEW HOLLAND AMBRA GR 75 MD to the coupler.
1. Mount the coupler (1) to pump shaft with the supplier
logo facing out, toward the engine.
2. Align the coupler on the pump shaft. The distance (A)
should be 49 mm (1 29/32 in).
3. Torque the set screws to 25.7 - 28.3 N·m (19.0 - 20.9 lb
ft).
93111555A 1
4. Move the pump inward until the mounting flange is flush

with the mounting surface of the hydrostatic pump.
5. Apply LOCTITE® 243 to the pump mounting bolts (1).
Install washers on the bolts and install the bolts into
the pump mounting flange. Torque the mounting bolts
to 86 - 117 N·m (63.4 - 86.3 lb ft).
931001928 2
47540694 28/04/2014
29.4 [29.218] / 72
6. Connect gear pump hydraulic hoses (1) as shown.
931001956 3
7. Connect the gear pump supply hose (1), and tighten

the hose clamp.
931001955 4
8. Connect the case drain hose (1), and secure with the
clamp.
931001963 5
9. Connect the hydraulic hose (1), as shown.
931001972 6
47540694 28/04/2014
29.4 [29.218] / 73
10. Connect the hoses (1) for the left-hand side of the
drive motor.
931001971 7
11. Connect the hoses (1) for the right-hand side of the
drive motor.
931001970 8
12. Connect the top hydraulic hose (1).
931001966 9
13. Connect the oil supply hose (1), and tighten the hose
clamp.
931001965 10
47540694 28/04/2014
29.4 [29.218] / 74
14. Connect the hose (1) for the right-hand side.
931001964 11
15. Connect the hydraulic oil, temperature sender (1), and

secure with the nut.
931001963 12
16. Connect the electrical connectors (2) for the front (1)
and rear solenoids.
20111248 13
17. Connect the sensor wires (1) located on the bottom of

the pumps.
931001961 14
47540694 28/04/2014
29.4 [29.218] / 75
Servo control - Adjust

In order to correct a faulty hydrostatic drive, a systematic diagnostic procedure must be followed. Before attempting
any of the procedures below, determine if the hydrostatic pump is faulty by raising the machine off of the ground and
supporting the machine with a suitable lifting device, disconnecting the control linkage on the pump, releasing the
brakes, running the machine, and observing the wheel/track motion.
If you disconnect the linkage and the problem disappears, inspect the linkage and correct the problem. Please see
Mechanical control - Adjust (29.200) for linkage adjustment procedures.
If the machine travels with the linkage disconnected, please see the following steps:
Center the servo piston

1. Raise the machine off of the ground, and support the
machine with a suitable lifting device.
2. Disconnect and cap the servo inlet line (1).
NOTE: Disconnecting the servo inlet line will allow you to
adjust both hydrostatic pumps without receiving hydraulic
interference.
RAPH12SSL0449AA 1
3. Start the machine, and run at a high idle.

4. Release the brakes.
5. Locate the faulty pump.
6. Remove the jam nut (1).
NOTE: You do not need to remove the hydrostatic pumps
for the following procedures; The hydrostatic pumps have
been removed for picture clarity.
RAPH12SSL0439AA 2
47540694 28/04/2014
29.4 [29.218] / 76
7. Turn the servo adjustment screw in one direction until

the wheels/track begin to rotate. Record the position of
the adjustment screw.
NOTE: If the adjustment screw requires more than one, full
turn to begin tire/track movement, please see the steps in
the “Center the servo piston spring” section of this docu-
ment.
8. Turn the servo adjustment screw in the opposite direc-
tion until the wheels/track begin to rotate. Record the
position of the adjustment screw.
NOTE: If the adjustment screw requires more than one, full
turn to begin tire/track movement, please see the steps in
the “Center the servo piston spring” section of this docu-
ment.
RAPH12SSL0441AA 3
9. Repeat steps 7 and 8 to verify your records.

10. Center the servo adjustment screw based on your
records.
11. Install the jam nut.
12. Connect the servo inlet line.
13. Follow the steps in the “Center the servo control valve”
section of this document.
Center the servo control valve

1. Disconnect the linkage on the faulty hydrostatic pump.
2. Loosen the adjustment bracket bolts (1) on the servo
control of hydrostatic pump that is faulty.
RAPH12SSL0438AA 4
3. Adjust the bracket for the servo control until the wheels/
track begin to move. Mark this position.
4. Adjust the bracket for the servo control in the opposite
direction. When the wheels/track begin to move in the
opposite direction, mark this position.
5. Repeat steps 3 and 4 to verify your markings. Make
additional marks if necessary.
6. Center the adjustment bracket between your markings,
and tighten the adjustment bracket bolts.
7. Reinstall the linkage. You may need to adjust the
linkage. Please see Mechanical control - Adjust
(29.200) for linkage adjustment procedures.
47540694 28/04/2014
29.4 [29.218] / 77
8. Move the faulty hydrostatic pump’s control levers in

both directions. The servo control is properly adjusted
when an even amount of lever travel is required to be-
gin the rotation of the wheels/tracks in either direction.
Readjust the servo control and/or the linkage if neces-
sary.
9. Test drive the machine. If the machine steers in either
direction more than 1.8 m (6 ft) from the centerline af-
ter traveling 30.5 m (100 ft) forward or 15.2 m (50 ft)
backward, or if one or both of the pumps continue to
travel after the control levers have returned to neutral,
recheck the linkage. Please see Mechanical control -
Adjust (29.200) for linkage adjustment procedures.
Center the servo piston spring

If the adjustment screw requires more than one, full turn
to begin tire movement, or a pump has the tendency to
continue traveling in the direction that is was last going,
please see the following steps:
23111053 5
Exploded view of the piston spring assembly
47540694 28/04/2014
29.4 [29.218] / 78
1. Remove the jam nut (2).

2. Remove the bolts (1).
RAPH12SSL0439AA 6
3. Unscrew the servo piston cover (1).
RAPH12SSL0442AA 7
4. Check the nuts for looseness. Inspect the spring as-

sembly for damage and excessive movement. Adjust
the lock nut and nut if necessary.
NOTE: The nut (2) should be finger-tight against the spring
cup (1). If the nut (2) is too tight, you will find a gap between
the spring cup (1) and the retention ring (3). If the nut (2)
is loose, you will find a gap between the nut (2) and the
spring cup (1).
RAPH12SSL0440AA 8
5. Install the servo piston cover.

6. Install the bolts.
7. Install the jam nut.
8. Repeat the steps in the “Center the servo piston” sec-
tion of this document.
47540694 28/04/2014
29.4 [29.218] / 79
Servo control - Adjust

Travel adjustments for the Electro-Hydraulic (EH) pumps are less involved because the EH pumps do not have me-
chanical control linkage. Before attempting to adjust the pumps, verify that the problem is not with a drive motor. Also,
test the charge pressure and main relief pressure before proceeding. Please see Pump and motor components -
Pressure test (29.218) for test details. Please see Pump - General specification (29.218) and Motor - General
specification (29.218) for specifications about the hydrostatic pumps and drive motors.
If there are no problems with the drive motors and the charge pressure and main relief pressure are within specifica-
tions, please use the Electronic Service Tool (EST) to calibrate the joysticks and the ground drive.
If the machine continues to travel inappropriately after calibration, please see the following steps:
Center the piston

1. Raise the machine off of the ground, and support the
machine with a suitable lifting device.
2. Disconnect and cap the inlet line (1).
NOTE: Disconnecting the inlet line will allow you to adjust
both hydrostatic pumps without receiving hydraulic interfer-
ence.
931001814 1
3. Start the machine, and run at a high idle.

4. Release the brakes.
5. Observe the wheel/track movement. If the wheels/
tracks are not moving, please see the steps in the “Ad-
just the piston stops” section of this document.
6. If the wheels/tracks are moving, please continue with
step 7.
7. Loosen the jam nut (1) on the faulty pump.
NOTE: You do not need to remove the hydrostatic pumps
for the following procedures; The hydrostatic pumps have
been removed for picture clarity.
RAPH12SSL0443AA 2
47540694 28/04/2014
29.4 [29.218] / 80
8. Turn the adjustment screw (1) in one direction until the

wheels/track begin to rotate. Record the position of the
adjustment screw.
9. Turn the adjustment screw (1) in the opposite direction
until the wheels/track begin to rotate. Record the posi-
tion of the adjustment screw.
RAPH12SSL0443AA 3
10. Repeat steps 8 and 9 to verify your records.

11. Center the adjustment screw based on your records.
12. Tighten the jam nut.
13. Connect the inlet line.
14. Calibrate the joysticks and ground drive, using the
EST.
15. Test drive the machine. If the machine steers in either
direction more than 1.8 m (6 ft) from the centerline af-
ter traveling 30.5 m (100 ft) forward or 15.2 m (50 ft)
backward, please see the steps in the “Adjust the pis-
ton stops” section of this document.
Adjust the piston stops

If the machine steers in either direction more than 1.8 m
(6 ft) from the centerline after traveling 30.5 m (100 ft) for-
ward or 15.2 m (50 ft) backward, the piston stops (1) for
one of the hydrostatic pumps may be out of adjustment,
which is causing one pump to travel faster or slower than
the other pump.
RAPH12SSL0450AA 4
1. Test drive the machine. Observe which direction the

machine travels.
2. Shut off the machine.
47540694 28/04/2014
29.4 [29.218] / 81
3. To adjust the speed of the drive motor, you will need to

do the following:
• Determine which drive motor is traveling faster.
• Locate the hydrostatic pump associated with the
faster drive motor.
• Locate the two piston stop screws (2) on the faulty
pump.
NOTE: The piston stop screws may be covered. Re-
move the covers by gently tapping on the covers.
• Locate the forward and reverse solenoids on the
faulty pump.
• If the machine incorrectly travels forward, loosen the
jam nut (1) and adjust the piston stop screw (2) lo-
cated near the reverse solenoid. RAPH12SSL0443AA 5
If the machine incorrectly travels backward, loosen
the jam nut (1) and adjust the piston stop screw (2)
located near the forward solenoid.
NOTE: To limit speed, turn the piston stop screw in.
To gain speed, turn the piston stop screw out.
4. Tighten the jam nut (1).
5. Test drive the machine. Repeat steps 1 through 4 until
machine travels correctly at the desired speed.
47540694 28/04/2014
29.4 [29.218] / 82
Motor - Remove
L223 NA
L225 NA
L230 NA
WARNING
Crushing hazard!
Unit could fall if not properly supported. Follow jacking instructions provided for the unit. Use suitable
jack stands. Be sure to position them properly.
W0919A
DANGER
Crushing hazard!
Failure to engage the loader arm support pin could cause the loader arm to fall unexpectedly. Verify
that the loader arm support pin is engaged.
D0020A
DANGER
Heavy objects!
D0076A
Prior operation:
Tilt the ROPS.
1. Place suitable container under chain tank drain plug

and remove drain plug (1) and drain chain oil.
RAPH12SSL0087AA 1
2. The loader must be raised and supported with the tires

off the ground. Used adequate blocks or jack stands to
safely support the loader.
931002069 2
47540694 28/04/2014
29.4 [29.218] / 83
3. Remove the wheel hardware (1) and pull wheels from

hub.
931002070 3
4. Remove the six bolts (2) securing the drive chain in-
spection cover and remove cover.
931002080 4
5. Remove front and rear axle housing hardware (4).
931002082B 5
47540694 28/04/2014
29.4 [29.218] / 84
6. Remove front and rear axle housings
931002083B 6
7. Push the sprocket forward and remove chains from

drive sprocket, as shown.
931002084 7
931002085B 8
47540694 28/04/2014
29.4 [29.218] / 85
8. Label and disconnect hydraulic hoses (1) from hydro-

static drive motor and cap the open hoses and ports.
931002086 9
9. Disconnect shift tube (on 2 speed equipped models).

10. Remove and discard hydraulic motor mounting hard-
ware (2).
NOTE: DO NOT reuse motor mounting hardware after
tightening to spec. Hardware is permanently stretched
during tightening and must be discarded if loosened.
931002085B 10
11. DANGER
Heavy objects!
Lift and handle all heavy components us-
ing lifting equipment with adequate capacity.
Always support units or parts with suitable
slings or hooks. Make sure the work area is
clear of all bystanders.
Failure to comply will result in death or serious
injury.
D0076A
Use acceptable lifting equipment and remove the

drive motor/brake assembly.
931002087 11
47540694 28/04/2014
29.4 [29.218] / 86
Motor - Disassemble – Single speed drive motor

L223 NA
L225 NA
L230 NA
1. Make reference marks on the motor case for correct

alignment during assembly. Loosen and remove the
socket head cap screws alternately, one turn at a time
from the cover plate.
83115546 1
2. Remove the cover plate.
83115547 2
83115548 3
47540694 28/04/2014
29.4 [29.218] / 87
4. Remove the disc spring.
83115549 4
5. Use compressed air in the port to force the piston up

for removal.
83115550 5
6. Remove the piston
83115551 6
7. Remove the O-ring.
83115552 7
47540694 28/04/2014
29.4 [29.218] / 88
8. Loosen and remove the socket head cap screws and

washers from the brake housing.
83115553 8
9. Use a soft hammer to loosen the brake housing.
83115554 9
10. Remove the brake housing from the motor case.
83115555 10
11. Remove the brake discs and shims as one unit from
the shaft.
83115556 11
47540694 28/04/2014
29.4 [29.218] / 89
83115557 12
13. Loosen the plug for the flushing spool valve.
83115558 13
14. Remove the flushing spool valve plug.
83115559 14
15. Remove the flushing valve spool, 2 springs, and

washer from the valve port. Make a record of the parts
assembly for use during the assembly procedure.
83115560 15
47540694 28/04/2014
29.4 [29.218] / 90
16. Loosen the plug for the flushing valve poppet.
83115561 16
17. Remove the plug from the port.
83115562 17
18. Remove the spring and the flushing poppet.
83115563 18
19. Loosen the socket head cap screws.
83115564 19
47540694 28/04/2014
29.4 [29.218] / 91
20. Remove the socket head cap screws.
83115565 20
21. Remove the rear motor case.
83115566 21
22. Remove the seal from the rear case.
83115567 22
23. Drop the rear case assembly from approximately

80 mm (3.1 in) onto a wooden or plastic surface. This
will release the distributor from the rear case.
83115568 23
47540694 28/04/2014
29.4 [29.218] / 92
24. Remove the distributor from the rear case.
83115569 24
25. Make a record of the number of springs and the stop

pin location in the distributor for use during the assem-
bly procedure.
83115570 25
26. Remove the cam from the front case.
83115571 26
27. Remove the seal from the front case.
83115572 27
47540694 28/04/2014
29.4 [29.218] / 93
28. Remove the cylinder block from the front case.
83115573 28
29. Place the front case assembly in the press. Remove

the split ring from the shaft.
83115574 29
30. Press the shaft out of the front case.
83115575 30
31. Press the seal out of the front case.
83115576 31
47540694 28/04/2014
29.4 [29.218] / 94
32. Press the outer bearing cup from the front case.
83115577 32
33. Press the inner bearing cup from the front case.
83115578 33
47540694 28/04/2014
29.4 [29.218] / 95
Motor - Assemble – Single speed drive motor

L223 NA
L225 NA
L230 NA
1. If removed, install a new inner bearing cup in the front

case.
83115577 1
2. If removed, install a new outer bearing cup in the front

case.
83115578 2
3. Lubricate a new shaft seal with clean hydraulic oil. In-

stall the new shaft seal onto the shaft.
4. Place the shaft in a press. Warm the outer bearing.
Press the outer bearing onto the shaft.
5. Cover the splines on the shaft with tape to protect the
seal. Install the shaft into the front case. Remove the
tape from the splines.
6. Warm the inner bearing.
7. Press the inner bearing onto the shaft and into the inner
bearing cup. Press the bearing into the cup to a preload
of 5000 kg (11023.1 lb). Rotate the front case during
this procedure. Allow the assembly to cool.
47540694 28/04/2014
29.4 [29.218] / 96
8. Place special tool 380001894 onto the shaft. Using a

press and apply a preload 2000 kg (4409.2 lb) to the
inner bearing.
83115575 3
9. Install the split ring onto the shaft.
83115574 4
10. With the preload still applied, measure the gap be-
tween the split ring and the bearing.
83115574 5
11. Remove the split ring. Install a shim with a thickness

of 0.05 - 0.20 mm (0.002 - 0.008 in) greater than the
measured gap between the split ring and the bearing
surface.
83115574 6
47540694 28/04/2014
29.4 [29.218] / 97
12. Install the split ring on the shaft.
83115574 7
13. Release the preload from the bearing and remove the
front case assembly from the press.
14. Check the shaft to make sure it rotates in the front
case assembly.
15. Install the cylinder block onto the shaft.
83115566 8
16. Lubricate the seal with clean hydraulic oil. Install the
seal on the front case.
83115572 9
47540694 28/04/2014
29.4 [29.218] / 98
17. Install the cam on the cylinder block. Be sure to align

the cam with the alignment mark on the front case.
83115571 10
18. Install the springs and the stop pin in the distributor.
83115570 11
19. Lubricate the seals on the distributor with clean hy-

draulic oil. Install the distributor into the rear case. Be
careful not to dislodge the springs while installing the
distributor into the rear case. Make sure to the stop
pin is aligned with the hole in the rear case. Tap the
distributor with a soft hammer until it is seated in the
rear case.
83115569 12
seal on the rear case.
83115567 13
47540694 28/04/2014
29.4 [29.218] / 99
21. Use the marks made during disassembly and install

the rear case onto the cam.
83115566 14
22. Apply LOCTITE® 243 to the threads and install the

socket head cap screws into the rear case.
83115565 15
23. Tighten the socket head cap screws alternately from

side to side to a torque of 117 - 122 N·m (86.3 - 90.0 lb
ft).
83115564 16
24. Lubricate the spring and flushing poppet with clean

hydraulic oil. Install the spring and flushing poppet
into the port.
83115563 17
47540694 28/04/2014
29.4 [29.218] / 100
25. Lubricate the O-ring on the plug with clean hydraulic

oil. Install and tighten the plug.
83115561 18
26. Lubricate the springs and flushing spool with clean hy-
draulic oil. Install the 2 springs, washer, and flushing
spool into the valve port.
83115560 19
27. Lubricate the O-ring on the plug with clean hydraulic

oil. Install and tighten the plug.
83115558 20
28. Lubricate the O-ring with clean hydraulic oil. Install the
O-ring on the brake housing.
83115557 21
47540694 28/04/2014
29.4 [29.218] / 101
29. Lubricate with the brake discs and shims with clean
hydraulic oil. Install the brake discs and shims as one
unit on the shaft. Make sure all of the tabs on the
brakes discs are aligned.
83115556 22
30. Install the brake housing on the rear motor case.
83115555 23

socket head cap screws into the brake housing.
Tighten the socket head cap screws alternately from
ft).
83115553 24
seal in the brake housing.
83115552 25
47540694 28/04/2014
29.4 [29.218] / 102
33. Lubricate the seals on the piston with clean hydraulic

oil and install the piston into the brake housing.
83115551 26
34. Install the disc spring on top of the piston.
83115549 27
35. Install the gasket on the brake housing.
83115548 28
36. Install the cover plate onto the brake housing.
83115547 29
47540694 28/04/2014
29.4 [29.218] / 103
37. Install the socket head cap screws into the cover plate.
ft).
83115546 30
47540694 28/04/2014
29.4 [29.218] / 104
Motor - Disassemble – Two speed drive motor

L223 NA
L225 NA
L230 NA
1. Make reference marks on the motor case for correct

alignment during assembly. Loosen and remove the
socket head cap screws alternately, one turn at a time
from the cover plate.
83115546 1
83115547 2
83115548 3
47540694 28/04/2014
29.4 [29.218] / 105
4. Remove the disc spring.
83115549 4
5. Use compressed air in the port to force the piston up

for removal.
83115550 5
6. Remove the piston.
83115551 6
83115552 7
47540694 28/04/2014
29.4 [29.218] / 106
8. Loosen and remove the socket head cap screws and

washers from the brake housing.
83115553 8
9. Use a soft hammer to loosen the brake housing.
83115554 9
10. Remove the brake housing from the motor case.
83115579 10
11. Remove the brake discs and shims as one unit from
the shaft.
83115556 11
47540694 28/04/2014
29.4 [29.218] / 107
83115580 12
13. Remove the two speed spool valve and spring from
the valve port.
83115581 13
83115582 14
15. Loosen the socket head cap screws.
83115564 15
47540694 28/04/2014
29.4 [29.218] / 108
16. Remove the socket head cap screws.
83115565 16
17. Remove the rear motor case.
83115708 17
18. Remove the seal from the rear case.
83115567 18
19. Drop the rear case assembly from approximately

80 mm (3.1 in) onto a wooden or plastic surface. This
will release the distributor from the rear case.
83115568 19
47540694 28/04/2014
29.4 [29.218] / 109
20. Remove the distributor from the rear case. Make a

record of the number of springs and the stop pin lo-
cation in the distributor for use during the assembly
procedure.
83115709 20
21. Remove the cam from the front case.
83115571 21
22. Remove the seal from the front case.
83115572 22
23. Remove the cylinder block from the front case.
83115573 23
47540694 28/04/2014
29.4 [29.218] / 110
24. Place the front case assembly in the press. Remove

the split ring from the shaft.
83115574 24
25. Press the shaft out of the front case.
83115575 25
26. Press the seal out of the front case.
83115576 26
27. Press the inner bearing cup from the front case.
83115577 27
47540694 28/04/2014
29.4 [29.218] / 111
28. Press the outer bearing cup from the front case.
83115578 28
47540694 28/04/2014
29.4 [29.218] / 112
Motor - Assemble – Two speed drive motor

L223 NA
L225 NA
L230 NA
1. If removed, install a new outer bearing cup in the front

case.
83115575 1
2. If removed, install a new inner bearing cup in the front

case.
83115577 2
3. Lubricate a new shaft seal with clean hydraulic oil. In-

stall the new shaft seal onto the shaft.
4. Place the shaft in a press. Warm the outer bearing.
Press the outer bearing onto the shaft.
5. Cover the splines on the shaft with tape to protect the
seal. Install the shaft into the front case. Remove the
tape from the splines.
6. Warm the inner bearing.
7. Press the inner bearing onto the shaft and into the inner
bearing cup. Press the bearing into the cup to a preload
of 5000 kg (11023.1 lb). Rotate the front case during
this procedure. Allow the assembly to cool.
47540694 28/04/2014
29.4 [29.218] / 113
8. Place special tool 380001894 onto the shaft. Using a

press and apply a preload 2000 kg (4409.2 lb) to the
inner bearing.
83115575 3
9. Install the split ring onto the shaft.
20115834 4
10. With the preload still applied, measure the gap be-
tween the split ring and the bearing.
20115833 5
11. Remove the split ring. Install a shim with a thickness

of 0.05 - 0.20 mm (0.002 - 0.008 in) greater than the
measured gap between the split ring and the bearing
surface.
20115834 6
47540694 28/04/2014
29.4 [29.218] / 114
12. Install the split ring on the shaft.
20115834 7
13. Release the preload from the bearing and remove the
front case assembly from the press.
14. Check the shaft to make sure it rotates in the front
case assembly.
15. Install the cylinder block onto the shaft.
83115573 8
seal on the front case. Install the cam on the cylinder
block. Be sure to align the cam with the alignment
mark on the front case.
83115571 9
47540694 28/04/2014
29.4 [29.218] / 115
17. Install the springs and the stop pin in the distributor.
83115709 10
18. Lubricate the seals on the distributor with clean hy-

draulic oil. Install the distributor into the rear case. Be
careful not to dislodge the springs while installing the
distributor into the rear case. Make sure to the stop
pin is aligned with the hole in the rear case. Tap the
distributor with a soft hammer until it is seated in the
rear case.
83115569 11
seal on the rear case.
83115567 12
20. Use the marks made during disassembly and install

the rear case onto the cam.
83115583 13
47540694 28/04/2014
29.4 [29.218] / 116

socket head cap screws into the rear case.
83115565 14
22. Tighten the socket head cap screws alternately from

ft).
83115564 15
23. Lubricate the two speed valve spring and spool with
clean hydraulic oil. Install the two speed valve spring
and spool into the valve port.
83115560 16
24. Lubricate the O-ring with clean hydraulic oil. Install the
O-ring on the brake housing.
83115557 17
47540694 28/04/2014
29.4 [29.218] / 117
25. Lubricate with the brake discs and shims with clean
hydraulic oil. Install the brake discs and shims as one
unit on the shaft. Make sure all of the tabs on the
brakes discs are aligned.
83115556 18
26. Install the brake housing on the rear motor case.
83115579 19

socket head cap screws into the brake housing.
ft).
83115553 20
seal in the brake housing.
83115552 21
47540694 28/04/2014
29.4 [29.218] / 118
29. Lubricate the seals on the piston with clean hydraulic

oil and install the piston into the brake housing.
83115551 22
30. Install the disc spring on top of the piston.
83115549 23
31. Install the gasket on the brake housing.
83115548 24
32. Install the cover plate onto the brake housing.
83115547 25
47540694 28/04/2014
29.4 [29.218] / 119
33. Install the socket head cap screws into the cover plate.
ft).
83115546 26
47540694 28/04/2014
29.4 [29.218] / 120
Motor - Install
L223 NA
L225 NA
L230 NA
DANGER
Crushing hazard!
D0020A
WARNING
Crushing hazard!
Unit could fall if not properly supported. Follow jacking instructions provided for the unit. Use suitable
jack stands. Be sure to position them properly.
W0919A
DANGER
Heavy objects!
D0076A
1. Apply a bead of LOCTITE® 598 ULTRA BLACK adhe-

sive, (1), in corner between pilot and flange of mo-
tor, around diameter of pilot, similar to o-ring, (approxi-
mately 12.5 ml (0.4 US fl oz) per motor).
931001687A 1
2. Apply a 3 mm (0.1 in) bead of LOCTITE® 598 ULTRA

BLACK around the outside of the bolt holes of the mo-
tor flange and two dabs per nut between the nut and
motors.
931002004 2
3. Use acceptable lifting equipment and move the drive

motor/brake assembly (1) into the chassis mounting lo-
cation (2).
47540694 28/04/2014
29.4 [29.218] / 121
4. Install new mounting hardware (1) and torque to

122 N·m (90 lb ft) plus 60 degrees.
NOTE: DO NOT reuse motor mounting hardware. Hard-
ware is permanently stretched during tightening and must
be discarded if loosened.
931002085B 3
5. Connect the hydraulic hoses (1) to hydrostatic drive

motor to the correct ports
6. Connect shift tube (on 2 speed equipped models).
931002086 4
47540694 28/04/2014
29.4 [29.218] / 122
7. Connect chains to drive sprocket
931002085B 5
8. Install front (1) and rear axle housings.
931002083B 6
9. Install the chains to the drive sprockets.

10. Install front and rear axle housing hardware (1).
931002082B 7
47540694 28/04/2014
29.4 [29.218] / 123
11. Install chain oil drain plug (1). oil level is approximately
mid-way up the inspection cover. Cover must be in-
stalled before filling with oil.
RAPH12SSL0087AA 8
12. Install chain inspection cover (1) and mounting hard-

ware (2)
13. Fill chain tank to correct level and install check plug.
931002080A 9
14. Install wheels (1) and wheel hardware (2)
931002070 10
15. Remove supports and lower skid steer
931002069 11
47540694 28/04/2014
29.4 [29.218] / 124
Motor - Remove
C232 NA
C238 NA
Prior operation:
Rubber track - Remove (48.100)
1. Loosen and remove the upper and lower mounting

bolts (1) which fasten the rear cover (2) to the main
frame (3).
BS05C139_1 1
2. Apply vacuum to the reservoir. Refer to Oil reservoir -

Apply vacuum (35.300)
NOTE: Clean the hydraulic lines, fittings, and connectors
and the area around motor connections to prevent dirt from
entering the hydraulic system before the lines are discon-
nected from the motor.
BS05C164_1 2
3. Loosen and remove all of the hydraulic lines that are
connected to the drive motor. Place plugs in all of the
lines.
4. Stop the vacuum pump.
5. Loosen and remove all of the connectors from the ports
on the drive motor to allow room to slide the drive motor
out of the main frame. Install clean plastic plugs into the
ports (1) to avoid contamination.
47540694 28/04/2014
29.4 [29.218] / 125
6. Make a reference mark on the drive motor (2) and the

main frame (3) to be used for alignment of the drive
motor during the installation procedure.
7. Loosen and remove the mounting bolts (1) which fasten
the drive motor (2) to the main frame (3).
8. Slide the drive motor (2) out of the main frame (3) and
place on the bench.
BS05C164_2 3
Next operation:
Motor - Install (29.218)
47540694 28/04/2014
29.4 [29.218] / 126
Motor - Disassemble
C232 NA
C238 NA
1. Remove the 2 plugs from the cover plate.
83115710 1
2. Drain motor oil in an acceptable container.

83115711 2
4. Mark the position of the cover plate as a reference for

reassembly.
83115712VGFUKV 3
47540694 28/04/2014
29.4 [29.218] / 127
6. Remove the center gear.
83115713 4
7. Remove the gear plate.
83115714 5
8. Remove and discard the O-ring.
83115715 6
9. Mark the position (1) of all the gears as a reference for

reassembly.
10. Remove the snap rings.
83115716_4 7
47540694 28/04/2014
29.4 [29.218] / 128
11. Remove the gears.
83115717 8
12. Remove the bushing.
83115718 9
NOTE: Disassembly of the flushing spool valve

13. Remove the plugs.
83115725_2 10
14. Remove and discard the O-rings..
83115721 11
47540694 28/04/2014
29.4 [29.218] / 129
15. Remove the springs from both ends of the plunger.
83115722 12
16. Remove the spring seats from both ends of the

plunger.
83115723_3 13
17. Remove the plunger assembly.
83115724_2 14
NOTE: Disassembly of the two speed control

18. Remove the plugs.
83115725_3 15
47540694 28/04/2014
29.4 [29.218] / 130
19. Remove and discard the O-rings.
83115721 16
20. Remove the two speed spool (1).
83115726_3 17
NOTE: The two speed spool can only be removed from one opening.
21. Remove the spring (1).
83115727_3 18
NOTE: Disassembly of the flushing valve

22. Remove plug.
83115728_3 19
47540694 28/04/2014
29.4 [29.218] / 131
83115721 20
83115729_3 21
NOTE: Disassembly of the base plate

25. Remove the three plugs from around the bottom of the
base plate.
83115730 22
26. Remove the base plate mount bolts.
83115731_2 23
47540694 28/04/2014
29.4 [29.218] / 132
27. Carefully lift the base plate off the pins. Remove the
base plate.
83115732GSF 24
28. Turn the base plate upside down.
83115733 25
29. Remove the valve plate.
83115734 26
30. Remove the pins (1) from their seat..
83115733_3 27
47540694 28/04/2014
29.4 [29.218] / 133
31. Remove bearing from the base plate.
83115736 28
NOTE: Disassembly of the motor shaft and cylinder block

32. Remove the bearing inner ring from the motor shaft.
83115737 29
33. Remove the springs from the brake piston.
83115738 30
83115739 31
47540694 28/04/2014
29.4 [29.218] / 134
35. Mark the position of the brake piston as a reference

for reassembly.
83115740 32
36. Remove the brake piston.
83115741 33
37. Separate the brake spacer from the brake piston.
83115742 34
38. Remove and discard the O-rings from the brake pis-
ton.
83115743 35
47540694 28/04/2014
29.4 [29.218] / 135
39. Remove and discard the O-ring from the brake spacer.
83115744 36
NOTE: Remove the brake discs package

40. Remove the brake disc with internal teeth.
83115745 37
41. Then remove an external toothed steel disc.
83115746 38
42. Repeat the above steps until complete brake disc

package is removed.
NOTE: Brake disc package consists of 3 brake discs and
2 steel discs
83115747 39
47540694 28/04/2014
29.4 [29.218] / 136
43. Remove the cylinder block.
83115748 40
44. Remove the pistons and retainer plate from the cylin-
der block.
83115749 41
45. Remove pistons from the retainer plate.
83115767 42
46. Remove the spherical retainer plate holder.
83115751 43
47540694 28/04/2014
29.4 [29.218] / 137
47. Remove the 3 pins from the cylinder block (1) .
83115752 44
48. Remove the swash plate.
83115753 45
49. Remove the 2 pistons from their seat (1) .
83115754 46
50. Remove the springs from the pistons.
83115755 47
47540694 28/04/2014
29.4 [29.218] / 138
51. Remove the 2 steel balls from their seats.
83115756 48
52. Remove the motor shaft.
83115757 49
53. Remove the inner bearing ring from the motor shaft.
83115758 50
54. Remove the bearing.
83115759 51
47540694 28/04/2014
29.4 [29.218] / 139
55. Remove the seal ring.
83115760_2 52
47540694 28/04/2014
29.4 [29.218] / 140
Motor - Assemble
C232 NA
C238 NA
1. Install the seal ring.
83115760ASSD 1
2. Install the seal ring into the flanged hub.
83115761HJL 2
3. Apply a thin coat of grease over the seal ring (1).
83115762 3
4. Install bearing.
83115763 4
47540694 28/04/2014
29.4 [29.218] / 141
5. Seat the bearing into the flanged hub.
83115764GHK 5
6. Install the inner bearing ring onto the motor shaft.
83115765 6
7. Place the motor shaft into the bearing.
83115757 7
8. Place the 2 steel balls into their seats.
83115756 8
47540694 28/04/2014
29.4 [29.218] / 142
9. Install the springs inside the pistons.
83115755 9
10. Install the 2 pistons in their housings (1).
83115754 10
11. Install the swash plate.
83115753 11
12. Install the three pins into the cylinder block (1).
83115752 12
47540694 28/04/2014
29.4 [29.218] / 143
13. Install the spherical retainer.

NOTE: Ensure the two splines are aligned
83115751 13
14. Piston orifice must be free of dust or dirt.
83115766 14
15. Install the pistons into the retainer plate.
83115767 15
16. Install the pistons and retainer plate into the cylinder
lock.
83115749 16
47540694 28/04/2014
29.4 [29.218] / 144
17. Install the cylinder block into the flanged hub on the
motor shaft spline.
83115748 17
18. Install the brake disc package according to the follow-

ing order: first insert one brake disc with internal teeth.
83115745 18
19. Then insert an external toothed steel disc.
83115746 19
20. Repeat the steps until 3 brake discs and 2 steel discs
have been installed.
83115747 20
47540694 28/04/2014
29.4 [29.218] / 145
21. Install the O-rings on the brake piston.
83115743 21
22. Install the O-ring on the brake spacer.
83115744 22
23. Install the brake spacer on the brake piston, paying

attention not to damage the O-rings already in place.
83115742 23
24. Install the brake piston into the flanged hub while
aligning the reference marks previously applied.
83115741 24
47540694 28/04/2014
29.4 [29.218] / 146
25. Install O-ring.
83115739 25
26. Install the springs on the brake piston.
83115738 26
27. Install the bearing inner ring onto the motor shaft.
83115737 27
28. Install the bearing into the base plate (1).

29. Install the pins into the base plate (2).
83115735 28
47540694 28/04/2014
29.4 [29.218] / 147
30. Install the valve plate on the base plate with the bronze
surface upwards.
83115734 29
31. Install the 3 O-rings for the oil passages on the flanged
hub.
32. Place the base plate on the flanged hub.
NOTE: Ensure the base plate is centered on the two pins
and the oil passages are matched together
83115732GSF 30
33. Install the base plate mount bolts and tightened to a

torque of 145 N·m (106.95 lb ft).
83115731 31
34. Install the 3 plugs located around the bottom of the

base plate. Torque plus to 2 - 3 N·m (17.7 - 26.6 lb
in).
83115730 32
NOTE: Assembly of the two speed control
47540694 28/04/2014
29.4 [29.218] / 148
35. Install the spring (1) into the two-speed spool (2) .
83115727 33
36. Install the two speed spool (1) into the base plate.
NOTE: The spool will only fit through 1 of the 2 orifices.
83115726 34
37. Install the O-rings on the plugs.
83115721 35
38. Install and tighten the plugs to a torque of 49 - 59 N·m

(36.1 - 43.5 lb ft).
83115725 36
NOTE: Assembly of the flushing valve
47540694 28/04/2014
29.4 [29.218] / 149
39. Install the O-ring on the plug.
83115721 37
40. Install the spring into the base plate.
83115729_1 38
41. Install and tighten the plug to a torque of 88 - 96 N·m

(64.9 - 70.8 lb ft).
83115728 39
NOTE: Assembly of the flushing spool valve

42. Slide plunger (1) inside the base plate.
83115724 40
47540694 28/04/2014
29.4 [29.218] / 150
43. Install the spring seats (1) on each end of the plunger
(2) .
83115723_2 41
44. Install the springs on each end of the plunger.
83115722 42
45. Install the O-rings on the 2 plugs.
83115721 43
46. Install and tighten the 2 plugs to a torque of 149 -

165 N·m (109.9 - 121.7 lb ft)
83115725_1 44
47540694 28/04/2014
29.4 [29.218] / 151
47. Install the bushing into the gearbox (1).
83115768 45
48. Install the gears into the gearbox while aligning the
reference marks (1) previously applied to the gears.
83115717 46
49. Seat the gears.
83115769_1 47
50. Install the snap rings on the gears.
83115716 48
47540694 28/04/2014
29.4 [29.218] / 152
51. Install the O-ring around the gearbox.
83115715 49
52. Install the gear plate.
83115714 50
53. Install the center gear.
83115713 51
54. Use reference marks (1) to align and install the cover
plate on the gearbox.
83115712 52
47540694 28/04/2014
29.4 [29.218] / 153
83115711 53
56. Service gearbox with 550 - 650 ml (18.6 - 22.0 US fl

oz) .of NEW HOLLAND AMBRA HYPOIDE 140.
57. Install and tighten the end cover plugs to a torque of
20 - 30 N·m (14.8 - 22.1 lb ft).
83115710 54
47540694 28/04/2014
29.4 [29.218] / 154
Motor - Install
C232 NA
C238 NA
Prior operation:
Motor - Remove (29.218)
1. Slide the drive motor (1) into the main frame (2) mount-
ing location. If the same motor is being installed, use
the marks made during removal and align the drive mo-
tor in the main frame. If a new motor is being installed,
transfer the reference mark from the old motor to the
same location on the new motor and align the drive mo-
tor in the main frame.
BS05C164_3 1
2. Install the mounting bolts (1) into the main frame.
BS05C164_4 2
3. Tighten the mounting bolts to an initial torque of 67 -

163 Nm (50 - 120 lb ft) using the star tightening se-
quence shown. After the initial torque is complete,
tighten the mounting bolts to a final torque of 183 -
205 Nm (136 - 153 lb ft) using the star tightening se-
quence shown.
BS05C156_1 3
47540694 28/04/2014
29.4 [29.218] / 155
4. Remove the plastic plugs from the motor ports (1). In-
stall the connectors into the motor ports (1) and tighten
the connectors.
BS05C164_1 4
5. Apply vacuum to the reservoir. Refer to Oil reservoir -

Apply vacuum (35.300)
6. Start the vacuum pump. Remove the caps from the
lines and connect the lines to the drive motor. Tighten
all of the hydraulic lines.
7. Stop the vacuum pump and remove the vacuum pump
from the reservoir.
8. Install rubber tracks. Refer to Rubber track - Install
(48.100)
9. Start and run the engine at low idle for 2 to 5 minutes
and check for any leaks.
10. Stop the engine.
11. Install the rear cover (2) onto the main frame (3). In-
stall the upper and lower mounting bolts (1) into the
rear cover (2). Tighten the mounting bolts (1).
BS05C139_1 5
12. Check the oil level in the hydraulic reservoir and add
hydraulic oil as required. Refer to : Oil reservoir -
Filling (35.300)
47540694 28/04/2014
29.4 [29.218] / 156
Pump - Troubleshooting
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Problem Possible Cause Correction

One Transmission (Right 1.If you have a EH unit perform EH pump A. Is there still a problem?
or Left) Works Correctly electrical check and verify that unit has No: Troubleshooting complete.
and the Other Does Not been properly calibrated. Yes: Go to Step 2.
Check the interlock valve power/function.
2. Check the brake valve power/function. Is there still a problem?
Make sure park brakes are released. No: Troubleshooting complete.
Yes: Go to Step 3.
3. Check the pressure setting of the cir- Do - Check the Circuit Relief Valve Pres-
cuit relief valve for the transmission with the sure.
problem. Is there still a problem?
No: Troubleshooting complete.
Yes: Go to Step 4.
4. Check the charge pressure. Do - Check the Charge Pressure/Flow.
Machine does not have 1. If you have a EH unit perform EH pump Is there still a problem?
enough power electrical check and verify that unit has No: Troubleshooting complete.
been properly calibrated. Yes: Go to Step 2.
Check the interlock valve power/function.
2. Full throttle engine speed is OK, rated A. Problem in engine or fuel system. Repair
engine speed is low. as required.
B. Is there still a problem?
No: Troubleshooting complete.
Yes: Go to Step 3.
3. Check charge pressure. Refer to Pump and motor components -
Pressure test (29.218) to determine if the
pump or drive motor(s) have failed.
47540694 28/04/2014
29.4 [29.218] / 157
Index

Motor - Assemble – Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Motor - Assemble – Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Motor - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Motor - Disassemble – Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Motor - Disassemble – Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Motor - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Motor - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Motor - General specification – Single speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Motor - General specification – Two-speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Motor - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Motor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Motor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Motor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Motor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Pump - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Pump - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pump - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pump - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Pump - Measure – Piston travel (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Pump - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Pump - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Pump - Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Pump and motor components - Install – Charge pressure relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pump and motor components - Install – Charge pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Pump and motor components - Install – Drive shaft seal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pump and motor components - Install – Main relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pump and motor components - Pressure test – Charge pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pump and motor components - Pressure test – Main relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pump and motor components - Remove – Charge pressure relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
47540694 28/04/2014
29.4 [29.218] / 158
Pump and motor components - Remove – Charge pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pump and motor components - Remove – Drive shaft seal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pump and motor components - Remove – Main relief valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Servo control - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Servo control - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
47540694 28/04/2014
29.4 [29.218] / 159
PRINTED IN U.S.A.
47540694 28/04/2014
EN
SERVICE MANUAL
Brakes and controls
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
33
Contents
Brakes and controls - 33
[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
47540694 28/04/2014
33
Parking brake or parking lock - 110
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
33.1 [33.110] / 1
Contents
TECHNICAL DATA
Parking brake control valve

FUNCTIONAL DATA
Parking brake control valve

47540694 28/04/2014
33.1 [33.110] / 2
Brakes and controls - Parking brake or parking lock
Parking brake control valve - General specification

RAPH13SSL0966EA 1
Brake valve

T - Tank return
B1 - Brake motor 1
B2 - Brake motor 2

47540694 28/04/2014
33.1 [33.110] / 3
RAPH13SSL0965EA 1
Electrohydraulic (EH), brake valve

T - Tank return
B1 - Brake motor 1
B2 - Brake motor 2
LV - EH pilot pressure

47540694 28/04/2014
33.1 [33.110] / 4
RAPH13SSL0967EA 1

T - Tank return
B1 - Brake motor 1
B2 - Brake motor 2

47540694 28/04/2014
33.1 [33.110] / 5
RAPH14SSL0006FA 1

T - Tank return
B1 - Brake motor 1
B2 - Brake motor 2

47540694 28/04/2014
33.1 [33.110] / 6
RAPH14SSL0011FA 1

T - Tank return
B1 - Brake motor 1
B2 - Brake motor 2

47540694 28/04/2014
33.1 [33.110] / 7
RAPH12SSL0381EA 1

T - Tank return
B1 - Brake motor 1
B2 - Brake motor 2
47540694 28/04/2014
33.1 [33.110] / 8
Parking brake control valve - Component localisation

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
RAIL13SSL1004FA 1
Valve location
47540694 28/04/2014
33.1 [33.110] / 9
Index

Parking brake control valve - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Parking brake control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
33.1 [33.110] / 10
47540694 28/04/2014
33.1 [33.110] / 11
PRINTED IN U.S.A.
47540694 28/04/2014
EN
SERVICE MANUAL
Hydraulic systems
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
35
Contents
Hydraulic systems - 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.128] Auxiliary hydraulic function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.350] Safety and main relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.600] High flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9
[35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
[35.734] Tool quick coupler hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11
47540694 28/04/2014
35
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
35.1 [35.000] / 1
Contents
FUNCTIONAL DATA
Hydraulic systems
Hydraulic schematic frame 01 - Valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic schematic frame 03 – Pump and motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic schematic frame 04 - Pump and motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic schematic frame 01 - Valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic schematic frame 04 - Enhanced High Flow (EHF) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SERVICE
Hydraulic systems
Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Decontaminating (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Depressurising (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
47540694 28/04/2014
35.1 [35.000] / 2
Hydraulic systems - Hydraulic systems
Hydraulic systems - Component localisation

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
RAIL13SSL1004FA 1
Valve location
47540694 28/04/2014
35.1 [35.000] / 3
Hydraulic systems - Hydraulic schematic frame 01 - Valves

Component Call-out reference

Check valve (1)
Hydraulic coupler valve (if applicable) (2)
Ride control valve (if applicable) (3)
Self level valve (if applicable) (4)
Auxiliary coupler (5)
Main control valve (loader valve) (6)
Secondary auxiliary valve (if applicable) (7)
High flow valve (if applicable) (8)
Hydraulic oil filter (9)
47540694 28/04/2014
35.1 [35.000] / 4
RAIL14SSL0257JA 1
47540694 28/04/2014
35.1 [35.000] / 5
47540694 28/04/2014
35.1 [35.000] / 6
Hydraulic systems - Hydraulic schematic frame 03 – Pump and

motor

Right-hand drive motor (1)
Left-hand drive motor (2)
Two-speed/brake valve (3)
Hydrostatic pump assembly (4)
47540694 28/04/2014
35.1 [35.000] / 7
47540694 28/04/2014
35.1 [35.000] / 8
RAIL14SSL0259JA 1
47540694 28/04/2014
35.1 [35.000] / 9
47540694 28/04/2014
35.1 [35.000] / 10
Hydraulic systems - Hydraulic schematic frame 04 - Pump and

motor

Brake valve (3)
Brake/two-speed valve (4)
47540694 28/04/2014
35.1 [35.000] / 11
47540694 28/04/2014
35.1 [35.000] / 12
RAIL14SSL0260JA 1
47540694 28/04/2014
35.1 [35.000] / 13
47540694 28/04/2014
35.1 [35.000] / 14
Hydraulic systems - Hydraulic schematic frame 01 - Valves


Check valve (1)
Hydraulic coupler valve (if applicable) (2)
Ride control valve (if applicable) (3)
Self-leveling valve (if applicable) (4)
Auxiliary coupler (5)
Main control valve (6)
Secondary auxiliary valve (if applicable) (7)
High flow valve (if applicable) (8)
Hydraulic oil filter (9)
47540694 28/04/2014
35.1 [35.000] / 15
47540694 28/04/2014
35.1 [35.000] / 16
RAIL14SSL0261JA 1
47540694 28/04/2014
35.1 [35.000] / 17
47540694 28/04/2014
35.1 [35.000] / 18

motor

Electro hydraulic/brake valve (3)
Electro hydraulic/two-speed/brake valve (4)
47540694 28/04/2014
35.1 [35.000] / 19
47540694 28/04/2014
35.1 [35.000] / 20
RAIL14SSL0262JA 1
47540694 28/04/2014
35.1 [35.000] / 21
47540694 28/04/2014
35.1 [35.000] / 22

motor

Electro hydraulic/two-speed/brake valve (3)
47540694 28/04/2014
35.1 [35.000] / 23
47540694 28/04/2014
35.1 [35.000] / 24
RAIL14SSL0264JA 1
47540694 28/04/2014
35.1 [35.000] / 25
47540694 28/04/2014
35.1 [35.000] / 26
Hydraulic systems - Hydraulic schematic frame 04 - Enhanced High

Flow (EHF)
C238 NA
L230 NA

Flushing valve (1)
EHF pump (2)
Gear pumps (4)
47540694 28/04/2014
35.1 [35.000] / 27
47540694 28/04/2014
35.1 [35.000] / 28
RAIL14SSL0265JA 1
47540694 28/04/2014
35.1 [35.000] / 29
47540694 28/04/2014
35.1 [35.000] / 30
Hydraulic systems - Cleaning

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Prepare the portable filter CAS10162A by doing the

following steps:
(A) Remove all the hydraulic oil from the inlet and outlet
hoses for the portable filter.
(B) Remove the filter element from the portable filter.
(C) Remove all hydraulic oil from the portable filter.
(D) Clean the inside of the housing for the filter element.
(E) Install a new filter element in the portable filter.
2. Determine whether the contamination is microscopic or
visible.
3. If the contamination is microscopic:
(A) Check the maintenance schedule for the machine
to learn if the hydraulic oil must be changed. If nec-
essary, change the hydraulic oil. Change the hydraulic
filter.
(B) Do steps 6 through 37.
4. If the contamination is visible, do the following steps:
(A) Change the hydraulic oil and hydraulic filter.
(B) Do steps 5 through 37.
5. Check the amount of contamination in the hydraulic
system by doing the following steps:
(A) Disassemble one cylinder in two different circuits.
Check for damage to seals, scoring of the cylinder wall,
etc. Repair the cylinders as necessary.
(B) If, in your judgment, the damage to the cylinders
was caused by severe contamination and is not the
result of normal wear, it is necessary to remove, clean
and repair all valves, pumps, lines, cylinders, hydraulic
reservoir, etc. in the hydraulic system. To clean the
lines refer to the following procedure: Pump - Cleaning
(29.218)
6. Remove the cap from the reservoir and install the
adapter CAS1871 on the reservoir.
7. Connect the vacuum pump CAS10192 to the adapter
CAS1871. Oil reservoir - Apply vacuum (35.300)
47540694 28/04/2014
35.1 [35.000] / 31
8. Start the vacuum pump.

9. The hydraulic reservoir is located at the rear of the ma-
chine. Loosen and remove the drain plug from the
reservoir.
10. Using the fitting kit CAS10508, install the valve in the
hole for the drain plug. Make sure that the valve is
closed.
12. Connect the inlet hose for the portable filter to the
valve that is installed in the hole for the drain plug.
13. Disconnect the vacuum pump and remove CAS1871
adapter from reservoir.
14. Install the outlet hose for the portable filter in the hy-
draulic reservoir filler neck.
15. Open the valve that is installed in the hole for the drain
plug.
(A) Check fluid level in reservoir. Add if necessary.
16. Move the switch for the portable filter to the ON posi-
tion.
17. Start and run the engine at half throttle.
18. Run the portable filter for 10 minutes with the engine
running at half throttle.
19. Continue to run the portable filter. Increase the engine
speed to full throttle. Do the following to heat the oil
to operating temperature:
(A) Increase the engine speed to full throttle.
(B) Hold the bucket control lever in the ROLLBACK
position for five seconds.
(C) Return the bucket control lever in the NEUTRAL
position for five seconds.
(D) Repeat steps 19B and 19C until the oil is at oper-
ating temperature; 49 - 66 °C (120 - 150 °F).
20. With the engine running at full throttle and the portable
filter running, completely extend and retract the lift
cylinders and the bucket cylinders. Continue to op-
erate the cylinders, one after the other for 30 minutes.
NOTE: If the filter light in the machine illuminates, stop the engine, change the filter, then continue with procedure.
21. Decrease the engine speed to low idle.
22. Continue to run the portable filter for 10 minutes. Dur-
ing this time, move the hose up and down to help mix
the oil in the reservoir.
23. Stop the portable filter.
25. Remove the hose from the hydraulic reservoir.
26. Oil reservoir - Apply vacuum (35.300)
27. Close the valve that is installed in the hole for the drain
plug.
28. Disconnect the inlet hose for the portable filter from
the valve.
47540694 28/04/2014
35.1 [35.000] / 32
30. Remove the valve from the hole for the drain plug.
31. Install and tighten the drain plug.
33. Disconnect the vacuum pump from the opening in the
reservoir.
34. Install new hydraulic filter elements on the machine.
35. Start the engine. Check for oil leakage around the new
hydraulic filter.
37. Check the level of the oil in the reservoir and add oil
as required. Oil reservoir - Filling (35.300)
47540694 28/04/2014
35.1 [35.000] / 33
Hydraulic systems - Decontaminating

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Crushing hazard!
If you service the machine with the loader lift arms raised, always use the support strut. Remove the
retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support
strut. Lower the lift arms onto the support strut.
W0230A
1. Start and run the engine at 1500 rpm (r/min).

2. Completely retract all attachment cylinders on the ma-
chine. Stop the engine.
3. Depress the auxiliary hydraulic interlock override but-
ton, and leave the seat within 30 s. Move each control
lever in both directions to release pressure in the hy-
draulic circuits.
4. Loosen and remove the filler cap from the reservoir.
5. Drain the hydraulic oil from the reservoir.
(A) Have available acceptable equipment to drain the
hydraulic oil.
(B) Remove the drain plug from the bottom of the reser-
voir.
6. Remove the hydraulic filter element from the machine.
7. Install new hydraulic filter element on the machine.
8. Install the drain plug in the bottom of the reservoir.
9. Fill the hydraulic reservoir. Oil reservoir - Filling
(35.300)
10. Disconnect the line from the ROD end and BARREL
end of each cylinder.
11. Be sure all control levers are in the NEUTRAL posi-
tion.
12. Start and run the engine at low idle.
NOTICE: Check the oil level in the hydraulic reservoir fre-
quently while doing step 13. Have another person hold a
container under the hydraulic lines while you do step 13.
13. Slowly move the control lever for each bucket and lift
cylinders in both directions until oil begins to flow from
the open line. Hold the control lever in place until clean
oil flows from the open line.
15. Connect the system line to the BARREL end of each
cylinder.
16. Connect a suitable drain line to the ROD end of each
cylinder and place the other end in an acceptable con-
tainer for contaminated oil.
17. Start the engine and run the engine at low idle.
47540694 28/04/2014
35.1 [35.000] / 34
18. Slowly and completely extend all cylinders. As the pis-

ton rod comes in/out of the cylinder, oil will be pushed
out of the ROD end of the cylinders.
NOTICE: Any attachment or part of an attachment that is
raised must be supported with acceptable equipment to
prevent the attachment from falling.
19. Support any attachments that will be in the RAISED
position.
21. Disconnect the drain lines and connect the system
lines to the cylinders.
22. Check the oil level in the hydraulic reservoir. Add oil
as required.
23. Install the filler cap on the reservoir.
24. Remove the hydraulic filter element from the machine.
25. Install a new hydraulic filter element on the machine.
26. Start and run the engine at 1500 RPM, operate each
hydraulic circuit to completely extend and retract the
cylinders.
27. Stop the engine and check for leaks. Check the oil
level in the hydraulic reservoir. Add oil as required.
Oil reservoir - Filling (35.300)
47540694 28/04/2014
35.1 [35.000] / 35
Hydraulic systems - Depressurising

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Before removing components from the hydraulic sys-

tem, depressurize the circuit you are working on.
2. For hydraulic cylinders:
• Loader — support loader frame, shut off engine, use
manual boom lower valve to relieve pressure in base
end.
• Bucket – remove bucket from unit. Move coupler off
of stops at either end, shut off engine.
• Hydraulic Coupler – move coupler to unlocked posi-
tion, shut off engine.
3. For hydraulic pumps or motors:
• Shut off engine.
4. For Ride Control or Glide-Ride accumulator:
• Raise boom and support loader frame, shut off en-
gine, turn ignition “ON” (do not start), turn Ride Con-
trol/Glide-Ride switch on, use manual boom lower
valve to relieve pressure in base end of cylinder/ac-
cumulator.
5. For attachments connected to standard aux or stan-
dard high flow:
• All units are equipped with “connect under pressure”
manifold that bleeds pressure from circuit during
connect or disconnect.
6. For attachments connected to Enhanced High Flow
(EHF) aux:
• EHF attachments should all be motor driven which
will automatically bleed the pressure off when the
engine is turned off.
47540694 28/04/2014
35.1 [35.000] / 36
Index

Hydraulic systems - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic systems - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic systems - Decontaminating (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hydraulic systems - Depressurising (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Hydraulic systems - Hydraulic schematic frame 01 - Valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic systems - Hydraulic schematic frame 01 - Valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic systems - Hydraulic schematic frame 02 - Pump and motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hydraulic systems - Hydraulic schematic frame 03 – Pump and motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic systems - Hydraulic schematic frame 04 - Enhanced High Flow (EHF) (*) . . . . . . . . . . . . . . . . . . . . . . . . 27
47540694 28/04/2014
35.1 [35.000] / 37
47540694 28/04/2014
35.1 [35.000] / 38
Fixed displacement pump - 104
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
35.2 [35.104] / 1
Contents
TECHNICAL DATA
Fixed displacement pump

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE

Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
47540694 28/04/2014
35.2 [35.104] / 2
Hydraulic systems - Fixed displacement pump
Fixed displacement pump - General specification
RAPH14SSL0002GA 1
Type Gear pump
Pump displacement 36.6 cm³ (2.23 in³)
Engine RPM 2475 RPM
Pump flow at RPM 92.3 l/min (24.4 US gpm)
High flow pump displacement (if applicable) 13.7 cm³ (0.84 in³)
Combined pump flow at RPM (if applicable) 143.8 l/min (38.0 US gpm)
47540694 28/04/2014
35.2 [35.104] / 3
Fixed displacement pump - Flow test

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
CAUTION
Burn hazard!
Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that
exceed 49 °C (120 °F). Allow fluids to cool before proceeding.
C0107B
Pump efficiency test using the auxiliary couplers

system.
NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be
seated in the operators seat when the engine is running. The second person is to control the flow meter and take the
readings.
1. Attach the flow meter to the auxiliary couplers on the
loader arm.
NOTE: Verify that the flow inlet and outlet direction is cor-
rect on the flow meter.
RAPH12SSL0241AA 1
2. Start the machine and run at full throttle. Adjust the

machine’s RPM to 200 RPM less than the full throttle
RPM. Record the set RPM on the data collection sheet
located on the following page.
47540694 28/04/2014
35.2 [35.104] / 4
Pump flow with no restriction

3. Verify that the flow meter has no restriction on the hy-
draulic pump. Record the pump flow on the data col-
lection sheet located on the following page.
Please see Fixed displacement pump - General
specification (35.104) for specification about the gear
pumps.
NOTE: Image 2 is an example of a flow reading. Image 2
may not match your reading.
RAPH12SSL0242AA 2
Pump flow with restriction

4. Adjust the flow meter pressure until 152 bar (2200 psi)
is achieved. Verify that the machine is running at the
set RPM recorded on the data collection sheet located
on the following page. Adjust RPM if necessary.
Record the pump flow on the data collection sheet
pumps.
RAPH12SSL0243AA 3
Pump efficiency
5. Pump efficiency is determined by dividing the pump
flow with restriction value by the pump flow without re-
striction value, then multiplying that new value by 100.
Record the pump efficiency on the data collection sheet
NOTE: Pump efficiency should be no less than 70 %.
47540694 28/04/2014
35.2 [35.104] / 5
Engine RPM
- Set RPM __________RPM
Notes:
Test 1: Pump flow
- Pump flow at without restriction __________l/min __________gpm
Notes:
Test 2: Pump flow with restriction
- Pump flow with 152 bar (2200 psi) restriction __________l/min __________gpm
Notes:
Test 3: Pump efficiency
- Calculated pump efficiency __________%

NOTE: Calculated pump efficiency is determined by
dividing Test 2’s value by Test 1’s value, then multiplying
that new value by 100.
Notes:
47540694 28/04/2014
35.2 [35.104] / 6
Fixed displacement pump - Flow test

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
CAUTION
Burn hazard!
C0107B
Pump efficiency test using the “T” fitting method

system.
readings.
1. Locate the main control valve.
2. Install the “T” fitting (1) into the hydraulic gear pump
outlet, and attach the flow meter (2) hose to the “T”
fitting.
NOTE: Verify that the flow inlet direction is correct on the
flow meter.
RAPH12SSL0246AA 1
3. Place the other flow meter hose (1) with hose adapter
in the hydraulic tank.
NOTE: Verify that the flow outlet direction is correct on the
flow meter.
RAPH12SSL0247AA 2

47540694 28/04/2014
35.2 [35.104] / 7

pumps.
RAPH12SSL0242AA 3

pumps.
RAPH12SSL0243AA 4
Pump efficiency
47540694 28/04/2014
35.2 [35.104] / 8
Engine RPM
- Set RPM __________RPM
Notes:
Test 1: Pump flow
- Pump flow without restriction __________l/min __________gpm
Notes:
- Pump flow with 152 bar (2200 psi) restriction __________l/min __________gpm
Notes:

Notes:
47540694 28/04/2014
35.2 [35.104] / 9
Fixed displacement pump - Remove

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Pressurized system!
System is still under pressure. Release pressure according to instructions in this manual.
W1044A
Prior operation:
For depressurizing the hydraulics, refer to Hydraulic systems - Depressurising (35.000).
NOTICE: The hydrostatic pumps have different options for gear pumps. The pictures below may vary from the pump
you are working on. The procedure is the same.
1. Label and disconnect gear pump supply hose (1). Cap
open ports.
931001955 1
2. Label and disconnect gear pump hydraulic tube (1).

Cap open ports.
NOTE: Picture shown is of a single gear pump. If the pump
you are working on is a double gear pump, label and re-
move second hydraulic tube. Cap open ports.
931002073 2
3. Remove the gear pump retaining bolts (1). Remove

gear pump.
931002073 3
47540694 28/04/2014
35.2 [35.104] / 10
Fixed displacement pump - Install

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
NOTICE: The hydrostatic pumps have different options for gear pumps. The pictures below may vary from the pump
you are working on. The procedure is the same.
1. Install gear pump (1) and retaining bolts (2). Tighten
bolts to torque.
931002073 1
2. Connect gear pump hydraulic tube (1).

NOTE: Picture shown is of a single gear pump. If the pump
you are working on is a double gear pump, connect second
hydraulic tube.
931002073 2
3. Connect gear pump supply hose (1).
931001955 3
47540694 28/04/2014
35.2 [35.104] / 11
Index

Fixed displacement pump - Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fixed displacement pump - Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fixed displacement pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fixed displacement pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fixed displacement pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
47540694 28/04/2014
35.2 [35.104] / 12
Auxiliary hydraulic function control - 128
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
35.3 [35.128] / 1
Contents
TECHNICAL DATA
Control valve
General specification – Secondary auxiliary valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Control valve
SERVICE
Auxiliary hydraulic function control

Pressure test – Circuit relief valve. (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test – Circuit leakage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
47540694 28/04/2014
35.3 [35.128] / 2
Hydraulic systems - Auxiliary hydraulic function control
Control valve - General specification – Secondary auxiliary valve

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
RAPH14SSL0020FA 1
Secondary auxiliary valve
Operating pressure 207 - 217 bar (3000 - 3145 psi)

Maximum flow at supply inlet: 87 l/min (23.0 US gpm)
at ports A and B: 30 - 38 l/min (8 - 10 US gpm) at 138 bar (2000 psi).
Relief valve setting 221 bar (3200 psi) at 18.9 l/min (5.0 US gpm)
Port identification P – Pressure inlet
L – To main control valve
T – Tank return
A – Male auxiliary
B – Female auxiliary
47540694 28/04/2014
35.3 [35.128] / 3
Control valve - Component localisation

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
RAIL13SSL1004FA 1
Valve location
47540694 28/04/2014
35.3 [35.128] / 4
Auxiliary hydraulic function control - Pressure test – Circuit relief

valve.
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Park the machine on a level surface.

2. Lower all attachments to the floor.
3. Stop the engine.
4. Move the control levers in all directions to release any
circuit pressure.
5. The best way to connect the hand pump is directly to
the control valve. Disconnect the tube from the port
of the control valve and connect the hand pump to the
port. Please see Main control valve - General spec-
ification (35.359) for specifications on ports.
6. Remove all dirt and grease from the connecting point.
7. Connect the hose of the hand pump to the connecting
point, but do not tighten the connection.
8. Make sure that the hand pump is filled with oil. The
temperature of the oil must be at least 21°C (70°F).
9. Operate the hand pump to fill the hose of the hand
pump with oil. Then tighten the connections.
10. Operate the hand pump and read the pressure gauge.
Record the highest indication. Check the pressure
several times to make sure that the indications are
correct.
11. Compare the indication with the specification on Main
control valve - General specification (35.359) the
indication is not correct, replace the circuit relief valve.
NOTE: The circuit relief valves for the loader circuit are not
adjustable and must be replaced if they do not meet the
specification.
12. Repeat this test after installing a new circuit relief
valve.
47540694 28/04/2014
35.3 [35.128] / 5
Auxiliary hydraulic function control - Test – Circuit leakage

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
CAUTION
Burn hazard!
C0107B
system.
readings.
1. Locate the hydraulic gear pump(s). Install the “T” fitting
into the hydraulic gear pump outlet (1), and attach the
flow meter hose to the “T” fitting.
flow meter.
931001956 1
flow meter.
RAPH12SSL0247AA 2
3. Start the machine and run at full throttle.
47540694 28/04/2014
35.3 [35.128] / 6
is achieved. While watching the flow meter liter per
minute (l/min) gauge or gallon per minute (gpm) gauge,
activate the auxiliary couplers in both directions.
Compare the flow of every auxiliary function. Differ-
ences in pump flow indicate internal leaks and/or eas-
ier paths to tank.
NOTE: Pump flow should be within 4 l/min (1 US gpm)
of pump specification. Please see Fixed displacement
pump - General specification (35.104) for specifications
on the gear pumps.
RAPH12SSL0329AA 3
47540694 28/04/2014
35.3 [35.128] / 7
Test 6: Circuit leakage with restriction
NOTE: For “T” fitting test only
- Standard auxiliary up __________l/min __________gpm
- Standard auxiliary down __________l/min __________gpm
- Secondary auxiliary up (if applicable) __________l/min __________gpm
- Secondary auxiliary down (if applicable) __________l/min __________gpm
Notes:
47540694 28/04/2014
35.3 [35.128] / 8
Index

Auxiliary hydraulic function control - Pressure test – Circuit relief valve. (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Auxiliary hydraulic function control - Test – Circuit leakage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control valve - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Control valve - General specification – Secondary auxiliary valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
35.3 [35.128] / 9
47540694 28/04/2014
35.3 [35.128] / 10
Reservoir, cooler, and filters - 300
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
35.4 [35.300] / 1
Contents
SERVICE
Oil reservoir
Apply vacuum (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
47540694 28/04/2014
35.4 [35.300] / 2
Hydraulic systems - Reservoir, cooler, and filters
Oil reservoir - Apply vacuum

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Remove the cap from the hydraulic reservoir.

2. Install an adapter cap CAS1871 on the filler neck.
3. Connect the vacuum pump CAS10193 to the adapter.
47540694 28/04/2014
35.4 [35.300] / 3
Oil reservoir - Drain fluid

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.
Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect
fluids in proper containers. Obey all local and environmental regulations when disposing of chemi-
cals.
W0371A
Prior operation:
Remove the battery. Please see Battery - Remove (55.302)
NOTE: The drain plug for the hydraulic tank is located inside of the battery compartment.
1. Remove the filler cap on the hydraulic tank.
2. Place a container under the battery compartment.
3. Slowly remove the drain plug.
931001657 1
47540694 28/04/2014
35.4 [35.300] / 4
Oil reservoir - Filling

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Lower the loader lift arms to the ground and shut off the
engine.
2. Clean the reservoir filler cap and the area around the
filler cap with cleaning solvent.
3. Turn the filler cap 1/2 turn to relieve air pressure from
the reservoir. Do not remove the filler cap from the
reservoir until the pressure is relieved.
4. Remove the filler cap from the reservoir.
5. Add the correct oil to the reservoir until the proper oil
level in the reservoir is established. Fill the reservoir
until the oil level is at the midpoint of the sight gauge. 93106865 1
Install the reservoir cap.
6. Start and run the engine and operate the hydraulics.
Lower the loader lift arms to the ground. Stop the en-
gine and check the oil level in the reservoir. Add oil as
required.
47540694 28/04/2014
35.4 [35.300] / 5
Oil reservoir - Visual inspection

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Check the reservoir for wear, cracks, and leaks. Repair

as required.
NOTICE: Do not modify the strainer, as any material that
gets past the strainer can go directly to the gear pump,
control valve, cylinders, and auxiliary hydraulic attachment
and cause major damage to these components.
2. Inspect the strainer. Remove and replace if the strainer
is dirty or clogged.
3. Inspect the return line port, and suction line port, for
cracks and debris buildup. Repair as required.
47540694 28/04/2014
35.4 [35.300] / 6
Index

Oil reservoir - Apply vacuum (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil reservoir - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil reservoir - Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil reservoir - Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
47540694 28/04/2014
35.4 [35.300] / 7
47540694 28/04/2014
35.4 [35.300] / 8
Safety and main relief valves - 350
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
35.5 [35.350] / 1
Contents
TECHNICAL DATA
Main relief valve

SERVICE
Main relief valve

Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
47540694 28/04/2014
35.5 [35.350] / 2
Hydraulic systems - Safety and main relief valves
Main relief valve - General specification

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
RAIL12SSL0332GA 1
Main control valve
Main relief setting 207 - 217 bar (3000 - 3145 psi)

Circuit relief setting A1 = 220 - 235 bar (3190 - 3408 psi)
A2 = 255 - 270 bar (3698 - 3916 psi)
B2 = 225 - 240 bar (3263 - 3481 psi)
Valve identification (1) Main relief
(2) A1, pressure relief
(4) Load check
(5) B1, hydraulic, anti-cavitation
(6) B2, pressure relief
Port identification P – Supply inlet
T – Tank return
A1 – Lift cylinder base end
B1 – Lift cylinder rod end
A2 – Tilt cylinder rod end
B2 – Tilt cylinder base end
A3 – Auxiliary male coupler
B3 – Auxiliary female coupler
PLV – Work port lockout pilot supply
PLV Drain – Work port lockout tank return
P2 – High flow inlet
V – EH PRV supply
L – EH PRV tank return
47540694 28/04/2014
35.5 [35.350] / 3
Solenoid identification (7) Port lock
47540694 28/04/2014
35.5 [35.350] / 4
Main relief valve - Pressure test

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
CAUTION
Burn hazard!
C0107B
Pressure test using the auxiliary couplers

system.
readings.
loader arm.
RAPH12SSL0241AA 1
47540694 28/04/2014
35.5 [35.350] / 5
Main relief pressure

1. Activate the auxiliary function in one direction on the
machine, and hold the auxiliary switch in that position.
Slowly turn the pressure screw on the flow meter while
watching the flow meter pressure gauge and liter per
minute (l/min) gauge or gallon per minute (gpm) gauge.
Pump flow will remain relatively constant until the main
relief pressure is achieved. At the point of pressure re-
lief, pump flow will significantly drop below pump spec-
ification on the flow meter. Record the main relief pres-
sure.
Please see Main control valve - General specifica-
tion (35.359) for specification about the main control
valve.
RAPH12SSL0244AA 2
2. Release the auxiliary switch. Reset the flow meter.
Cracking pressure
3. Activate the auxiliary function in one direction on the
machine, and hold the auxiliary switch in that posi-
tion. Slowly turn the pressure screw on the flow me-
ter while watching the flow meter pressure gauge and
liter per minute (l/min) gauge or gallon per minute (gpm)
gauge. Pump flow will remain relatively constant un-
til the cracking pressure is achieved. At the point of
cracking pressure, pump flow will drop approximately
11 l/min (3 US gpm). Record the cracking pressure.
NOTE: Cracking pressure should be within 15 % of the
main relief pressure.
4. Release the auxiliary switch. Reset the flow meter.
47540694 28/04/2014
35.5 [35.350] / 6
Main relief valve - Pressure test

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
CAUTION
Burn hazard!
C0107B
Pressure test using the “T” fitting method

system.
readings.
fitting.
flow meter.
RAPH12SSL0246AA 1
flow meter.
RAPH12SSL0247AA 2
47540694 28/04/2014
35.5 [35.350] / 7
Main relief pressure

1. Stroke a bucket function to the end of the cylinder travel
on the machine, and hold the bucket in that position
using the joystick; This will put a load on the machine.
Slowly turn the pressure screw on the flow meter while
watching the flow meter pressure gauge and liter per
minute (l/min) gauge or gallon per minute (gpm) gauge.
Pump flow will remain relatively constant until the main
relief pressure is achieved. At the point of pressure re-
lief, pump flow will significantly drop below pump spec-
ification on the flow meter. Record the main relief pres-
sure.
Please see Main control valve - General specifica-
tion (35.359) for specification about the main control
valve.
RAPH12SSL0244AA 3
2. Release the stroked bucket function. Reset the flow

meter.
Cracking pressure
3. Stroke a bucket function to the end of the cylinder
travel on the machine, and hold the bucket in that
position using the joystick; This will put a load on the
machine. Slowly turn the pressure screw on the flow
meter while watching the flow meter pressure gauge
and liter per minute (l/min) gauge or gallon per minute
(gpm) gauge. Pump flow will remain relatively constant
until the cracking pressure is achieved. At the point of
cracking pressure, pump flow will drop approximately
11 l/min (3 US gpm). Record the cracking pressure.
NOTE: Cracking pressure should be within 15 % of the
main relief pressure.
4. Release the stroked bucket function. Reset the flow
meter.
47540694 28/04/2014
35.5 [35.350] / 8
Index

Main relief valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main relief valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Main relief valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
47540694 28/04/2014
35.5 [35.350] / 9
47540694 28/04/2014
35.5 [35.350] / 10
Main control valve - 359
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
35.6 [35.359] / 1
Contents
TECHNICAL DATA
Main control valve

SERVICE
Main control valve

Test – Circuit leakage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjust – Float detent (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove – Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install – Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove – Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install – Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove – Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install – Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove – Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install – Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remove – Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install – Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
47540694 28/04/2014
35.6 [35.359] / 2
Hydraulic systems - Main control valve
Main control valve - General specification

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
RAIL12SSL0332GA 1
Main control valve
Main relief setting 207 - 217 bar (3000 - 3145 psi)

Circuit relief setting A1 = 220 - 235 bar (3190 - 3408 psi)
A2 = 255 - 270 bar (3698 - 3916 psi)
B2 = 225 - 240 bar (3263 - 3481 psi)
Valve identification (1) Main relief
(4) Load check
(5) B1, hydraulic, anti-cavitation
(6) B2, pressure relief
T – Tank return
A1 – Lift cylinder base end
B1 – Lift cylinder rod end
A2 – Tilt cylinder rod end
B2 – Tilt cylinder base end
A3 – Auxiliary male coupler
B3 – Auxiliary female coupler
PLV – Work port lockout pilot supply
PLV Drain – Work port lockout tank return
P2 – High flow inlet
V – EH PRV supply
L – EH PRV tank return
47540694 28/04/2014
35.6 [35.359] / 3
Solenoid identification (7) Port lock
47540694 28/04/2014
35.6 [35.359] / 4
Main control valve - Test – Circuit leakage

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
CAUTION
Burn hazard!
C0107B
system.
readings.
fitting.
flow meter.
RAPH12SSL0246AA 1
flow meter.
RAPH12SSL0247AA 2
47540694 28/04/2014
35.6 [35.359] / 5
is achieved. While watching the flow meter liter per
minute (l/min) gauge or gallon per minute (gpm) gauge,
stroke each loader arm and bucket function to the end
of cylinder travel on the machine, and activate the pri-
mary auxiliary couplers in both directions. Record the
pump flow on the data collection sheet located on the
following page.
Compare the flow of every stroked function. Differ-
ences in pump flow indicate internal leaks and/or easier
paths to tank.
NOTE: Pump flow should be within 4 l/min (1 US gpm)
of pump specification. Please see Fixed displacement
pump - General specification (35.104) for specifications
on the gear pumps.
RAPH12SSL0329AA 3
47540694 28/04/2014
35.6 [35.359] / 6
Test 6: Circuit leakage with restriction
NOTE: For “T” fitting test only
- Bucket rollback __________l/min __________gpm
- Bucket dump __________l/min __________gpm
- Loader raise __________l/min __________gpm
- Loader lower __________l/min __________gpm
- Auxiliary up __________l/min __________gpm
- Auxiliary down __________l/min __________gpm
Notes:
47540694 28/04/2014
35.6 [35.359] / 7
Main control valve - Adjust – Float detent

1. Angle between lift control rod and ear on jackshaft must

be 90 °or less when spool is in neutral.
2. If angle is greater then 90 ° increase length of rod by
turning out the clevis ends on rod.
23112922A 1
3. If length of rod from ear on jackshaft to valve spool

is increased, the grip will need to be repositioned by
adjusting connecting rod.
23112923 2
4. Activate the left control lever inward fully. The handle

should remain activated. If detent still does not hold
check clearance between rod end and pivot. If rod end
is hitting, shorten connecting rod between grip and jack
shaft. After decreasing length of connecting rod, you
must check to confirm grip does not hit window or side
screen during full raise.
23112924 3
47540694 28/04/2014
35.6 [35.359] / 8
Main control valve - Remove – Proportional auxiliary valve retract

solenoid
200 Series Compact Track Loaders NA Mechanical hydraulic controls
Prior operation:
Tilt the ROPS
1. Locate proportional auxiliary valve retract solenoid (1)

on the loader valve block (2).
931002092B 1
2. Disconnect connector (1) from the proportional auxil-

iary valve retract solenoid (2).
931002095 2
3. Remove the two bolts securing the proportional auxil-

iary valve retract solenoid on the loader valve block.
47540694 28/04/2014
35.6 [35.359] / 9
Main control valve - Install – Proportional auxiliary valve retract

solenoid
200 Series Compact Track Loaders NA Mechanical hydraulic controls
1. Insert the proportional auxiliary valve retract solenoid

(1) into the loader valve block (2).
931002092B 1
2. Connect connector (1) to the proportional auxiliary

valve retract solenoid (2).
931002095 2
3. Insert the two retaining screws (1) into proportional aux-

iliary valve retract solenoid. Tighten to 5 N·m (3.7 lb ft).
931002095 3
47540694 28/04/2014
35.6 [35.359] / 10
Main control valve - Remove – Proportional auxiliary valve extend

solenoid
Prior operation:
Tilt the ROPS
1. Locate proportional auxiliary valve extend solenoid (1)

on the loader valve block (2).
931002092B 1
2. Disconnect connector (1) from the proportional auxil-

iary valve extend solenoid (2).
931002095 2
3. Remove the two bolts securing the proportional auxil-

iary valve extend solenoid on the loader valve block.
47540694 28/04/2014
35.6 [35.359] / 11
Main control valve - Install – Proportional auxiliary valve extend

solenoid
1. Insert the proportional auxiliary valve extend solenoid

(1) into the loader valve block (2).
931002092B 1
2. Connect connector (1) to the proportional auxiliary

valve extend solenoid (2).
931002095 2
3. Insert the two retaining screws (1) into proportional aux-

iliary valve extend solenoid. Tighten to 5 N·m (3.7 lb
ft).
931002095 3
47540694 28/04/2014
35.6 [35.359] / 12
Main control valve - Remove – Spool solenoids

Prior operation:
Tilt the ROPS
1. Locate the following solenoids:

1. Loader valve retract
2. Loader valve extend
3. Bucket valve extend
4. Bucket valve retract
5. Auxiliary valve extend
6. Auxiliary valve retract
2. Disconnect the electrical connector from the solenoid.
3. Remove the two bolts securing the solenoid on the
loader valve block. RAPH12SSL0445AA 1
4. Remove the solenoid.
47540694 28/04/2014
35.6 [35.359] / 13
Main control valve - Install – Spool solenoids

1. Locate the following solenoids:

1. Loader valve retract
2. Loader valve extend
3. Bucket valve extend
4. Bucket valve retract
5. Auxiliary valve extend
6. Auxiliary valve retract
2. Install the solenoid.
3. Insert the two retaining screws into the solenoid.
Torque the bolts to 5 N·m (44 lb in). RAPH12SSL0445AA 1
4. Reconnect the electrical connector.
47540694 28/04/2014
35.6 [35.359] / 14
Main control valve - Remove – Spool position sensors

1. Locate the following sensors:

1. Boom position sensor
2. Bucket position sensor
3. Auxiliary sensor
2. Disconnect the electrical connector.
3. Remove the nut holding the sensor.
4. Remove the sensor.
RAPH12SSL0446AA 1
47540694 28/04/2014
35.6 [35.359] / 15
Main control valve - Install – Spool position sensors

1. Locate the following sensors:

1. Boom position sensor
2. Bucket position sensor
3. Auxiliary sensor
2. Insert the sensor into the main control valve.
3. Thread the nut onto sensor.
4. Connect the electrical connector.
RAPH12SSL0446AA 1
47540694 28/04/2014
35.6 [35.359] / 16
Main control valve - Remove – Loader port lock solenoid

1. Locate the loader control valve (1) on the right hand

side of the machine.
NOTE: Image 1 is an example of the main control valve
for Electro-Hydraulic (EH) controlled machines. The loader
control valve on mechanically controlled machines is in the
same location.
RAPH12SSL0446AA 1
2. Disconnect the electrical connector (1) from the sole-

noid.
931002090 2
3. Remove the nut from the solenoid (1).
931002090 3
4. Remove the solenoid.
47540694 28/04/2014
35.6 [35.359] / 17
Main control valve - Install – Loader port lock solenoid

1. Place solenoid onto the loader control valve. Thread

nut (1) onto valve body.
931002090 1
2. Connect the electrical connector (1) to the solenoid.
931002090 2
47540694 28/04/2014
35.6 [35.359] / 18
Main control valve - Remove

WARNING
Burn hazard!
Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid
temperature should not exceed 40 °C (104 °F).
W0241A
WARNING
W0358A
WARNING
Pressurized system!
Never attempt to drain fluids or remove filters when the engine is running. Turn off the engine and
relieve all pressure from pressurized systems before servicing the machine.
W0905A
WARNING
4. Shut off engine.
W0047A
NOTICE: Before removing components from the hydraulic system, depressurize the system you are working on. See
reference Hydraulic systems - Depressurising (35.000)
Prior operation:
Tilt the ROPS.
1. Apply vacuum to hydraulic reservoir.

2. Label and disconnect the four rear solenoid connec-
tions (1).
931001708 1
47540694 28/04/2014
35.6 [35.359] / 19
3. Label and disconnect the six front solenoid connections

(1).
931001709 2
4. Label and disconnect six hydraulic tubes (1) from con-

trol valve and cap open ports.
931001713 3
5. Label and disconnect drain hoses (1) from control

valve.
931001715 4
6. Label and disconnect two hoses (1) and one tube (2)
from top of control valve.
931001710 5
47540694 28/04/2014
35.6 [35.359] / 20
7. Disconnect hydraulic tubes (1) located at bottom of

valve block.
931001714 6
8. Disconnect hydraulic hoses (1) from solenoid block.
931001711 7
9. Remove the three valve mounting bolts (1) (one

shown).
931001718 8
10. Remove loader valve.
931001719 9
47540694 28/04/2014
35.6 [35.359] / 21
Main control valve - Install

1. Position the control valve into the machine mounting

location.
931001719 1
2. Install the three valve mounting bolts (1) (one shown).
931001718 2
3. Connect hydraulic hoses (1) to solenoid block.
931001711 3
47540694 28/04/2014
35.6 [35.359] / 22
4. Connect hydraulic tubes (1) located at the bottom of

valve block.
931001714 4
5. Connect two hoses (1) and one tube (2) to the top of
control valve.
931001710 5
6. Connect the two drain hoses (1) to control valve.
931001715 6
7. Connect the six hydraulic tubes (1) to there correct

ports on the control valve.
931001713 7
47540694 28/04/2014
35.6 [35.359] / 23
8. Connect the six front solenoid connections (1).
931001709 8
9. Connect rear solenoid connections (1).
931001708 9
47540694 28/04/2014
35.6 [35.359] / 24
Index

Main control valve - Adjust – Float detent (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Main control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main control valve - Install – Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main control valve - Install – Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Main control valve - Install – Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Main control valve - Install – Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Main control valve - Install – Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main control valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main control valve - Remove – Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Main control valve - Remove – Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Main control valve - Remove – Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Main control valve - Remove – Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Main control valve - Remove – Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Main control valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Main control valve - Test – Circuit leakage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
47540694 28/04/2014
35.6 [35.359] / 25
47540694 28/04/2014
35.6 [35.359] / 26
High flow hydraulics - 600
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
35.7 [35.600] / 1
Contents
TECHNICAL DATA
Pilot valve
High flow hydraulic pump
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General specification – Enhanced High Flow (EHF) pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
High flow hydraulics

Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview – Enhanced high flow (EHF) system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pilot valve
SERVICE
Pilot valve
Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
High flow hydraulic pump
Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pressure test – Enhanced High Flow (EHF) relief valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
47540694 28/04/2014
35.7 [35.600] / 2
Hydraulic systems - High flow hydraulics
Pilot valve - General specification

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
RAPH14SSL0021EA 1
High flow valve
Hydraulic requirements Flow : 45 l/min (12 US gpm)

System pressure: 210 bar (3050 psi)
Maximum pressure drop across the valve: 45 l/min
(12 US gpm) at 10 bar (145 psi)
Relief valve setting 224 bar (3250 psi)
T – Tank return
AUX – Auxiliary outlet
47540694 28/04/2014
35.7 [35.600] / 3
High flow hydraulic pump - General specification
RAPH14SSL0003GA 1
High flow pump
Type Gear pump
Pump displacement 13.7 cm³ (0.84 in³)
Engine RPM 1800 RPM
Pump flow 34.8 l/min (9.2 US gpm)
High flow hydraulic pump - General specification – Enhanced High

Flow (EHF) pump
C238 NA
L230 NA
47540694 28/04/2014
35.7 [35.600] / 4
RAPH14SSL0015FA 1
EHF pump
Pump displacement 53 cm³ (3.2 in³)

Pump flow at 2500 RPM 126 - 133 l/min (33 - 35 US gpm)
Pressure relief setting, port A 266 - 286 bar (3857 - 4147 psi)
Pressure relief setting, port B 197 - 217 bar (2856.5 - 3146.5 psi)
Port identification A – Auxiliary line
B – Auxiliary line
T1 – Case drain
T2 – Case drain
X1 – Control pressure (before the orifice)
X2 – Control pressure (before the orifice)
R – Air bleed
Ma – Pressure gauge, operating pressure, port A
Mb – Pressure gauge, operating pressure, port B
G – Pressure, auxiliary circuit
S – Boost suction
Y – Pilot pressure
Ps – Control pressure supply
Fa – Filter outlet
Fe – Filter inlet
47540694 28/04/2014
35.7 [35.600] / 5
High flow hydraulics - Overview

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
If equipped with a high flow system, the operator can com-

mand additional flow to the auxiliary circuit by engaging
auxiliary high flow function. This will provide increased
flow to the auxiliary circuit. Please see High flow hy-
draulic pump - General specification (35.600) for spec-
ifications about the high flow pumps.
High flow feature is engaged by pressing the rocker switch

(1) mounted on left hand A post. The switch selects HF
(high flow) or HP (high pressure) and is illuminated when
high flow or enhanced high flow (EHF) is on. This allows
the operator to enable/disable the function depending on
the attachment requirements. NOTE: HP will activate only
if the machine is equipped with EHF. RCPH11SSL003AAD 1
The External Auxiliary Control can be controlled ONLY if ALL of the following conditions are met
1. Operator is seated properly
2. Operator Restraint engaged
3. The ignition is in the ON position
4. HF switch is activated
47540694 28/04/2014
35.7 [35.600] / 6
High flow hydraulics - Overview – Enhanced high flow (EHF) system

C238 NA
L230 NA
If equipped with an enhanced auxiliary high flow sys-

tem (EHF), the operator can command flow and higher
pressure to an additional auxiliary circuit by selecting HF
(high flow) or HP (high pressure) on the rocker switch (1).
Please see High flow hydraulic pump - General spec-
ification – Enhanced High Flow (EHF) pump (35.600)
for specification about the EHF pump. The loader control
valve standard auxiliary circuit is unaffected when High
Flow is disabled. When enhanced high flow/pressure
is enabled, the loader control valve standard auxiliary
circuit is limited to 2nd Aux circuit flow of 30.3 l/min (8 US
gpm). The 275 bar (4000 psi) high flow setting can only
be used with approved attachments and is controlled by
a circuit interlock installed at the multifunction plug with RCPH11SSL003AAD 1
the attachment.
The Enhanced High Flow Auxiliary Control can be controlled only if all of the following conditions are met
1. Operator is seated properly
2. Operator Restraint engaged
3. The ignition is in the ON position
4. Engine is running
5. Hydraulic Enable switch is activated
6. Multifunction high pressure interlock plug connected ("HP" mode only)
47540694 28/04/2014
35.7 [35.600] / 7
Pilot valve - Component localisation

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
RAIL13SSL1004FA 1
Valve location
47540694 28/04/2014
35.7 [35.600] / 8
Pilot valve - Pressure test

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
system.
1. Connect a 345 bar (5000 psi) pressure gauge to the
high flow, outlet auxiliary coupler.
NOTE: Verify flow direction for accurate reading and ma-
chine safety.
93106839B 1
2. Start the machine, and raise the engine speed to full

throttle.
3. Engage the auxiliary hydraulics and stroke a bucket
function to the end of the cylinder travel on the machine,
and hold the bucket in that position using the joystick;
This will put a load on the machine.
4. Select High Flow (HF) on the rocker switch (1).
RCPH11SSL003AAD 2
5. Record the pressure on the pressure gauge.

Please see Pilot valve - General specification
(35.600) for specifications on the high flow pilot valve.
6. Release the stroked bucket function and disengage the
auxiliary hydraulics.
47540694 28/04/2014
35.7 [35.600] / 9
7. If the recorded pressure is not within specification, re-

move the cap (1) on the relief valve and adjust.
931001689 3
8. Repeat steps 2 through 7 until the relief valve is within

specification.
47540694 28/04/2014
35.7 [35.600] / 10
Pilot valve - Remove

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Locate valve (1) on floor of the skid loader under hy-

draulic pump.
931001948 1
2. Disconnect the left hydraulic tube (2).

NOTE: Arrow indicates forward direction.
931001689 2
3. Disconnect hydraulic tubes (3) and (4) from the right of

the valve.
931001689 3
47540694 28/04/2014
35.7 [35.600] / 11
4. Disconnect the valves electrical connection (5).
931001689 4
5. Remove the two mounting bolts (2).
931001689 5
6. Remove valve.
931001690 6
47540694 28/04/2014
35.7 [35.600] / 12
Pilot valve - Install

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Locate the proper location on the floor for installation of

valve.
931001948 1
2. Install the two mounting bolts (1) through the valve and
secure it to the floor.
931001689 2
3. Connect the two hydraulic tubes (2) and (3) to the right
side of the valve.
931001689 3
47540694 28/04/2014
35.7 [35.600] / 13
4. Connect the top hydraulic tube (4).

931001689 4
5. Connect electrical connection (5).

931001689 5
47540694 28/04/2014
35.7 [35.600] / 14
High flow hydraulic pump - Flow test

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
CAUTION
Burn hazard!
C0107B
Efficiency test using the auxiliary couplers

system.
readings.
loader arm.
RAPH12SSL0241AA 1

3. Select HF on the rocker switch (1) and activate the
auxiliary couplers.
RCPH11SSL003AAD 2
47540694 28/04/2014
35.7 [35.600] / 15

pumps.
RAPH12SSL0242AA 3

pumps.
RAPH12SSL0243AA 4
Pump efficiency
47540694 28/04/2014
35.7 [35.600] / 16
Engine RPM
- Set RPM __________RPM
Notes:
Test 1: Pump flow
- Pump flow at full throttle without restriction __________l/min __________gpm
Notes:
- Pump flow at full throttle with 152 bar (2200 psi) __________l/min __________gpm
restriction
Notes:

Notes:
47540694 28/04/2014
35.7 [35.600] / 17
High flow hydraulic pump - Flow test

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
CAUTION
Burn hazard!
C0107B
Efficiency test using the “T” fitting method

system.
readings.
fitting.
flow meter.
RAPH12SSL0246AA 1
flow meter.
RAPH12SSL0247AA 2

47540694 28/04/2014
35.7 [35.600] / 18
5. Select High Flow (HF) on the rocker switch (1) and ac-
tivate the auxiliary couplers.
RCPH11SSL003AAD 3

pumps.
RAPH12SSL0242AA 4

pumps.
RAPH12SSL0243AA 5
47540694 28/04/2014
35.7 [35.600] / 19
Pump efficiency
47540694 28/04/2014
35.7 [35.600] / 20
Engine RPM
- Set RPM __________RPM
Notes:
Test 1: Pump flow
- Pump flow at full throttle without restriction __________l/min __________gpm
Notes:
- Pump flow at full throttle with 152 bar (2200 psi) __________l/min __________gpm
restriction
Notes:

NOTE: Pump efficiency should be no less than 70 %
Notes:
47540694 28/04/2014
35.7 [35.600] / 21
High flow hydraulic pump - Pressure test – Enhanced High Flow

(EHF) relief valves
C238 NA
L230 NA
CAUTION
Burn hazard!
C0107B
ATTENTION: Prolonged use of the EHF system with a pressure gauge attached to either auxiliary coupler will result
in EHF pump damage.
system.
NOTE: Two persons are required to perform the pressure tests to safely avoid possible injury. One person must be
seated in the operators seat when the engine is running. The second person is to take the readings.
1. Install a 414 bar (6000 psi) pressure gauge to the high
flow, male auxiliary coupler (1).
RCPH11SSL015BAD 1
2. Start the engine and run at 2500 RPM.

3. Select High Flow (HF) on the rocker switch (1).
4. Activate the auxiliary couplers.
RCPH11SSL003AAD 2
47540694 28/04/2014
35.7 [35.600] / 22
5. Read the pressure gauge, record the reading, and shut

off the EHF system.
RAPH12SSL0448AA 3
6. Please see High flow hydraulic pump - General

specification – Enhanced High Flow (EHF) pump
(35.600) for specifications on the EHF pump. If the
pressure is not within specification, repair or replace.
7. Install a 414 bar (6000 psi) pressure gauge to the high
pressure, female auxiliary coupler (1).
RCPH11SSL015BAD 4
8. Select High Pressure (HP) on the rocker switch (1).

9. Activate the auxiliary couplers.
RCPH11SSL003AAD 5
47540694 28/04/2014
35.7 [35.600] / 23
10. Read the pressure gauge, record the reading, and

shut off the machine.
RAPH12SSL0447AA 6
11. Please see High flow hydraulic pump - General

specification – Enhanced High Flow (EHF) pump
(35.600) for specifications on the EHF pump. If the
pressure is not within specification, repair or replace.
47540694 28/04/2014
35.7 [35.600] / 24
Index

High flow hydraulic pump - Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
High flow hydraulic pump - Flow test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
High flow hydraulic pump - General specification – Enhanced High Flow (EHF) pump (*) . . . . . . . . . . . . . . . . . . . . 4
High flow hydraulic pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
High flow hydraulic pump - Pressure test – Enhanced High Flow (EHF) relief valves (*) . . . . . . . . . . . . . . . . . . . . . 22
High flow hydraulics - Overview – Enhanced high flow (EHF) system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
High flow hydraulics - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pilot valve - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pilot valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pilot valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pilot valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pilot valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
47540694 28/04/2014
35.7 [35.600] / 25
47540694 28/04/2014
35.7 [35.600] / 26
Front loader arm hydraulic system - 701
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
35.8 [35.701] / 1
Contents
TECHNICAL DATA
Front loader arm hydraulic system

General specification - Lockout valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ride control solenoid valve block
Accumulator
FUNCTIONAL DATA

Overview – Loader lock control valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accumulator
SERVICE

Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lift arm cylinder
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Relief valve
Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Accumulator
47540694 28/04/2014
35.8 [35.701] / 2
Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Discharging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Charging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DIAGNOSTIC

Testing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
47540694 28/04/2014
35.8 [35.701] / 3
Hydraulic systems - Front loader arm hydraulic system
Front loader arm hydraulic system - General specification - Lockout

valve
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
RAPH12SSL0340GA 1
Loader arm lockout valve
Hydraulic requirements: Flow = 22.7 l/min (6 US gpm).

System pressure = 210 bar (3050 psi).
Port identification 1 - Tank return

2 - Lift cylinder base port
47540694 28/04/2014
35.8 [35.701] / 4
Front loader arm hydraulic system - General specification

RAPH14SSL0006FA 1

T - Tank return
B1 - Brake motor 1
B2 - Brake motor 2
Front loader arm hydraulic system - General specification

47540694 28/04/2014
35.8 [35.701] / 5
RAPH12SSL0381EA 1

T - Tank return
B1 - Brake motor 1
B2 - Brake motor 2
47540694 28/04/2014
35.8 [35.701] / 6
Ride control solenoid valve block - General specification

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
RAPH12SSL0338GA 1
Ride control valve
Hydraulic Requirements Flow = 22.7 l/min (6 US gpm)

System Pressure = 210 bar (3045 psi)
Maximum pressure drop across valve = 10 bar (145 psi) at 23 l/min (6 US
gpm)
Port Identification 1 – Tank Return
2 – Lift Cylinder Rod Port
3 – Accumulator
4 – Lift Cylinder Base Port
47540694 28/04/2014
35.8 [35.701] / 7
Accumulator - General specification

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Manufacturer Parker
Fluid Capacity 750 ml (25.4 US fl oz)
Charge with dry nitrogen 21 bar (300 psi)
Port Internal straight thread 3/4-16 UNF - 2B
47540694 28/04/2014
35.8 [35.701] / 8
Front loader arm hydraulic system - Overview – Loader lock control

valve
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
On-Road regulations require the loader arm and bucket to be locked in a ‘traveling’ position. To prevent the operator
from inadvertently lowering or raising the loader or bucket causing damage to roadway, vehicles or machine.
The operator places the bucket and loader in the appropriate position. Then the operator then switches the loader
lock to the on position, locking the bucket and loader in the set position. The operator will not be able to move the
bucket and loader until the loader lock switch has been turned off. The switch will illuminate when Loader Lock is on.
The function is always active when hydraulics are enabled.
A Mechanical Machine with Loader Lock on will trigger trouble code 4952. This is expected.
47540694 28/04/2014
35.8 [35.701] / 9
Front loader arm hydraulic system - Component localisation

RAIL13SSL1004FA 1
Valve location
47540694 28/04/2014
35.8 [35.701] / 10
Ride control solenoid valve block - Component localisation

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
RAIL13SSL1004FA 1
Valve location
47540694 28/04/2014
35.8 [35.701] / 11
Accumulator - Component localisation

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
RAIL13SSL1004FA 1
Valve location
47540694 28/04/2014
35.8 [35.701] / 12
Front loader arm hydraulic system - Pressure test

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. If the hydraulic oil is not at operating temperature run

the engine at full throttle and hold the bucket control
lever in the ROLLBACK position for 30 seconds. Then
return the bucket control lever to NEUTRAL for 15 sec-
onds. Repeat this cycle until the temperature of the oil
is at least 52°C (125°F).
2. Disconnect the hydraulic lines from the implement con-
troller where they connect to the main control valve.
3. Connect a 41 bar (600 psi) pressure gauges to pilot
line at spool ends.
4. Start the engine and run at high idle. Read the pressure
gauge and record the pressure reading at high idle.
Pressure should be 0 bar (0.0 psi) with lever in neutral.
5. Move the implement controller lever to raise the loader
control arms. Read the pressure gauge and record the
pressure reading.
6. Move the implement controller lever to lower the loader
control arms. Read the pressure gauge and record the
pressure reading.
7. The pressure readings should vary from 0 bar (0.0 psi)
to 25 bar (360 psi) at high idle for a given angle on the
implement control handle.
8. If the pressure readings are correct, the test is com-
plete. If the pressure readings are not correct, repair or
replace the charge/hydrostatic pump assembly or the
main control valve.
47540694 28/04/2014
35.8 [35.701] / 13
Lift arm cylinder - Remove

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Heavy objects!
W0398A
WARNING
Burn hazard!
W0241A
WARNING
W0358A
WARNING
Pressurized system!
W0905A
WARNING
4. Shut off engine.
W0047A
47540694 28/04/2014
35.8 [35.701] / 14
1. Label and disconnect cylinder hoses (1) and cap open

ports
93112872 1
2. Remove lift cylinder rod end pin (2) and retaining bolt
(1) and nut (3) from boom arm.
93112873 2
3. Remove rod end pins and washers (1).
931001616 3
4. Lower cylinders (1) down.
93112875 4
47540694 28/04/2014
35.8 [35.701] / 15
5. Remove lock nut (1) and pin retaining bolt (2) on frame.
93112874 5
6. Remove rod end pins and washers from both sides of

the frame.
931001630 6
7. Remove cylinders
931001632 7
Next operation:
Lift arm cylinder - Install (35.701)
47540694 28/04/2014
35.8 [35.701] / 16
Lift arm cylinder - Install

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Heavy objects!
W0398A
Prior operation:
Lift arm cylinder - Remove (35.701)
1. Lubricate the rod end pins, (1), with LOCTITE® SILVER

GRADE ANTI-SEIZE 767 lubricant.
2. Install the cylinder onto the skid steer.
931001630 1
3. Install pin retaining bolt (1), and locknut, (2).

4. Torque the upper pivot pin hardware to 38 Nm ( 28 lb
ft.
931001629 2
5. Install the rod end pins and washers (1) through the lift
arms and cylinder end.
931001616 3
47540694 28/04/2014
35.8 [35.701] / 17
6. Install rod end snap rings (1).
931001618 4
7. Install the hydraulic cylinder hoses (1), and position to

prevent contact with other components, fenders, etc.
Tighten hose fittings to standard torque.
8. Lower the lift arm
9. Start the skid steer and cycle the boom several times
to remove trapped air from the system and check the
cylinder for leaks.
931001628 5
47540694 28/04/2014
35.8 [35.701] / 18
Lift arm cylinder - Disassemble

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Prior operation:
Lift arm cylinder - Remove (35.701)
1. Clean the outside of the cylinder. If the hoses were

removed from the cylinder, remove the hoses.
2. Fasten the tube (1) in a vise, or other holding equipment
can be used. Be careful not to damage the tube.
3. Loosen the gland (5) in the tube with a gland wrench.
4. To prevent damage to the tube, pull the piston rod (3)
straight out of the tube.
5. Fasten the piston rod end in a vise. To prevent damage
to the piston rod, place a padded support below the
piston rod near the piston.
6. Loosen and remove the nut that connects the piston on
the piston rod.
7. Remove the piston (6) from the piston rod.
8. Remove and discard the seal (11), wear ring (13) and
backup ring (12) from the piston.
9. Remove and discard the O-ring (9), backup ring (10),
seals (8), and wiper (7) from the gland (5).
20111254 1
47540694 28/04/2014
35.8 [35.701] / 19
(1) Tube (4) Bushing (7) Wiper (10) Backup ring (13) Wear ring
(2) Bushing (5) Packing gland (8) Seal (kit) (11) Seal (14) Nut
(3) Piston Rod (6) Piston (9) O-ring (12) Backup Ring (15) Rod end
47540694 28/04/2014
35.8 [35.701] / 20
Lift arm cylinder - Assemble

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Prior operation:
Lift arm cylinder - Disassemble (35.701)
20111254 1
1. Tube 7. Wiper 13. Wear ring

2. Bushing 8. Seal (kit) 14. Nut
3. Piston Rod 9. O-ring 15. Rod end
4. Bushing 10. Backup ring
5. Packing gland 11. Seal
6. Piston 12. Backup Ring
NOTE: If a new gland is being installed, put the part number of the cylinder on the new gland.
1. Before assembly, lubricate the rod (3) and the cylinder
bore with hydraulic oil.
2. Lubricate a new seal (8) with clean hydraulic oil. Insert
the new seal into the gland so the lips are toward the
small end of the gland.
3. Lubricate a new wiper (7) with hydraulic oil. Insert the
new wiper into the gland so the lips are toward the large
end of the gland.
4. Lubricate a new backup ring (10) with clean hydraulic
oil. Insert the new backup ring into the groove on the
outside of the gland so the flat side is toward the large
end of the gland.
47540694 28/04/2014
35.8 [35.701] / 21
5. Lubricate a new O-ring (9) with clean hydraulic oil. In-

sert the O-ring into the groove and onto the backup ring
on the outside of the gland.
6. Fasten the piston rod end (15) in a vise.
7. Remove any marks or sharp edges on the chamfered
end of the piston rod.
8. Lubricate the bore of the gland with clean hydraulic oil.
9. Push the gland onto the piston rod. If the gland will not
slide easily onto the piston rod, use a soft hammer to
drive the gland onto the piston rod.
10. To prevent damage to the piston rod, place a support
below and near the end of the piston rod. Use a shop
cloth between the support and the piston rod.
11. Install the piston (6) onto the end of the piston rod.
12. Clean the threads on the end of the piston rod and
the threads of the nut using Loctite cleaning solvent.
Allow all the parts to dry. Apply 1/2 in of LOCTITE® 242
onto the threads of the piston rod 1/4 in from the open
end of the piston rod.
NOTE: Do not apply LOCTITE® 242 to the first 1/4 in of the
piston rod threads.
13. Install the nut (14).
14. Tighten the nut to a torque of 365 - 469 Nm ( 270 -
346 lb ft). A torque multiplier can be used to tighten
the nut.
15. Lubricate a new backup ring (12) with clean hydraulic
oil. Slide the backup ring into the center groove on the
outside of the piston.
16. Lubricate a new seal (11) with clean hydraulic oil.
Slide the new seal onto the backup ring on the out-
side of the piston.
17. Lubricate a new wear ring (13) with clean hydraulic
oil. Slide the new wear ring into the end groove on the
opposite end of the piston.
18. Lubricate the inside of the tube and the piston with
clean hydraulic oil. Use a piston ring compression tool
to hold the new wear ring in place.
19. Push the tube straight onto the piston.
20. Start the tube onto the piston rod assembly. Push the
tube onto the piston rod until the compression tool is
clear of the piston rod. Be careful not to damage the
wear ring and the seal.
21. When the piston is in the smooth part of the tube, start
the gland into the tube.
22. Lubricate the new O-ring on the gland with clean hy-
draulic oil.
23. Tighten the gland to the torque of 407 Nm ± 68 Nm (
300 lb ft ± 50 lb ft).
47540694 28/04/2014
35.8 [35.701] / 22
24. If hoses were removed with the cylinder, install new

O-rings, if equipped, on the hose fittings. Lubricate
the new O-rings with clean hydraulic oil and install the
hoses.
47540694 28/04/2014
35.8 [35.701] / 23
Ride control solenoid valve block - Remove

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Burn hazard!
W0241A
WARNING
W0358A
WARNING
Pressurized system!
W0905A
WARNING
4. Shut off engine.
W0047A
1. Locate ride control valve (1) on the skid steer chassis.
931001804 1
47540694 28/04/2014
35.8 [35.701] / 24
2. Disconnect the valve electrical connection (1).
931001696 2
3. Remove hose clamp and disconnect drain hose (1) and

cap open ports.
931001693 3
4. Disconnect the lower hydraulic tube (1) and cap open

ports.
931001693 4
5. Disconnect the two upper hydraulic tubes (1) and cap

open ports.
931001698 5
47540694 28/04/2014
35.8 [35.701] / 25
6. Remove mounting hardware (1).
931001698 6
7. Remove valve.
931001700 7
Next operation:
Ride control solenoid valve block - Install (35.701)
47540694 28/04/2014
35.8 [35.701] / 26
Ride control solenoid valve block - Install

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Prior operation:
Ride control solenoid valve block - Remove (35.701)
1. Locate valve (1) position on body.
931001804 1
2. Install mounting hardware (1).
931001698 2
3. Connect upper tubes (1).
931001698 3
47540694 28/04/2014
35.8 [35.701] / 27
4. Connect the lower hydraulic tube (1).
931001693 4
5. Connect drain hose (1) and secure with hose clamp.
931001693 5
6. Connect valve electrical connection (1).
931001696 6
7. Disengage cab lock and tilt cab down.
47540694 28/04/2014
35.8 [35.701] / 28
Relief valve - Pressure test

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA

3. Stop the engine.
circuit pressure.
5. The best way to connect the hand pump is directly to
the control valve. Disconnect the tube from the port
of the control valve and connect the hand pump to the
port. Please see Main control valve - General spec-
ification (35.359) for specifications on ports. By con-
necting directly to the control valve, you avoid the pos-
sibility of a bad reading because of cylinder movement.
point, but do not tighten the connection.
8. Make sure that the hand pump is filled with oil. The
temperature of the oil must be at least 21°C (70°F).
pump with oil. Then tighten the connections.
several times to make sure that the indications are
correct.
11. Compare the indication with the specification on Main
control valve - General specification (35.359) the
indication is not correct, replace the circuit relief valve.
NOTE: The circuit relief valves for the loader circuit are not
adjustable and must be replaced if they do not meet the
specification.
valve.
47540694 28/04/2014
35.8 [35.701] / 29
Accumulator - Visual inspection

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
BS96H067 1
1. Tube 5. Quad ring 9. Guard 13. Body

2. Gland with gas valve 6. O-ring 10. Gas valve assembly 14. Gland without gas valve
3. Piston 7. Backup ring (if used) 11. Cap
4. Seal 8. Cap screw 12. Valve core
Prior operation:
Accumulator - Disassemble (35.701)
1. Clean all parts in cleaning solvent.
47540694 28/04/2014
35.8 [35.701] / 30
2. Illuminate the inside of the tube (1). Inspect the inside

of the tube for deep grooves or other damage. If the
tube is damaged, replace with a new tube or cylinder.
3. In a rotary motion, use an emery cloth with medium grit
to remove small scratches on the piston (3), glands (2)
and (14), and tube (1).
4. Inspect the glands (2) and (14), for rust or corrosion.
Clean and remove the rust or corrosion from the gland.
5. Inspect the piston (3). Check to see if it is worn or
damaged. If the piston is worn or damaged, replace
with a new accumulator.
6. Inspect the gland ends of the tube (1) for sharp edges.
Remove the sharp edges. Sharp edges can damage
the seals (4), quad ring (5), and O-rings (6).
Next operation:
Accumulator - Assemble (35.701)
47540694 28/04/2014
35.8 [35.701] / 31
Accumulator - Pressure test

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
BS04D004 1
1. Ensure that the oil side of the accumulator is completely

discharged.
2. Put the ride control switch in the "On" position.
3. Lower the loader to the floor. Put the loader control
lever in the "Float" position.
4. Stop the engine. Put the key in the "On" position.
5. Move the loader control lever in all directions to release
any pressure in the hydraulic circuits. Put the loader
control lever in the "Float" position.
6. Find the right and left solenoid valves for the ride control
system. Find the pin in the coil end of the solenoid.
Depress the pin in the solenoid valves with a soft pin
(such as a welding rod) to release any pressure in the
loader lift circuit.
7. Leave the ride control switch and key switch in the "On"
postion.
8. Leave the loader control lever in the "Float" position.
9. Close the valves (B) and (C) on the nitrogen charging
kit.
10. Turn the stem out of valve (F) until the stem stops.
11. Remove the cap screws and guard from the accumu-
lator.
47540694 28/04/2014
35.8 [35.701] / 32
12. Remove the cap from the valve stem on the accumu-
lator.
13. Connect valve (F) to the valve stem.
14. Make sure that valve (D) is open.
15. Turn the stem into valve (F) and read the pressure on
gauge (E).
16. The pressure must be 275 - 325 psi ( 1897 -
2241 kPa, 19 - 23 bar). If the pressure is too low,
charge the accumulator with dry nitrogen.
47540694 28/04/2014
35.8 [35.701] / 33
Accumulator - Discharging
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
NOTICE: Do not attempt to disassemble any accumulator until the nitrogen charge is properly discharged.
NOTICE: To help prevent equipment damage, the low pressure gauge (3) must be shut "Off" during high pressure (
150 psi/ 10 bar and above) applications.
934477A 1
(A) - Regulator (C) - Low pressure gauge (E) (G) - To nitrogen tank
(B) (D) (F) (H) - To accumulator
1. Use the accumulator charging kit CAS10899 to dis-
charge the accumulator. The tool must be discon-
nected from the nitrogen tank.
2. Close valves (B), (C) and (D).
3. Adjust the regulator (A) to the minimum pressure set-
ting by turning the knob counterclockwise.
4. Turn the T-handle on valve (F) fully out.
5. Remove the guard and cap from the accumulator
charging stem.
6. Connect valve (F) to the stem on the accumulator.
7. Turn the T-handle inward on valve (F) to engage the
pin in the valve stem.
8. Open valve (D). Check the charge pressure on gauge
(E).
47540694 28/04/2014
35.8 [35.701] / 34
9. Partially open valve (B) to discharge the accumulator.

The accumulator charge will bleed down through the
regulator.
10. Once the accumulator is fully discharged, disconnect
valve (F) from the accumulator stem.
47540694 28/04/2014
35.8 [35.701] / 35
Accumulator - Charging
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
SPECIAL TOOLS
BS06M002 1
380001676 Nitrogen Regulator Valve
BS06M003-01 2
380001390 Accumulator Charging Hose
NOTE: Check the pressure in the accumulator according to the instructions in this section. Keep the nitrogen charging
kit connected to the accumulator.
47540694 28/04/2014
35.8 [35.701] / 36
BT09C458 3
Nitrogen Charging Kit
NOTE: Do not expose the accumulator to temperatures above 120°F (49°C). A charged accumulator contains nitrogen
compressed to 1600 PSI (11 032 kPa). High heat will cause the safety plug to blow out of the accumulator and the
escaping nitrogen will propel the accumulator at a dangerous rate of speed. M407
Charging Accumulator with Nitrogen

WARNING
Explosion hazard!
Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an explo-
sion.
W0975A
WARNING
Explosion hazard!
Do not expose the accumulator to temperatures above 120°F (49°C). A charged accumulator contains
nitrogen compressed to 110 bar (1600 PSI). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
W0977C
NOTICE: The four valves A, D, and E must be in the positions noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen tank refer to image 3.
1. Close the shutoff valve (D) by turning it all the way to
the left (counterclockwise).
2. Close the gauge valve (E) by turning it all the way to
the right (clockwise).
3. Connect the charging gauges to the nitrogen supply
tank, open the supply tank valve.
47540694 28/04/2014
35.8 [35.701] / 37
4. Slowly turn valve (D) clockwise while watching the

pressure gauge (B). Stop turning valve (D) when the
needle on gauge (B) reaches 10 bar (145 psi).
NOTE: If the needle goes over the needed pressure,
quickly open and close valve (E) and check the pressure
again.
The charging kit is now ready to be installed on the accu-
mulator.
5. Remove the cap from the accumulator.
6. Loosen the sealing plug with an Allen wrench.
7. Back off the needle valve (A) on the accumulator end
of the charging hose by turning it counterclockwise to
the maximum position. This prevents nitrogen from es-
caping from the accumulator when the charging hose
is attached to the accumulator gas charging valve.
8. Install the charging hose fitting onto the accumulator.
9. Tighten the needle valve by turning it clockwise. Slowly
open the gauge valve (E) and observe the reading on
the gauge. This reading is the nitrogen pressure level
inside the accumulator.
10. Fill the accumulator to a charge pressure of 20.7 -
22.4 bar (300 - 325 psi).
11. Close valve (E) by turning to the right (clockwise). Af-
ter a few minutes open valve (E) and check the accu-
mulator for leakage.
12. Back off the needle valve (A) on accumulator end of
the charging hose by turning it counterclockwise the
maximum amount. This will prevent nitrogen from es-
caping from the accumulator as the hose is removed.
13. Close the valve on the nitrogen supply tank.
14. Adjust the regulator (D) to the minimum pressure set-
ting by turning the knob counterclockwise.
15. Slowly remove the charging hose from the accumula-
tor pressure valve.
NOTE: A small amount of nitrogen will escape when disconnecting the hose.
16. Install the cap on the accumulator, torque to
1.13 N·m (10 lb in).
NOTE: A small amount of nitrogen will escape when disconnecting the hose.
47540694 28/04/2014
35.8 [35.701] / 38
Accumulator - Disassemble
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Prior operation:
Accumulator - Remove (35.701)
1. Fasten the accumulator tube (1) in a vise with soft jaws.

Be careful not to damage the tube.
NOTICE: The gland with the gas valve must be removed
first.
2. Loosen and remove the glands (2) or (14) from each
end of the tube.
3. Use a rod and push the piston (3) out of the gas valve
end of the tube.
4. Remove and discard the seals (4) and quad ring (5)
from the piston.
5. Remove and discard the O-rings (6) and if used, the
backup ring (7) from the glands.
6. Loosen and remove the cap screws (8) and guard (9).
7. Loosen and remove the gas valve assembly (10).
8. Remove the O-ring (6), cap (11), and valve core (12)
from the body (13).
BS96H067 1
47540694 28/04/2014
35.8 [35.701] / 39

Next operation:
Accumulator - Visual inspection (35.701)
47540694 28/04/2014
35.8 [35.701] / 40
47540694 28/04/2014
35.8 [35.701] / 41
Accumulator - Assemble
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
BS96H068 1

Prior operation:
Accumulator - Disassemble (35.701)
1. Slide one new seal (4), on one end of the piston.

2. Slide one new quad ring (5) into the middle groove of
the piston.
3. Slide one new seal (4) on the other end of the piston.
4. Lubricate the bore of the tube (1) and the piston (3) with
clean hydraulic oil.
NOTE: The piston must be installed slowly to prevent dam-
age to the threads on the quad ring.
47540694 28/04/2014
35.8 [35.701] / 42
5. Start the piston (3) into the gas valve end of the tube
(1). A soft hammer and wood block may be used to
drive the piston farther into the tube. Carefully drive
the piston at least 2 in ( 51 mm) into the tube. Keep
pressure against the piston when driving the piston into
the tube, to prevent damage to the quad ring (5). Follow
the same procedure for the non-gas valve end of the
tube.
6. If used, install a new back ring (7) on the gland (2).
Make sure the backup ring is installed. Follow the same
procedure for the non-gas valve end of the tube.
7. Install the O-ring (6) next to the backup ring (7). If a
backup ring is not used, install an O-ring in the groove
on the gland. Follow the same procedure for the non-
gas valve end of the tube.
BS04D006 2
8. Lubricate the O-ring (6) and the backup ring (7) with
clean hydraulic oil. Start the gland (2) into the tube (1).
Follow the same procedure for the non-gas valve (14)
end of the tube.
9. Fasten the tube (1) in the vise. Tighten the gland (2).
Follow the same procedure for the non-gas valve end
of the tube
10. Install a new O-ring (6)on the body (13)of the gas
valve assembly (10).
11. Install the valve core (12) in the body (13).
12. Lubricate the O-ring (6) with clean hydraulic oil. Install
and tighten the gas valve assembly (10)in the gland
(2).
13. Install the cap (11).
14. Charge the accumulator with dry nitrogen. Please re-
fer to Accumulator - Charging (35.701)
15. Install the guard (9) and cap screws (8).
Next operation:
Accumulator - Install (35.701)
47540694 28/04/2014
35.8 [35.701] / 43
Front loader arm hydraulic system - Testing

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
N° Test Point Expected Result Other Result (Possible Cause)

1 Check Result Result
Check to ensure the cab door is fully Door is closed. Door is opened.
closed (If equipped with cab door). Action Action
Go to test 2 Close door.
Check the cab door switch (If equipped Switch is okay. No power or ground.
with cab door). Action Door switch is misaligned.
Go to test 3 Action
Repair.
Check the Implement Controller interlock Valve functioning as designed. No power or ground.
valve power/function. Action Valve doesn’t function.
Go to test 4 Action
Repair or replace.
Check the charge pressure. Charge pressure okay. Low charge pressure.
Action Action
Go to test 5 Check the charge pressure..
Check the pilot pressure from the Im- Pilot pressure is okay. Low pilot pressure.
plement Controller to the Loader Control Action Action
Valve. Go to test 6 Please see Front loader arm hy-
draulic system - Pressure test
(35.701)
Check the main control valve function. Main control valve is okay. Main control valve not functioning
as designed.
Action
Repair or replace the main control
valve.
47540694 28/04/2014
35.8 [35.701] / 44
Index

Accumulator - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Accumulator - Charging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Accumulator - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Accumulator - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Accumulator - Discharging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Accumulator - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Accumulator - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Accumulator - Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Front loader arm hydraulic system - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front loader arm hydraulic system - General specification - Lockout valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front loader arm hydraulic system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front loader arm hydraulic system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front loader arm hydraulic system - Overview – Loader lock control valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front loader arm hydraulic system - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Front loader arm hydraulic system - Testing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Lift arm cylinder - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Lift arm cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lift arm cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Lift arm cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Relief valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Ride control solenoid valve block - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ride control solenoid valve block - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ride control solenoid valve block - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Ride control solenoid valve block - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
47540694 28/04/2014
35.8 [35.701] / 45
47540694 28/04/2014
35.8 [35.701] / 46
Front loader bucket hydraulic system - 723
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
35.9 [35.723] / 1
Contents
SERVICE
Front loader bucket hydraulic system

Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSTIC
Front loader bucket hydraulic system

Testing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47540694 28/04/2014
35.9 [35.723] / 2
Hydraulic systems - Front loader bucket hydraulic system
Front loader bucket hydraulic system - Pressure test

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. If the hydraulic oil is not at operating temperature run

the engine at full throttle and hold the bucket control
lever in the ROLLBACK position for 30 seconds. Then
return the bucket control lever to NEUTRAL for 15 sec-
onds. Repeat this cycle until the temperature of the oil
is at least 52°C (125°F).
2. Disconnect the hydraulic lines from the implement con-
troller where they connect to the main control valve.
3. Connect a 41 bar (600 psi) pressure gauges to pilot
line at spool ends.
4. Start the engine and run at high idle. Read the pressure
gauge and record the pressure reading at high idle.
Pressure should be 0 bar (0.0 psi) with lever in neutral.
5. Move the implement controller lever to tilt the loader
bucket. Read the pressure gauge and record the pres-
sure reading.
6. Move the implement controller lever to dump the loader
bucket. Read the pressure gauge and record the pres-
sure reading.
7. The pressure readings should vary from 0 bar (0.0 psi)
to 25 bar (360 psi) at high idle for a given angle on the
implement control handle.
8. If the pressure readings are correct, the test is com-
plete. If the pressure readings are not correct, repair or
replace the charge/hydrostatic pump assembly or the
main control valve.
47540694 28/04/2014
35.9 [35.723] / 3
Hydraulic systems - Front loader bucket hydraulic system
Front loader bucket hydraulic system - Testing

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA

Check to ensure the cab door is fully Door is closed. Door is opened.
closed (If equipped with cab door). Action Action
Go to test 2 Close door.
Check the cab door switch (If equipped Switch is okay. No power or ground.
with cab door). Action Door switch is misaligned.
Go to test 3 Action
Repair.
Check the Implement Controller interlock Valve functioning as designed. No power or ground.
valve power/function. Action Valve doesn’t function.
Go to test 4 Action
Repair or replace.
Check the charge pressure. Charge pressure okay. Low charge pressure.
Action Action
Go to test 5 Check the charge pressure..
Check the pilot pressure from the Im- Pilot pressure is okay. Low pilot pressure.
plement Controller to the Loader Control Action Action
Valve. Go to test 6 Please see Front loader arm hy-
draulic system - Pressure test
(35.701)
Check the main control valve function. Main control valve is okay. Main control valve not functioning
as designed.
Action
Repair or replace the main control
valve.
47540694 28/04/2014
35.9 [35.723] / 4
Index

Front loader bucket hydraulic system - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front loader bucket hydraulic system - Testing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47540694 28/04/2014
35.9 [35.723] / 5
47540694 28/04/2014
35.9 [35.723] / 6
Front loader hydraulic system control - 724
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
35.10 [35.724] / 1
Contents
FUNCTIONAL DATA
Loader bucket self-leveling controls

Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE

Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove – Solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install – Solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSTIC

Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
47540694 28/04/2014
35.10 [35.724] / 2
Hydraulic systems - Front loader hydraulic system control
Loader bucket self-leveling controls - Overview

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
As the loader arm cylinder extends, flow from the rod port
is directed to port A (1). Flow entering port A (1) is able
to pass through the adjustable orifice and fixed orifice in
the flow divider spool. The proportion of the flow split is
determined by size of the adjustable orifice. Please see
the charts below for specifications about your machine’s
flow split.
The remainder of the flow passes through the fixed ori-
fice, out port B (4) back to the control valve and returns
to tank. The flow that passes through the adjustable ori-
fice flows out port D (2) and is teed to the base end of
the bucket cylinders. The resistance on the movement
of the bucket cylinders creates a pressure high enough to
open the unloading spool in the self-leveling valve. As the
bucket cylinders extends, the flow from the rod port of the
bucket cylinders enters port C (3) past the open unload-
ing spool around the flow divider spool and out port B (4)
back to the control valve and returns to tank.
RAIL12SSL0327BA 1
Models: L213, L215, L216

Flow split proportion Port D = 48 %
Port B = 52 %
Models: L218, C238

Port B = 40 %
Models: L220, L221

Port B = 60 %
Models: L223, C227

Port B = 50 %
Models: L225, L230, C232

Port B = 28 %
Port identification chart

Self leveling valve port ID A = Lift cylinder rod end
B = CV work port B1
C = Tilt cylinder rod end
D = Tilt cylinder base end
47540694 28/04/2014
35.10 [35.724] / 3
Loader bucket self-leveling controls - Exploded view

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
RAPH12SSL0328FA 1
Self-leveling valve
Self-leveling valve identification

(1) Plug (2) O-ring (3) Flow divider spool
(4) Valve body (5) Load check plunger (6) Load check spring
(7) Pin (8) Adjustment cap (9) Set screw
(10) Jam nut (11) Cap (12) Spring
(13) Plunger (14) Unloading spool
47540694 28/04/2014
35.10 [35.724] / 4
Loader bucket self-leveling controls - Sectional view

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
The self-leveling control valve consists of a spring loaded, flow divider spool (10) with a fixed orifice (4) in the center.
The fixed orifice (4) controls how far the flow divider spool (10) opens when oil is directed to it. An adjustable orifice
(3) is used to control the amount of oil sent out of the valve body, and therefore regulates the amount of leveling for
the bucket. The self-leveling valve has a check valve assembly (5) that allows oil to flow to the base of the bucket
cylinder and prevents oil from backfeeding through the self-leveling valve when the bucket spool is actuated. The
unloading spool (9) allows a controlled amount of oil to escape from the rod end of the bucket cylinder as self-leveling
is occurring. Because bucket leveling is controlled by a flow divider spool (10), the amount of leveling that occurs
depends on the oil flow from the loader lift cylinder, and therefore changes with engine speed.
The system is designed to operate with the engine at high idle. At speeds less than high idle, the bucket may not
maintain level as the loader is raised. Raising the loader very slowly can affect the bucket leveling, because sufficient
oil flow is not available to provide adequate pressure through the fixed orifice (4).
47540694 28/04/2014
35.10 [35.724] / 5
RAIL13SSL0993GA 1
Self-leveling valve
Self-leveling valve identification

(1) Self-leveling solenoid (5) Check valve (9) Unloading spool
(2) Port A (6) Port D (10) Flow divider spool
(3) Adjustable orifice (7) Port C (11) Port B
(4) Fixed orifice (8) Unloading valve spring
47540694 28/04/2014
35.10 [35.724] / 6
Loader bucket self-leveling controls - Component localisation

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
RAIL13SSL1004FA 1
Valve location
47540694 28/04/2014
35.10 [35.724] / 7
Loader bucket self-leveling controls - Adjust

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
DANGER
Crushing hazard!
D0020A
1. Locate the set screw (1) on the top, right of the self-
leveling valve.
NOTE: The set screw (1) may be covered. Remove the
cover by gently tapping on the cover.
2. Loosen the jam nut on the set screw (1).
3. Turn the set screw (1)
• counter-clockwise to increase flow to the bucket
cylinders
• clockwise to decrease flow to the bucket cylinders
4. Tighten the jam nut.
931001981 1
47540694 28/04/2014
35.10 [35.724] / 8
Loader bucket self-leveling controls - Remove – Solenoid

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Prior operation:
Tilt the ROPS.
1. Locate self level valve solenoid Y-318 (1) on the right

side, middle of the machine.
931001804 1
2. Disconnect connector X-318 (1) from the self level

valve solenoid Y-318 (2).
931001701 2
3. Loosen and remove nut (1). Remove the self level

valve solenoid Y-318 (2).
931001702 3
Next operation:
Loader bucket self-leveling controls - Install – Solenoid (35.724)
47540694 28/04/2014
35.10 [35.724] / 9
Loader bucket self-leveling controls - Install – Solenoid

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Prior operation:
Tilt the ROPS.
1. Insert the self level valve solenoid Y-318 (1) into the
valve block (2).
931001702 1
2. Thread nut (1) on stud and tighten to standard torque.
931001701 2
3. Reconnect connector X-318 (1) to the self level valve

solenoid Y-318 (2).
931001701 3
47540694 28/04/2014
35.10 [35.724] / 10
Loader bucket self-leveling controls - Remove

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Prior operation:
Tilt the ROPS.
NOTE: Never loosen any hydraulic lines without first relieving all pressure in the system. Refer to Hydraulic systems
- Depressurising (35.000)
1. Locate control valve (1).
931001804 1
2. Disconnect electrical connection (1).
931001701 2
3. Disconnect hydraulic tube (1) and cap open ports.
931001702 3
47540694 28/04/2014
35.10 [35.724] / 11
4. Disconnect lower tubes (1) and cap ports.
931001981 4
5. Disconnect front tube (1) and cap port.
931001981 5
6. Remove mounting hardware (1).
931001981 6
7. Remove control valve.
931001707 7
47540694 28/04/2014
35.10 [35.724] / 12
Loader bucket self-leveling controls - Install

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Install control valve (1) onto body in correct location.
931001804 1
2. Install mounting hardware (1).
931001981 2
3. Connect front tube (1).
931001981 3
47540694 28/04/2014
35.10 [35.724] / 13
4. Connect lower tubes (1).
931001981 4
5. Connect hydraulic tube (1).
931001702 5
6. Connect electrical connection (1).
931001701 6
47540694 28/04/2014
35.10 [35.724] / 14
Loader bucket self-leveling controls - Troubleshooting

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA

Boom delay at start of Bucket self-leveling is designed to work at Run engine at high idle.
self level or unstable high idle.
self-level.
Air in system. Cycle boom and bucket slowly to rid system
of air.
Loaded bucket dumps Unloading spool is leaking. Remove and inspect unloading spool for
or uncurls when control damage.
valve is in neutral.
Insufficient self-level. Adjustable orifice is out of adjustment. Replace the self-leveling valve.
Broken unloading spool spring. Replace unloading spool Replace unload-
ing spool
Flow divider spool stuck towards adjust- Remove flow divider spool and check for
ment pin side. damage.
With bucket dumped, Dampening orifice in the unloading spool is Remove unloading spool and clean damp-
boom is slow in starting plugged. ening orifice.
to raise.
Bucket does not move in Bucket self-leveling is designed to work at Run engine at high idle.
self-level. high idle.
Adjustable orifice is screwed in all the way. Replace the self-leveling valve.
Dampening orifice in the unloading spool is Remove unloading spool and clean damp-
plugged. ening orifice.
Bucket does not maintain Flow divider spool is stuck. Check flow divider spool for free operation.
level while raising at high
idle.
Excessive bucket drift Bad bucket cylinder packing Repack cylinder.
towards the dump
direction.
Excessive loader control valve port leak- Replace loader valve.
age.
Unloading spool in the leveling valve stuck. Check unloading spool for free operation.
Excessive bucket drift Bad bucket cylinder packing. Repack cylinder.
towards the roll back
direction.
Excessive loader control valve leakage. Replace loader valve.
Defective lift check in the leveling valve Check lift check for leakage.
External leakage. Damaged o-ring. Replace o-ring.
47540694 28/04/2014
35.10 [35.724] / 15
Index

Loader bucket self-leveling controls - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Loader bucket self-leveling controls - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Loader bucket self-leveling controls - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Loader bucket self-leveling controls - Install – Solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Loader bucket self-leveling controls - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Loader bucket self-leveling controls - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Loader bucket self-leveling controls - Remove – Solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Loader bucket self-leveling controls - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Loader bucket self-leveling controls - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Loader bucket self-leveling controls - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
47540694 28/04/2014
35.10 [35.724] / 16
Tool quick coupler hydraulic system - 734
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
35.11 [35.734] / 1
Contents
TECHNICAL DATA
Tool quick coupler hydraulic system

FUNCTIONAL DATA

SERVICE

Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Quick coupler cylinder
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
47540694 28/04/2014
35.11 [35.734] / 2
Hydraulic systems - Tool quick coupler hydraulic system
Tool quick coupler hydraulic system - General specification

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
RAPH12SSL0386EA 1
Hydraulic coupler valve
Relief pressure 172 bar (2500 psi)

Port identification P - Pump supply inlet
T - Tank return
C1 - Cylinder base end
C2 - Cylinder rod end
47540694 28/04/2014
35.11 [35.734] / 3
Tool quick coupler hydraulic system - Component localisation

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
RAIL13SSL1004FA 1
Valve location
47540694 28/04/2014
35.11 [35.734] / 4
Tool quick coupler hydraulic system - Pressure test

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA

3. Stop the engine.
circuit pressure.
5. Connect the hand pump is directly to the control valve.
Disconnect the tube from the port of the control valve
and connect the hand pump to the port.
point. Do not tighten the connection.
8. Verify that the hand pump is filled with oil. The temper-
ature of the oil must be at least 21°C (70°F).
pump with oil. Tighten the connections.
several times to verify that the indications are correct.
11. Compare the indication with the specification of the
hydraulic coupler valve. If the indication is not correct,
repair or replace the circuit relief valve.
valve.
47540694 28/04/2014
35.11 [35.734] / 5
Tool quick coupler hydraulic system - Remove

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Pressurized system!
System is still under pressure. Release pressure according to instructions in this manual.
W1044A
1. Label and disconnect electrical connection (1).
931001722 1
2. Label and disconnect the bucket hydraulic tubes (1)

and cap the open ports.
931001720 2
3. Label and disconnect the supply tube (1) and cap the
open ports.
931001720 3
47540694 28/04/2014
35.11 [35.734] / 6
4. Label and disconnect the drain hose (1).
931001720 4
5. Remove the mounting hardware (2).
931001720 5
6. Remove the command valve.
931001721 6
47540694 28/04/2014
35.11 [35.734] / 7
Tool quick coupler hydraulic system - Install

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Locate where the command valve (1) should be posi-

tioned on the body.
931001720 1
2. Install the mounting hardware (1).
931001720 2
3. Connect the valve drain hose (1).
931001720 3
47540694 28/04/2014
35.11 [35.734] / 8
4. Connect the valve supply tube (1).
931001720 4
5. Connect the bucket hydraulic tubes (2).
931001720 5
6. Connect the electrical connection (1).
931001722 6
47540694 28/04/2014
35.11 [35.734] / 9
Quick coupler cylinder - Remove

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Burn hazard!
W0241A
WARNING
W0358A
WARNING
Pressurized system!
W0905A
WARNING
4. Shut off engine.
W0047A
1. Remove snap ring (1).
931001791 1
47540694 28/04/2014
35.11 [35.734] / 10
2. Remove retaining pin (1).
931001788 2
3. Disconnect hydraulic hoses (1) and (2), from manifold.
931001786 3
4. Remove rod end hydraulic hose (1).
931001789 4
5. Disengage the roll pin and bucket locking pin (1).
931001783 5
47540694 28/04/2014
35.11 [35.734] / 11
6. Remove cylinder.
931001784 6
Next operation:
Quick coupler cylinder - Install (35.734)
47540694 28/04/2014
35.11 [35.734] / 12
Quick coupler cylinder - Install

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Prior operation:
Quick coupler cylinder - Remove (35.734)
1. Hold cylinder in mounting location on the skid steer and

engage bucket locking pin (1) through the rod end.
931001782 1
2. Through the top of the cylinder install the retaining pin

(1).
931001788 2
3. Secure the retaining pin with a snap ring (1).
931001791 3
47540694 28/04/2014
35.11 [35.734] / 13
4. Connect the rod end hydraulic hose (1).
931001789 4
5. WARNING
Unexpected movement!
When cylinders are connected to the machine
hydraulic system, cycle the hydraulic circuits
several times to remove air from the cylinder
and hose. Air in the system can cause erratic
operation or can cause equipment to drop un-
expectedly.
ous injury.
W1083A
Connect hydraulic hoses (1) and (2), to the manifold.

931001786 5
47540694 28/04/2014
35.11 [35.734] / 14
Index

Quick coupler cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Quick coupler cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Tool quick coupler hydraulic system - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tool quick coupler hydraulic system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tool quick coupler hydraulic system - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tool quick coupler hydraulic system - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tool quick coupler hydraulic system - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
47540694 28/04/2014
35.11 [35.734] / 15
PRINTED IN U.S.A.
47540694 28/04/2014
EN
SERVICE MANUAL
Frames and ballasting
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
39
Contents
Frames and ballasting - 39
[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
47540694 28/04/2014
39
Ballasts and supports - 140
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
39.1 [39.140] / 1
Contents
SERVICE
Counterweight
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
47540694 28/04/2014
39.1 [39.140] / 2
Frames and ballasting - Ballasts and supports
Counterweight - Remove
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
DANGER
Heavy objects!
D0076A
Prior operation:
Remove the battery. See Battery - Remove (55.302).
Left hand side

1. Support the counterweight with a suitable lifting device.
Remove corner mounting hardware (1).
2. Remove the counterweight.
RAPH12SSL0289AA 1
Right hand side

3. Support the counterweight with a suitable lifting device.
Remove corner mounting hardware (1).
4. Remove the counterweight.
RAPH12SSL0041AA 2
47540694 28/04/2014
39.1 [39.140] / 3
Center bumper
5. Support the center bumper with a suitable lifting device.
Remove center bumper mounting hardware (1).
RAPH12SSL0040AA 3
6. Remove center bumper (3).
931001656 4
47540694 28/04/2014
39.1 [39.140] / 4
Counterweight - Install
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
DANGER
Heavy objects!
D0076A
1. Place rear center bumper (1) in position.
931001656 1
2. Install center bumper mounting hardware (2).
RAPH12SSL0040AA 2
3. Install left hand side counterweight and secure in place

with mounting hardware (3).
931001655 3
NOTE: Perform the same operation on right hand side.
Next operation:
47540694 28/04/2014
39.1 [39.140] / 5
Battery - Install (55.302).
47540694 28/04/2014
39.1 [39.140] / 6
Index

Counterweight - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Counterweight - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
39.1 [39.140] / 7
PRINTED IN U.S.A.
47540694 28/04/2014
EN
SERVICE MANUAL
Wheels
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
44
Contents
Wheels - 44
[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1
[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2
47540694 28/04/2014
44
Wheels - 44
Front wheels - 511
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
44.1 [44.511] / 1
Contents
Wheels - 44
Front wheels - 511
TECHNICAL DATA
Front wheels
47540694 28/04/2014
44.1 [44.511] / 2
Wheels - Front wheels
Front wheels - General specification

L223 NA
L225 NA
L230 NA
WARNING
Explosion hazard!
Always maintain correct tire pressure as indicated in this manual. DO NOT inflate tires above the
recommended pressure. Excessive pressure could result in tire failure.
W0109A
WARNING
Explosion hazard!
Tires must be replaced by skilled personnel with the proper tools and technical knowledge. Unskilled
personnel replacing wheels or tires could result in serious physical injuries, tire damage, and/or wheel
distortion. Always have a qualified tire mechanic service wheels and tires.
W0171A
NOTE: The following also applies to rear wheels.
The skid steer will be hard to turn and the tires will wear faster if the correct pressure is not maintained. When a
worn or damaged tire is replaced, the replacement must be the same size and tread design as the other tires on the
machine. Two different sized tires on one side of the machine will cause accelerated tire wear, loss of power, and
excessive strain on the drivetrain. Replace worn tires in pairs with the two new tires used on the same side of the
loader. If this tilts the loader too much, replace all four tires.
Adding air to the tires

Tire pressure gauges should be checked at regular intervals for calibration and accuracy.
TIRE SIZE PRESSURE

XD2002 10x16.5 40 - 60 psi
XD2002 12x16.5 40 - 60 psi
Beefy Baby II 10x16.5 40 - 60 psi
Hulk 10x16.5 40 - 60 psi
Hulk 12x16.5 40 - 60 psi
Bulky Hulk 33/15.5x16.5 40 - 60 psi
King Kong 10x16.5 40 - 60 psi
Hippo 31/15.5x16.5 40 - 60 psi
Hippo 33/15.5x16.5 40 - 60 psi
Wheel torque
Taper nut 169.5 N·m (125 lb ft)
Flange nut 203.5 N·m (150 lb ft)
This procedure is only for adding air to the tire. If the tire has lost most or all of the air, do the following:
1. Before you add air, have the wheel correctly installed on the machine or put the wheel in a restraining device (tire
inflation cage).
2. Use an air hose with a remote shutoff valve, self-locking air chuck and wear eye protection.
3. Stand behind the tread of the tire and make sure all persons are away from the side of the tire before you start to
add air.
4. Inflate the tire to the recommended air pressure. Do not inflate the tire more than the recommended maximum
pressure given on the tire.
47540694 28/04/2014
44.1 [44.511] / 3
Index
Wheels - 44
Front wheels - 511

Front wheels - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
44.1 [44.511] / 4
Wheels - 44
Rear wheels - 520
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
44.2 [44.520] / 1
Contents
Wheels - 44
Rear wheels - 520
TECHNICAL DATA
Rear wheels
47540694 28/04/2014
44.2 [44.520] / 2
Wheels - Rear wheels
Rear wheels - General specification

L223 NA
L225 NA
L230 NA
WARNING
Explosion hazard!
Always maintain correct tire pressure as indicated in this manual. DO NOT inflate tires above the
recommended pressure. Excessive pressure could result in tire failure.
W0109A
WARNING
Explosion hazard!
Tires must be replaced by skilled personnel with the proper tools and technical knowledge. Unskilled
personnel replacing wheels or tires could result in serious physical injuries, tire damage, and/or wheel
distortion. Always have a qualified tire mechanic service wheels and tires.
W0171A
The skid steer will be hard to turn and the tires will wear faster if the correct pressure is not maintained. When a
worn or damaged tire is replaced, the replacement must be the same size and tread design as the other tires on the
machine. Two different sized tires on one side of the machine will cause accelerated tire wear, loss of power, and
excessive strain on the drivetrain. Replace worn tires in pairs with the two new tires used on the same side of the
loader. If this tilts the loader too much, replace all four tires.
Adding air to the tires

Tire pressure gauges should be checked at regular intervals for calibration and accuracy.
TIRE SIZE PRESSURE

XD2002 10x16.5 40 - 60 psi
XD2002 12x16.5 40 - 60 psi
Hulk 10x16.5 40 - 60 psi
Hulk 12x16.5 40 - 60 psi
Bulky Hulk 33/15.5x16.5 40 - 60 psi
Hippo 31/15.5x16.5 40 - 60 psi
Hippo 33/15.5x16.5 40 - 60 psi
Wheel torque
Taper nut 169.5 N·m (125 lb ft)
Flange nut 203.5 N·m (150 lb ft)
This procedure is only for adding air to the tire. If the tire has lost most or all of the air, do the following:
1. Before you add air, have the wheel correctly installed on the machine or put the wheel in a restraining device (tire
inflation cage).
2. Use an air hose with a remote shutoff valve, self-locking air chuck and wear eye protection.
3. Stand behind the tread of the tire and make sure all persons are away from the side of the tire before you start to
add air.
4. Inflate the tire to the recommended air pressure. Do not inflate the tire more than the recommended maximum
pressure given on the tire.
47540694 28/04/2014
44.2 [44.520] / 3
Index
Wheels - 44
Rear wheels - 520

Rear wheels - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
44.2 [44.520] / 4
47540694 28/04/2014
44.2 [44.520] / 5
PRINTED IN U.S.A.
47540694 28/04/2014
EN
SERVICE MANUAL
Tracks and track suspension
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
48
Contents
Tracks and track suspension - 48
[48.100] Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.1
[48.130] Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2
[48.134] Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.3
[48.138] Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.4
47540694 28/04/2014
48
Tracks - 100
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
48.1 [48.100] / 1
Contents
Tracks - 100
SERVICE
Rubber track
Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
47540694 28/04/2014
48.1 [48.100] / 2
Tracks and track suspension - Tracks
Rubber track - Tension adjust

C232 NA
C238 NA
1. Follow the procedure in Steps 1 and 2 of Rubber track

- Remove (48.100) and raise and install blocks under
the machine to securely block the machine in the raised
position so that the tracks are off the ground.
231002469 1
2. Remove the screws (1) from the adjuster cover (2) and
remove the cover (2).
231002468A 2
3. Tighten the grease valve (1) to a torque of 90 ± 10 Nm

(66 ± 10 lb ft). Install a power grease gun on the grease
zerk (3) on the grease valve (1).
231002478 3
4. To tighten the track, apply grease to the adjuster (2) to

increase the tension to the track.
231002478 4
47540694 28/04/2014
48.1 [48.100] / 3
5. Apply grease to the adjuster until the distance from the

bottom of the 2 center rollers (1) to the top surface (2)
of the track is within 12 - 19 mm (0.47 - 0.75 in)
231002475 5
6. To loosen the track, loosen the grease valve on the ad-

juster until grease discharges from the adjuster. Allow
the grease to discharge from the adjuster until the dis-
tance from the bottom of the two center rollers to the
top surface of the track is within 12 - 19 mm (0.47 -
0.75 in) as shown in the step above. When the dis-
tance is within the specifications, tighten the grease
valve to a torque of 90 ± 10 Nm (66 ± 10 lb ft) .
NOTE: DO NOT remove the grease valve body from the
adjuster. Internal parts (ball, spring, and poppet) may be
lost.
47540694 28/04/2014
48.1 [48.100] / 4
Rubber track - Remove

C232 NA
C238 NA
1. Park the machine on a level surface with the bucket

approximately 125 mm (5 in) off of the ground and stop
the engine.
231002469 1
2. Place 101 mm (4 in) blocks on the ground under the

bucket. Enter the operators compartment and start the
engine and lower the bucket until the front of the ma-
chine is raised off the ground. Stop the engine and exit
the operators compartment. Place a floor jack under
the rear of the machine and raise the rear of the ma-
chine until the tracks are completely off of the ground.
Install blocks under the machine to securely block the
machine in the raised position with the tracks off the
ground.
3. Remove the screws (1) from the adjuster cover (2) and
remove the cover.
231002468A 2
4. Slowly loosen the grease valve (1) on the adjuster (2)

until the grease begins to discharge from the adjuster
(2). Allow the grease to completely discharge from the
adjuster (2) to release the tension on the track as the
idler wheel moves rearward.
NOTE: DO NOT remove the grease valve body from the
adjuster. Internal parts (ball, spring, and poppet) may be
lost.
231002478 3
47540694 28/04/2014
48.1 [48.100] / 5
5. The idler wheel (1) can be moved farther rearward ei-

ther by pushing the idler wheel rearward or by lifting on
the center (2) of the track.
231002469 4
6. Lift the track (2) off of the drive sprocket (1) to allow
room for the drive sprocket (1) to slide off of the hub.
Next operation: Refer to Sprocket - Remove (48.130)
and remove the drive sprocket (1).
231002469 5
7. Remove the rubber track from the main frame (2)
231002469 6
47540694 28/04/2014
48.1 [48.100] / 6
Rubber track - Install

C232 NA
C238 NA
1. Follow the procedure in Steps 1 and 2 of Rubber track

- Remove (48.100) and raise and install blocks under
the machine to securely block the machine in the raised
position so that the tracks are off the ground.
231002469 1
2. Install the track around the rear idler wheel (1). Make
sure the rear idler wheel is between the guide teeth (2)
on the track.
231002473 2
3. Continue towards the front idler wheel (1) engaging the

track guide teeth (3) between the rollers (2) and then
around the front idler wheel (1). Make sure the front
idler wheel (1) is between the guide teeth (3) on the
track.
Next operation: Refer to Sprocket - Install (48.130)
and install the drive sprocket.
Next operation: Refer to Rubber track - Tension ad-
just (48.100) and adjust the tension of the track.
231002474 3
47540694 28/04/2014
48.1 [48.100] / 7
Index
Tracks - 100
Rubber track - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rubber track - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rubber track - Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
48.1 [48.100] / 8
Track frame and driving wheels - 130
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
48.2 [48.130] / 1
Contents
SERVICE
Sprocket
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47540694 28/04/2014
48.2 [48.130] / 2
Tracks and track suspension - Track frame and driving wheels
Sprocket - Remove
C232 NA
C238 NA
1. Prior operation: Refer to Rubber track - Tension ad-

just (48.100) and completely loosen the tension on the
track.
Make reference marks on the cover (1) and the drive
sprocket (2) to be used for alignment and the bolt
torque procedure during installation.
231002477A 1
2. Loosen and remove the socket head cap screws (1)

from the drive sprocket (2). Use acceptable lifting
equipment and lift the track above the drive sprocket
to allow the guide teeth to disengage from the drive
sprocket. Slide the drive sprocket off of the hub and
remove the drive sprocket.
231002477A 2
47540694 28/04/2014
48.2 [48.130] / 3
Sprocket - Install
C232 NA
C238 NA
NOTE: Photos are for reference only. Photo shows socket head cap screws installed on the drive sprocket.
1. Slide the drive sprocket over the hub. If the same
sprocket that was removed is being installed, use the
alignment marks made during removal to align the drive
sprocket on the hub. Lift the track above the drive
sprocket to allow the drive sprocket to engage the guide
teeth (1) on the track. Make sure the drive sprocket is
between the guide teeth (1) on the track.
231002477A 1
2. Install the socket head cap screws (1) into the drive
sprocket (2).
231002477A 2
3. Use the reference mark on the hub as the starting point

and tighten the socket head cap screws to a torque of
67 - 163 Nm (50 - 120 lb ft) in the sequence shown.
231002477A 3
47540694 28/04/2014
48.2 [48.130] / 4
4. Tighten the socket head cap screws to a final torque of

285 - 320 Nm (208 - 235 lb ft) in the sequence shown.
Next operation: After the drive sprocket has been in-
stalled, follow the procedure - Rubber track - Tension
adjust (48.100) and adjust the tension of the track.
231002477A 4
47540694 28/04/2014
48.2 [48.130] / 5
Index

Sprocket - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sprocket - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
48.2 [48.130] / 6
Track tension units - 134
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
48.3 [48.134] / 1
Contents
SERVICE
Track tensioner
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Idler wheel
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
47540694 28/04/2014
48.3 [48.134] / 2
Tracks and track suspension - Track tension units
Track tensioner - Remove

C232 NA
C238 NA
Prior operation:
Refer to Rubber track - Remove (48.100) and remove the track from the machine
1. Remove the track from the machine.
231002469 1
2. Slide the track tension assembly (2) out of the main

frame (1).
231002470 2
3. Slide the yoke assembly (2) off of the track tension as-
sembly (1).
231002470 3
47540694 28/04/2014
48.3 [48.134] / 3
Track tensioner - Install

C232 NA
C238 NA
1. Slide the yoke assembly (2) onto the track tension as-
sembly (1).
231002471 1
2. Slide the track tension assembly (2) into the main frame
(1).
231002470 2
Next operation:
Refer to Rubber track - Install (48.100) and install the track.
After the track has been installed, follow the procedure Rubber track - Tension adjust (48.100) and adjust the tension
of the track.
47540694 28/04/2014
48.3 [48.134] / 4
Idler wheel - Remove

C232 NA
C238 NA
Prior operation:
Refer to Rubber Track - Rubber track - Remove (48.100) and remove the track from the machine.
1. Front Idler Wheel:

Remove the track from the machine. Slide the track
tension assembly (2) out of the main frame (1).
231002470 1
2. Loosen and remove the mounting screw (1) in the yoke

(2) which fastens the front idler wheel (3) to the yoke
(2). Remove the front idler wheel (3) from the yoke (2).
231002471 2
3. Rear Idler Wheel:

Loosen and remove the cap screw (1) and washer from
the rear idler wheel (2). Remove the rear idler wheel (2)
from the main frame (3).
231002472 3
47540694 28/04/2014
48.3 [48.134] / 5
Idler wheel - Install

C232 NA
C238 NA
NOTE: Apply LOCTITE® 243 to the threads of the front and rear idler wheel mounting bolts prior to installation.
1. Front Idler Wheel:
Install the front idler wheel (3) into the yoke (2). Install
the screw into the yoke and into the front idler wheel.
Tighten the screw (1) to a torque of 183 - 205 Nm (136
- 153 lb ft)
231002471 1
2. Slide the track tension assembly (2) into the main frame
(1).
231002470 2
3. Rear Idler Wheel:

Install the rear idler wheel (2) into the main frame (3).
Install the screw (1) into the main frame and into the
rear idler wheel (2). Tighten the screw (1)to a torque of
555 - 620 Nm (406 - 460 lb ft).
231002472 3
Next operation:
After the track has been installed, follow the procedure - Rubber track - Tension adjust (48.100) and adjust the
tension of the track.
47540694 28/04/2014
48.3 [48.134] / 6
Index

Idler wheel - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Idler wheel - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Track tensioner - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Track tensioner - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
48.3 [48.134] / 7
47540694 28/04/2014
48.3 [48.134] / 8
Track rollers - 138
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
48.4 [48.138] / 1
Contents
Track rollers - 138
SERVICE
Track rollers
Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Track rollers
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
47540694 28/04/2014
48.4 [48.138] / 2
Tracks and track suspension - Track rollers
Track rollers - Adjust

C232 NA
C238 NA
1. Make sure all paint is removed from contact surface on

end cap and shaft.
23112927 1
2. Inspect inside edge at all roller locations for any excess

paint or rough edges. Remove as required.
23112928 2
23112929 3
3. Add one Keeper to each end of the rear idler. Two

Keepers total are required.
23112930 4
47540694 28/04/2014
48.4 [48.138] / 3
4. Start both bolts, but do not tighten.
23112931 5
5. Insert one shim (1) on each end of the rear idler (2). A
total of two shims are needed, the arrows show there
location. Be sure to add medium strength thread locker
(3)
23112932 6
23112933 7
6. Move Idler as far back in holes as possible and tighten

bolts.
23112934 8
47540694 28/04/2014
48.4 [48.138] / 4
7. Make sure the idler end cap ears are not pinched by
track frame after bolts are tight.
23112935 9
8. Install roller with out bolts and push roller against inside
track frame wall.
9. Use shim as guide to determine the required number
of shims needed to fill gap between the roller and the
track frame wall.
10. Maximum of one shim on each end of the roller.
11. If only one shim is required, install between roller and
the outside track frame wall.
12. Install shim as shown
23112937 10
13. Install bolts in roller, but do not tighten. Repeat shim

procedure for all three rollers, then add medium
strength thread lock, before tightening all of the bolts.
23112938 11
47540694 28/04/2014
48.4 [48.138] / 5
14. Spin all rollers by hand.
23112939 12
NOTE: Rollers should spin easily by hand, using only your palm to grip the roller.
If a roller does not spin freely

15. Remove edge of track frame wall for 2 inches on each
side of roller hole.
16. Install roller and confirm roller spins freely.
23112940 13
47540694 28/04/2014
48.4 [48.138] / 6
Track rollers - Remove

C232 NA
C238 NA
Prior operation:
Refer to Rubber track - Remove (48.100) and remove the track from the machine.
NOTE: Photos are for reference only. Photo shows track installed on the machine.
1. After the track has been removed from the machine,
loosen and remove the cap screws and washers (1)
from the roller (2). Remove the roller (2) from the track
assembly.
231002476 1
2. Repeat the procedure above and remove the remaining

rollers (1) from the track assembly.
231002476 2
47540694 28/04/2014
48.4 [48.138] / 7
Track rollers - Install

C232 NA
C238 NA
NOTE: Photos are for reference only. Photo shows track installed on the machine.
NOTE: Apply Locktite 243 to the threads of the roller mounting bolts prior to installation.
1. Install the roller (2) into the mounting location in the
track frame. Install the cap screw (1) and washer into
the track frame and through the roller pilot hole. Tighten
the mounting bolt (1) to a torque of 336 - 371 Nm. (248
- 274 lb ft)
231002476 1
2. Install the remaining rollers in the track frame mounting

locations. Install the cap screw and washer into the
track frame and through the roller pilot hole. Tighten
the mounting bolt to a torque of 336 - 371 Nm. (248 -
274 lb ft)
231002476 2
Next operation:
After the track has been installed, follow the procedure Rubber track - Tension adjust (48.100) and adjust the tension
of the track.
47540694 28/04/2014
48.4 [48.138] / 8
Index
Track rollers - 138

Track rollers - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Track rollers - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Track rollers - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
47540694 28/04/2014
48.4 [48.138] / 9
PRINTED IN U.S.A.
47540694 28/04/2014
EN
SERVICE MANUAL
Cab climate control
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
50
Contents
Cab climate control - 50
[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
47540694 28/04/2014
50
Heating - 100
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
50.1 [50.100] / 1
Contents
Heating - 100
SERVICE
Cab heater
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
47540694 28/04/2014
50.1 [50.100] / 2
Cab climate control - Heating
Cab heater - Remove

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Prior operation:
Tilt the ROPS.
1. Remove the operators seat. If unit is equipped with EH

controls remove the control towers.
93104685 1
2. At the front of the chassis, remove the cleanout hole

blockoff plate (1), by removing the four hardware bolts
(2).
93104642 2
3. Remove the cab lift strut and floor pan. Do not remove
the cab tip safety lock!
4. Remove spring (3), from the hole on left hand side con-
trol shield. Remove shields (1), and (2), from below the
heel plate.
23112407 3
5. Drain the existing coolant from the engine and radiator.

Save for reuse.
47540694 28/04/2014
50.1 [50.100] / 3
6. Remove heater hoses (1), from the back exterior of the

cab and the front corners of the upper chassis. Cap
open ports.
93112374 4
7. Disconnect the cab supply hose (1), and cab return

hose (2) from the heater box (3).
23112404 5
8. Disconnect the heater supply hose (1), from the ther-

mostat housing and install plug fitting. Disconnect the
heater return hose (2), from the engine coolant inlet
tube (3), and connect EGR coolant hose.
23112404 6
9. Remove the heater hoses (1), and all heater hose hard-
ware from the machine. The hoses are mounted under
the engine, between the flywheel side engine mounts.
23112404 7
10. Disconnect the chassis harness electrical connector

from the water valve.
11. Remove the headliner and left hand and right hand
consoles.
47540694 28/04/2014
50.1 [50.100] / 4
12. Remove three fir tree fasteners, to remove the rear

trim panel (1), over the heater box and washer bottle.
NOTE: Washer bottle cap (2), must be removed first.
93104640 8
13. Remove the six directional louvers (1), in the ducts (2).
93104640 9
14. Remove the fir tree fasteners (1), from cab side, and
bolts (2) from the heater box. Remove ducts (3), and
(4), from the heater box.
93104691 10
93104640 11
15. Disconnect heater box electrical connector from the

cab harness.
47540694 28/04/2014
50.1 [50.100] / 5
16. Remove the heater box (1), from the firewall.
93104649 12
17. Remove air intake duct (1), from firewall.
93104649 13
47540694 28/04/2014
50.1 [50.100] / 6
Cab heater - Install

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Tip cab and remove seat; remove the cover plate from
behind the seat, if equipped. If unit has EH controls
remove the control towers.
2. Remove HVAC switch blanking decal from left hand
console.
93104685 1
3. Take the left hand console loose from the a-post. Add
heater control decal (1), fan switch (2), temperature
control potentiometer (3), and knobs (4), and (5).
4. The right hand console and headliner must be removed
in order to install the deluxe cab harness and roof foam
for added sound reduction. If neither are needed the
right hand console and headliner may be left in place.
5. If converting from an open cab without radio, remove
and replace the cab harness with a deluxe cab har-
ness and remove the rear cover from behind the seat,
if equipped.
6. [Optional] Clean and degrease underside of roof panel 93104650 2
and install roof foam using firm even pressure.
7. Remove the blocking plates that cover the fresh air in-
take hole and plumbing holes in the firewall and cab
floor.
8. Install the heater box sealing foam at the back of the
cab floor.
9. Bolt the air intake duct (1) to the firewall.
93104649 3
47540694 28/04/2014
50.1 [50.100] / 7
10. Bolt the heater box (2) to the firewall. Be careful to

ensure that the plumbing ports are inserted properly
through the hole in the cab floor.
11. Connect heater box electrical connector to the cab
harness.
12. Install ducts (1) and (2) to heater box using bolts (3)
and anchor to side of cab using fir tree fasteners (4).
Ensure that wiring harness is not pinched between the
ducts and the cab side.
93104691 4
13. Install directional louvers (5) in the ducts.

14. Reinstall headliner and consoles.
15. Remove silicone from bottom of J tubes inside the rear
of the cab.
16. Install the rear trim panel (6) over the heater box and
washer bottle using push in fasteners (7). Cap must
be removed from washer bottle to install, then re-
placed once the panel is secure. Ensure the seat belt
is routed through the slot in the panel and the upper
lip of the panel is under the air filter access cover. Se-
cure the panel with fir tree fasteners.
93104640 5
17. Apply silicone to bottom of J tubes (A) (fill drain hole

(B) in tube with silicone) at back exterior of cab and in
the front corners of the upper chassis.
93112374 6
47540694 28/04/2014
50.1 [50.100] / 8
18. Apply silicone in seam (Y) of upper chassis on both

left hand and right hand sides.
19. Apply silicone in corner hole (Z) of assembled upper
and lower chassis on both left hand and right hand
sides.
93104644 7
20. Clean and degrease front surface of the chassis

crossmember behind the cab. Apply crossmember
foam (1) with firm even pressure.
21. Remove floorplate. Cab lift struts may have to be re-
moved in order to remove floorplate. Do not remove
the cab tip safety lock!
93104643 8
47540694 28/04/2014
50.1 [50.100] / 9
23112404 9
22. Install the water valve (1) to the water valve bracket
(2) using bolts (3) and nuts (4), and bolt under the
floorboard with bolts (5) and nuts (6). Ensure that the
water valve is facing with the inlet to the left.
23. Connect the chassis harness electrical connector to
the water valve.
24. Connect the short guarded heater return hose (7) be-
tween the front port of the water valve (1) and the
straight section of the "Y" fitting (8), securing with con-
stant tension clamps (9).
25. Secure the short guarded return hose (7) and "Y"
fitting (8) to the front mounting bolt of the water valve
bracket (2) using a p-clamp (10). Leave the rear
mounting bolt of the water valve bracket off until the
return hose to the engine is installed.
26. Drain the existing coolant from the engine and radia-
tor. Save for reuse.
27. Remove the EGR coolant return hose (C). Save the
p-clamp from the starter mount bolt (D) for reuse.
47540694 28/04/2014
50.1 [50.100] / 10
23112404A 10
28. Install the hose barb splice connector (11) on the small
end of the short formed heater supply hose (12). Se-
cure with a constant tension clamp (9).
29. Install the large end of the short formed heater supply
hose onto the EGR coolant outlet and secure with a
hose clamp (13).
30. Route heater supply hose (14) from the connector (15)
to the water valve (1).
31. Route the heater supply and return hoses from the
engine to the front of the machine. Both hoses (16)
and (14) route under the engine between the flywheel
side engine mounts. The cordura sleeve (17) must be
installed over both hoses where they pass under the
engine and tandem pump.
32. Secure the supply hose (14) to the starter mount bolt
with the p-clamp (18) previously removed and route
the hose through the loop of the EGR coolant supply
hose before connecting to the EGR.
33. Connect the supply hose (14) to the hose barb splice
connector (11) on the short formed heater supply hose
(12) and to the inlet of the water valve (1). Secure with
constant tension clamps (9).
34. Connect the return hose (16) to the open hose nipple
on the engine coolant inlet tube (X) where the EGR
coolant return hose was previously removed. Secure
with a constant tension clamp (9).
47540694 28/04/2014
50.1 [50.100] / 11
23112404B 11
35. Connect the other end of the return hose (1) to the
straight section of the "Y" fitting (2) under the water
valve (3) using a constant tension clamp (4). Secure
to the rear mounting bolt of the water valve bracket
with a p-clamp (5), a flange bolt (6) and a square nut
(7).
36. Connect the guarded cab supply hose (8) to the wa-
ter valve (3) outlet and to the heater box inlet using
a nylon hose elbow (9) and constant tension clamps
(4). On medium frame wheeled units route the hose
between the left side chain tank and the motor loop
hoses.
37. Connect the guarded cab return hose (10) to the
branch of the "Y" fitting (2) and to the heater box inlet
using a nylon hose elbow (9) and constant tension
clamps (4). On medium frame wheeled units route
the hose between the left side chain tank and the
motor loop hoses.
38. Install the carriage bolt (1) to the square hole in the
seat pan and hold in place with a flange nut (2).
39. Place a p-clamp (3) over both hoses and attach to the
carriage bolt on the seat pan. Order of installation is
washer (4), then p-clamp, then flange nut (2).
23112404C 12
47540694 28/04/2014
50.1 [50.100] / 12
NOTE: The next three steps apply to large frame units only.
40. Install the large spring mount bracket (5) between the
brake control valve and the chassis nut cages that the
valve mounts to.
41. Install another p-clamp (3) over both hoses, securing
one end of each spring (6) on the closing bolt (7) of
the p-clamp. There should be 350 mm between this
p-clamp and the p-clamp mounted to the seat pan.
42. Connect the other end of the spring to the spring
mounting bracket (5) on the loader valve and the
brake valve.
43. Install the shields (1) and (2) below the heel plate.
44. Hook the spring (3) into the hole on the left hand con-
trol shield
45. [OPTIONAL] Install the seat pan mat.
46. Reinstall the seat.
47. Refill the cooling system and run the engine to check
for leaks.
48. Reinstall the floor pan.
49. [OPTIONAL] Install the heelplate mat followed by the
floormat. 23112407 13
a. Apply 2 rows of seal strip (1) around the outside edge of

plate (2).
23111106 14
50. Install the front cleanout hole blockoff plate (2) using
4 bolts (3).
51. Set the cab down and tip it up again to ensure that the
hoses are dropping into the chassis correctly without
kinking.
93104642 15
47540694 28/04/2014
50.1 [50.100] / 13
Index
Heating - 100
Cab heater - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cab heater - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
50.1 [50.100] / 14
Air conditioning - 200
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
50.2 [50.200] / 1
Contents
TECHNICAL DATA
Air conditioning
FUNCTIONAL DATA
Air conditioning
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview – Mechanical system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview – Electrical system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Air conditioning
Leakage test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Discharging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Evacuate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Charging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressor drive belt
Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSTIC
Air conditioning
Problem solving (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
47540694 28/04/2014
50.2 [50.200] / 2
Cab climate control - Air conditioning
Air conditioning - General specification

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
A/C system capacities

• 1.5 kg (3.3 lb) of R134A refrigerant.
• 197 ml (6.67 US fl oz) of PAG SP20
Air Temperature (F) Entering A/C Inlet - Outlet Temperature Inlet - Outlet Temperature
Unit Differential Differential
(Fresh or Recirculated) (Low Humidity) (High Humidity)
50 10 10
60 15 10
70 20 15
80 25 20
90 30 25
100 30 25
110 35 30
Ambient Air Temperature (F) Suction Pressure (PSIG) at Discharge Pressure (PSIG) at
Entering Condenser Evaporator Outlet Compressor Outlet
50 5-15 75-125
60 5-15 100-150
70 10-20 125-175
80 10-20 150-225
90 15-25 175-250
100 15-25 200-275
110 15-30 225-352
NOTE: The pressure temperature chart is based on the following conditions:
(1) Engine operating at 1500 rpm. No engine load.

(2) Fan speed control in maximum position (full clockwise) and all louvers open.
(3) Cab temperature control set to maximum cooling (full counterclockwise).
(4) A/C switch ON. Cab door open.
(5) All panels and access doors installed and closed.
(6) Cab filter clean and installed. Heater valve closed.
(7) Measurements taken 15 minutes after start-up.
(8) The warmest inlet air temperature (Fresh or Recirculated) should be used for the differential equations.
47540694 28/04/2014
50.2 [50.200] / 3
Air conditioning - Overview

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
The function of the HVAC system is to improve the operator's comfort by conditioning the air inside the cab.
In AC mode, temperature control is achieved by absorbing the heat within the cab into a refrigerant and then allowing
the heat absorbed by the refrigerant to be transferred to the outside air.
In heat mode, temperature control is achieved by air absorbing heat from a heat exchanger (heater core).
The blower switch can provide 4 speed levels (off, low, medium, high) to the electric fan motor (2) (internal to HVAC
Box). Low and medium speeds are provided through a resistor (internal to HVAC Box).
The fan blows a mix of outside and cab air (1) across an evaporator (3) and across the heater core (4), providing
conditioned air entering the cab through vents (5), and is energized anytime the ignition is on.
ACPATHSL57 1
HVAC air flow path
In AC mode, with the A/C switch on and an electric fan speed selected, the condenser fan and the A/C compressor
are energized, starting the refrigeration cycle and providing cool air to the cab.
In heat mode, with AC Switch off and the temperature control potentiometer set to “hot”, the potentiometer provides
a control signal to the water valve which directs hot engine coolant to flow to the heater core. The electric fan motor
(internal to HVAC Box) blows air across the evaporator (not in use) and hot heater core, providing hot air to cab.
If both AC switch is on and temperature control potentiometer is turned to "hot", both the Water Valve and AC compo-
nents are energized, and the air will cool across the evaporator, then heat across the heater core, then enter the cab.
The blower switch, AC switch, and temperature control potentiometer are all located on the Left Console.
There are three safety switches in the system that protect the compressor. The single-level pressure switch (internal
to HVAC Box) protects from a liquid lock condition in the refrigeration cycle. The high pressure switch protects against
an overpressure condition caused by a system blockage or compressor failure. The thermostat (internal to HVAC Box)
is a freeze sensor, located on the condenser, that cycles the A/C compressor off preventing an ice over condition,
which would prevent heat transfer.
47540694 28/04/2014
50.2 [50.200] / 4
Air conditioning - Overview – Mechanical system

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
The principal components of an air conditioning system are
• Refrigerant
• Evaporator
• Compressor
• Condenser
• Expansion Valve
To achieve the absorption and the release of heat, which is, in essence, the function of an air conditioning system,
requires the use of a suitable refrigerant, a liquid that has a relatively low temperature boiling point, plus certain de-
sirable safety and stability features. The refrigerant used in the air conditioning system is R-134a.
The refrigerant starts as a low temperature, low pressure liquid and enters the evaporator. The evaporator (1) consists
of a number of turns of continuous coils mounted in a series of thin cooling fins to provide a maximum heat transfer
area in a minimum amount of space.
Low temperature refrigerant in the evaporator absorbs heat from the hotter air in the cab, cooling the air.
The Electric Fan Motor (internal to HVAC Box) blows a mix of outside air and recirculated cab air across the evaporator
and blows this cool air into the cab.
The refrigerant now changes to a high temperature, low pressure vapor and leaves the evaporator, moving to the
suction (low pressure) side of the compressor.
REFCYCLESL57 1
Refrigeration Cycle
The compressor (2) acts as a pump which raises the refrigerant temperature and pressure by compression to a higher
degree of temperature than the ambient (outside air) temperature and provides the driving force required to circulate
the volume of refrigerant through the system.
Refrigerant is drawn into the compressor as a high temperature, low pressure vapor which is compressed and then
pumped out as a high temperature, high pressure vapor to the condenser. The thermostat (internal to HVAC Box)
cycles power to the A/C compressor via removing power to compressor relay control.
The condenser (3) consists of a number of turns of continuous coil mounted in a series of thin cooling fins to provide
a maximum of heat transfer in a minimum area of space.
The condenser receives the high temperature, high pressure refrigerant vapor from the compressor. The hot vapor
passes through the condenser coils and outside air is pushed across the condenser by the condenser fan.
Heat moves from the hot refrigerant vapor into the cooler outside air flowing across the condenser coils and fins.
When the refrigerant vapor reaches the pressure and temperature that will induce a change of state to a liquid, a large
quantity of heat is transferred to the outside air and the refrigerant changes to a low temperature, high pressure liquid.
The refrigerant from the condenser enters the expansion valve (4) as a low temperature, high pressure liquid. The
expansion valve allows the refrigerant to expand rapidly, which causes the pressure and temperature of the refrigerant
to be reduced and the refrigerant leaves the expansion valve as a low temperature, low pressure liquid.
47540694 28/04/2014
50.2 [50.200] / 5
Air conditioning - Overview – Electrical system

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
The HVAC system has several power inputs. One line of source power comes from the accessory relay to the HVAC
box. This energizes the auxiliary relay for the electric fan coil (internal to HVAC Box). The accessory relay is powered
from the instrument cluster when the ignition is on, which shuts the auxiliary relay for electric fan.
NOTE: See HVAC Box overview for more information Heating, Ventilation, and Air-Conditioning (HVAC) control
system - Overview (55.050)
The auxiliary relay for electric fan main power comes directly from the battery via the HVAC fuse. The auxiliary relay
for electric fan is shut anytime the ignition is on, allowing power to the water valve and the temperature control po-
tentiometer, also allowing power to the blower switch. Power is provided to the A/C switch from the blower switch,
anytime a fan speed is selected. The blower switch, AC switch, and temperature control potentiometer are all located
on the left console.
Since the water valve and temperature control potentiometer are energized, cab heat is available anytime the ignition
is on.
When the AC switch is turned “on” and an electric fan speed is selected,
power is provided to HVAC, through the single-level pressure switch (internal to HVAC box), through thermostat (in-
ternal to HVAC box), out the HVAC box to the HVAC high pressure switch and back into HVAC Box to the compressor
relay coil (internal to HVAC box), shutting the compressor relay (internal to HVAC box). When the compressor relay
is shut, this allows
battery power the compressor fuse through the HVAC box to the compressor relay, and out of the HVAC box to the
A/C compressor.
When the A/C switch is turned “on” and an electric fan speed is selected,
power is also applied to the condenser relay coil, shutting the condenser relay, providing battery power via a fuse to
the condenser fan.
The blower switch, since energized, can provide four speed levels (off, low, medium, high) to the electric fan motor
(internal to HVAC box). This is done through a resistor (internal to HVAC box).
47540694 28/04/2014
50.2 [50.200] / 6
Air conditioning - Leakage test

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Avoid injury!
Avoid breathing air-conditioning refrigerant, lubricant vapor or mist. If accidental system discharge
occurs, ventilate the work area before resuming service.
W1000B
NOTICE: A/C systems are to be maintained by a certified professional. Do not attempt the following without A/C
certification.
Vacuum test
1. Shut off the engine.
2. Make sure the charging station manifold gauge valves
are in the closed position. Connect the hose from the
low pressure gauge to the port on the suction hose.
Connect the hose from the high pressure gauge to the
port on the discharge hose . Turn in both thumbscrews
to depress the service valves.
3. Open the high and low valves.
4. Make certain the refrigerant tank gas and liquid valves
are open.
5. Move the main power switch to the ON position and
depress the vacuum start switch. Run a vacuum on
the A/C system for fifteen minutes. Watch the high and
low pressure gauges. If the machine does not hold a
vacuum, inspect all connections and components for
damage.
6. Repair all leaks and recharge the system.
Electronic leak detection test

7. Verify the appropriate amount of refrigerant in the ma-
chine.
8. Start the engine and run the A/C system for approxi-
mately ten minutes.
9. Use the electronic leak detector to inspect all connec-
tions. Use instructions from manufacturer of the leak
finding tool.
ATTENTION: Engine is running. Be aware of moving com-
ponents. Failure to comply could result in death or serious
injury.
10. Shut off the engine.
47540694 28/04/2014
50.2 [50.200] / 7
11. Use the electronic leak detector to inspect all connec-

tions. Use instructions from manufacturer of leak find-
ing tool.
NOTE: When checking compressor seal for a leak, remove
the dust cover and rotate the clutch shaft clockwise.
NOTE: To properly check the expansion valve for leaks,
remove the insulation tape.
UV leak detection test

13. Please see the instructions from the manufacturer of
the UV leak detection tool for proper use.
47540694 28/04/2014
50.2 [50.200] / 8
Air conditioning - Discharging

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
certification.
1. Recovered refrigerant passes through an oil separator
and filter-drier before entering the refrigerant tank. The
moisture indicator will turn green when dry refrigerant
passes over it.
2. If possible, run the air conditioning system for ten min-
utes before starting the recovery process. Turn the sys-
tem off before proceeding.
3. Clean the external surfaces of the compressor and
hoses. Remove the caps from the service ports on the
suction hose and pressure hose.
are open.
7. Connect the main power plug to a 115 volt AC out-
let. Move the main power switch to the ON position
and depress the recovery start switch. The compres-
sor will shut OFF automatically when recovery is com-
plete. Wait for five minutes and observe the manifold
pressure gauges for a pressure rise. If pressure rises
above zero PSI, depress the hold/cont switch. Then
wait for the compressor to automatically shut OFF.
8. Drain the oil separator of the A/C system oil. Open the
air purge valve long enough to let some of the compres-
sor discharge pressure back into the separator.
9. Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the oil
drain valve completely.
10. Fill the A/C compressor with fresh PAG oil equal to the
amount in the reservoir.
11. Disconnect the hoses from the service ports and in-
stall the caps.
47540694 28/04/2014
50.2 [50.200] / 9
Air conditioning - Evacuate

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
certification.
1. Recovered refrigerant passes through an oil separator
and filter-drier before entering the refrigerant tank. The
moisture indicator will turn green when dry refrigerant
passes over it.
2. If possible, run the air conditioning system for ten min-
utes before starting the recovery process. Turn the sys-
tem off before proceeding.
3. Clean the external surfaces of the compressor and
hoses. Remove the caps from the service port on the
suction and from the service port pressure hoses.
low pressure gauge to the port on the suction hose .
are open.
7. Connect the main power plug to a 115 volt AC out-
let. Move the main power switch to the ON position
and depress the recovery start switch. The compres-
sor will shut OFF automatically when recovery is com-
plete. Wait for five minutes and observe the manifold
pressure gauges for a pressure rise. If pressure rises
above zero PSI, depress the hold/cont switch. Then
wait for the compressor to automatically shut OFF.
8. Drain the oil separator of the A/C system oil. Open the
air purge valve long enough to let some of the compres-
sor discharge pressure back into the separator.
9. Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the oil
drain valve completely.
10. Fill the A/C compressor with fresh PAG oil equal to the
amount in the reservoir.
11. Disconnect the hoses from the service ports and in-
stall the caps.
47540694 28/04/2014
50.2 [50.200] / 10
12. Replace the receiver-drier if one or more of the follow-

ing conditions occurs before you remove the air and
moisture from the system.
(A.) The system has been opened for service before.
(B.) Receiver-drier has operated two or more years.
(C.) Disassembly of compressor shows small particles
of moisture removing material (gold or brown parti-
cles).
(D.) Large system leak (broken hose, break in line).
(E.)Too much air or moisture in system.
(F.) Removal of compressor caused the system to be
open (uncapped) longer than 5 minutes.
port on the discharge hose. Turn in both thumbscrews
14. Removal of air and moisture from the system is neces-
sary after the refrigerant has been removed from the
system after the system has been opened for main-
tenance. Air enters the system when the system is
opened. Air has moisture that must be removed to
prevent damage to the system components.
15. Air and moisture are removed from the system by a
vacuum pump. A vacuum pump is on the only equip-
ment made that will lower the pressure in a system
enough to change the moisture to a vapor so that the
moisture can be removed.
NOTE: Refer to the vacuum pump manufacturer's user
manual for additional information.
16. Connect the main power plug to a 115 volt AC outlet.
Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum of
45 minutes and press the Enter key. The display will
flash once indicating the programmed data has been
accepted.
17. Press the Charge Key. Program and Charge will ap-
pear on the display.
18. Program 1.5 kg (3.3 lb) of R134A refrigerant. and
press the enter key. The display will flash once in-
dicating the programmed data has been accepted.
19. Full open the low and high pressure valves.
20. Open the red (vapor) and blue (liquid) valves on the
tank.
21. Press the Vacuum key. Automatic will show on the
display and after a slight delay, the vacuum pump will
start. The display will show the amount of time pro-
grammed and begin a countdown to zero.
47540694 28/04/2014
50.2 [50.200] / 11
22. When the programmed time has elapsed, an auto-

matic hold occurs. Check the low pressure gauge to
see that the A/C system maintains a 28 - 29 1/2 inof
mercury (Hg). The low pressure gauge must not in-
crease faster than one inch of mercury (Hg) in 15 min-
utes. If the system will not hold vacuum, a leak exists
that must be corrected before recharging can begin.
See Air conditioning - Leakage test (50.200) for a
leak test.
47540694 28/04/2014
50.2 [50.200] / 12
Air conditioning - Remove

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Prior operation:
Evacuate the A/C system. See Air conditioning - Evacuate (50.200)
certification.
1. Raise cab to disconnect air conditioning system hoses
NOTE: If R134A is still in system, it should be drained and
captured prior to disconnecting hoses.
931001817 1
2. Label and disconnect heater hoses (2) and cap open

ports.
NOTE: Drain coolant into a suitable container prior to dis-
connecting heater hoses.
931001817 2
3. Remove seat hardware (3).
931001759 3
47540694 28/04/2014
50.2 [50.200] / 13
4. Disconnect seat safety switch electrical connection (4).
931001793 4
5. Remove operators seat.
93109313 5
6. Remove mounting screws (5) and remove cover (6).
931001752 6
7. Remove rear panel hardware (7).
931001751 7
47540694 28/04/2014
50.2 [50.200] / 14
8. Remove window wash bottle lid (8).
931001775 8
9. Remove rear panel exposing air conditioning unit.
931001774 9
10. Remove left hand side and right hand side duct work
hardware (9).
931001763 10
11. Remove air condition unit mounting hardware (10).
931001769 11
47540694 28/04/2014
50.2 [50.200] / 15
12. Disconnect air condition electrical connector (11).
931001771 12
13. Remove air condition unit.
931001773 13
47540694 28/04/2014
50.2 [50.200] / 16
Air conditioning - Install

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
certification.
1. Position the air condition (A/C) unit in the cab.
931001773 1
2. Connect A/C electrical connection (1).
931001771 2
3. Install left and right hand side A/C mounting hardware

(2).
931001769 3
47540694 28/04/2014
50.2 [50.200] / 17
4. Install left hand side and right hand side duct work and
secure with hardware (3).
931001763 4
5. Install the rear panel (4).
931001774 5
6. Install rear panel hardware (5).
931001751 6
7. Install window washer bottle lid (6).
931001775 7
47540694 28/04/2014
50.2 [50.200] / 18
8. Install cover and mounting screws (7).
931001752 8
9. Position operators seat in the cab.
86095343 9
10. Connect seat safety switch electrical connection (A).
931001793 10
11. Install operators seat hardware (2).
931001759 11
47540694 28/04/2014
50.2 [50.200] / 19
12. Connect heater hoses (3).
931001757 12
13. Connect air condition hoses (4).
931001757 13
14. After the heater/air conditioning assembly has been

installed refer to Radiator - Filling (10.400) and refill
the cooling system.
15. Refer to Air conditioning - Evacuate (50.200). Con-
nect the Refrigerant Recovery, Recycling and Charg-
ing Station to the high and low charge ports in the hose
fitting on the compressor. Evacuate the system to re-
move all moisture from the system.
16. Refer to Air conditioning - Charging (50.200) and
charge the system with reclaimed or new refrigerant.
Start the engine and test the air conditioning system
for proper operation.
47540694 28/04/2014
50.2 [50.200] / 20
Air conditioning - Charging

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
certification.
1. The system charge capacity is 1.5 kg (3.3 lb) of R134A
refrigerant.
Press the charge key to begin refrigerant charging. Au-
tomatic and Charge will appear on the display. The dis-
play shows the programmed amount and counts down
to zero as charging proceeds. When charging is com-
pleted, the display shows CPL.
2. Completely close the high and low pressure manifold
valves.
3. Start the engine and run at 1500 rpm. Operate the
air conditioner system at maximum cooling setting and
blower speed with the door and windows open.
NOTE: The compressor will not operate if the system pres-
sure is too low or too high. If the compressor fails to op-
erate and the condenser blowers also fail to operate when
you actuate the A/C switch, check the system pressure to
determine if refrigerant is present. Check for continuity at
the pressure switch located at the receiver-dryer and the
temperature switch located at the evaporator.
4. Observe the pressure gauge readings to determine that
the correct amount of refrigerant has entered the sys-
tem.
NOTICE: Check the OEM equipment manual before
performing this step to avoid damaging recovery unit.
Pressure reading should be obtainable with valves closed.
Damage may occur if the machine is started with the
valves accidently open or if either or both valves are
opened while the A/C system operating.
5. Stop the engine, close any open valves and carefully
remove the manifold gauge hoses.
6. Install the caps on the service ports on the suction
hose, and discharge hose.
47540694 28/04/2014
50.2 [50.200] / 21
Compressor drive belt - Tension adjust

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Use the following procedure to adjust the air condition-

ing compressor belt.
1. Loosen the adjusting bracket bolt (1).
2. Loosen the mounting bolt (2).
3. Loosen the adjusting bolt jam nut (3).
4. Tighten the adjusting bolt (4) until tight. The belt
is tightened correctly when a force of 1 kg (2.2 lb)
is applied perpendicular to the belt at the center of
the span with a 3 mm (0.1 in) deflection.
5. Tighten the adjusting bolt jam nut (3).
6. Tighten the adjusting bracket bolt (1) and mounting
bolt (2).
RAPH12SSL0064BA 1
NOTE: Check the compressor belt tension after the first 10 hours of operation on a new machine or if a new belt has
been installed. Measure the deflection of the belt at center of span with perpendicular load of applied, and adjust as
necessary.
47540694 28/04/2014
50.2 [50.200] / 22
Air conditioning - Problem solving

C232 TIER 4 [NDM451672 - ] NA
OPERATION
To understand the electrical flowpaths and help narrow down the troubleshooting efforts, refer to HVAC System Elec-
trical overview Air conditioning - Overview – Electrical system (50.200).
TROUBLESHOOTING
Before troubleshooting ensure that

1. HVAC FUSE F-001 is good.
2. COMPRESSOR FUSE F-002 is good.
3. ACCESSORY RELAY K-018 is good. See Electrical system - Component identification Relay Index (55.000).
4. Switches are operated in accordance with Operator's Manual.
No heat Faulty TEMPCONTROL Z-017 potentiometer Heating, Ventilation, and Air-Condition-
ing (HVAC) control system - Testing
HVAC Heat Components (55.050)
Faulty WATER VALVE Z-019 Heating, Ventilation, and Air-Condition-
Faulty Fan Relay (internal to HVAC Box) Heating, Ventilation, and Air-Condition-
HVAC Box (55.050)
Poor Heat Faulty TEMPCONTROL Z-017 potentiometer Heating, Ventilation, and Air-Condition-
Faulty WATER VALVE Z-019 Heating, Ventilation, and Air-Condition-
Poor cooling No voltage at connector X-74 pin B. Faulty CONDENSER RELAY or associated
wiring. See Fuse and controller power
relay - Testing Relay Testing (55.640)
and Fuse and relay box - Testing Con-
denser Relay Control (55.100)
Faulty HVAC CONDENSER FAN Air-conditioning condenser - Testing –
Condenser Fan (50.200)
Thermostat (internal to HVAC Box) not cy- Heating, Ventilation, and Air-Condition-
cling correctly ing (HVAC) control system - Testing
HVAC Box (55.050)
Poor cooling after engine Faulty WATER VALVE Z-019 Heating, Ventilation, and Air-Condition-
is at normal temperature ing (HVAC) control system - Testing
Faulty TEMPCONTROL Z-017 potentiometer Heating, Ventilation, and Air-Condition-
No cooling Faulty Fan Relay (internal to HVAC Box) Heating, Ventilation, and Air-Condition-
HVAC Box (55.050)
Faulty BLOWER SWITCH S-020 Heating, Ventilation, and Air-Condition-
Blower Switch (55.050)
Faulty AC SWITCH S-017 Heating, Ventilation, and Air-Condition-
ing (HVAC) control system - Testing A/C
Switch (55.050)
47540694 28/04/2014
50.2 [50.200] / 23

Faulty Single-Level Pressure Switch (inter- Heating, Ventilation, and Air-Condition-
nal to HVAC Box) ing (HVAC) control system - Testing
HVAC Box (55.050)
Faulty Thermostat (internal to HVAC Box) Heating, Ventilation, and Air-Condition-
HVAC Box (55.050)
Faulty HVAC HIGH PRESSURE SWITCH Heating, Ventilation, and Air-Condition-
HVAC High Pressure Switch (55.050)
Faulty Compressor Relay (internal to HVAC Heating, Ventilation, and Air-Condition-
Box) ing (HVAC) control system - Testing
HVAC Box (55.050)
Faulty A/C COMPRESSOR Air-conditioning compressor - Testing
A/C Compressor (50.200)
No fan speeds available No voltage at HVAC Box pin 14 Faulty HVAC FUSE F-001 or associated
wiring
No voltage at HVAC Box pin 11 Faulty ACCESSORY RELAY K-018 or asso-
ciated wiring. See Fuse and controller
power relay - Testing Relay Testing
(55.640) and Fuse and relay box - Test-
ing Accessory Relay Control (55.100)
Faulty BLOWER SWITCH S-020 Heating, Ventilation, and Air-Condition-
Blower Switch (55.050)
Faulty Fan Relay (internal to HVAC Box) Heating, Ventilation, and Air-Condition-
HVAC Box (55.050)
Faulty Electric Fan Motor (internal to HVAC Heating, Ventilation, and Air-Condition-
box) ing (HVAC) control system - Testing
HVAC Box (55.050)
Faulty HVAC Box ground wiring Use Electrical system - Testing General
Wire Testing (55.000) to ensure proper
ground from HVAC Box pin 1
Only high speed fan Faulty Resistor (internal to HVAC Box) Heating, Ventilation, and Air-Condition-
available ing (HVAC) control system - Testing
HVAC Box (55.050)
Only one fan speed is not Wiring problem common to HVAC BOX Use Electrical system - Testing General
available A-003 (Resistor) and BLOWER SWITCH Wire Testing (55.000) to locate faulty wire
S-020
47540694 28/04/2014
50.2 [50.200] / 24
Index

Air conditioning - Charging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Air conditioning - Discharging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air conditioning - Evacuate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air conditioning - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air conditioning - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Air conditioning - Leakage test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air conditioning - Overview – Electrical system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air conditioning - Overview – Mechanical system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air conditioning - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air conditioning - Problem solving (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air conditioning - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compressor drive belt - Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
47540694 28/04/2014
50.2 [50.200] / 25
PRINTED IN U.S.A.
47540694 28/04/2014
EN
SERVICE MANUAL
Electrical systems
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55
Contents
Electrical systems - 55
[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.031] Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
[55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.10
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11
[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12
[55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13
[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14
[55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16
47540694 28/04/2014
55
Electrical system - 000
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.1 [55.000] / 1
Contents
FUNCTIONAL DATA
Electrical system
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Electrical system
Electronic Service Tool (EST) - H1 - Calibration procedures – Requirements (*) . . . . . . . . . . . . . . . . . . . . 4
Electronic Service Tool (EST) - H1 - Calibration procedures – Troubleshooting (*) . . . . . . . . . . . . . . . . . . . 5
Electronic Service Tool (EST) - H1 - Calibration procedures – Joystick (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electronic Service Tool (EST) - H1 - Calibration procedures – Ground Drive (*) . . . . . . . . . . . . . . . . . . . . . 7
Electronic Service Tool (EST) - H1 - Calibration procedures – Throttle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electronic Service Tool (EST) - H1 - Calibration procedures – Loader valve (*) . . . . . . . . . . . . . . . . . . . . 11
Electronic Service Tool (EST) - H1 - Calibration procedures – Loader start pressure (*) . . . . . . . . . . . . . 13
DIAGNOSTIC
Electrical system
Testing - Diode (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Testing - Wires (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Testing - Relay (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
47540694 28/04/2014
55.1 [55.000] / 2
Electrical systems - Electrical system
Electrical system - Overview

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
An electrical circuit is comprised of three basic elements; a source of electrical energy which provides the current
used by the electrical circuit, a load which converts the electrical current into a work form such as heat or light or an
electromagnetic energy field and conductors which are used to route the electrical current from the source to the load
and back to the source. The device used to provide the electrical current in a direct current (DC) circuit is typically a
battery. The battery uses a chemical action to create and store the needed electrical energy. An alternator which con-
verts mechanical energy into electrical energy and is driven by an engine is used to recharge the battery. Load devices
are designed to utilize the two natural products created when electrical current flows through a conductive material,
that being heat and a magnetic field. Lamps heat alloyed conductive materials to a temperature that produces visible
light where as heater elements use an alloyed material to produce heat. Solenoids and motors use the magnetic field
produced by the current flow to attract or repel ferrous material and produce linear or rotary motion. Stranded or solid
copper or copper clad wire is used to conduct the electrical current between the source and the loads. The return path
to the source from the loads in battery sourced systems is often the metallic materials that are the components of the
machine or what is referred to as frame or chassis ground. The negative terminal on the battery is then connected to
the frame or chassis, thus completing the electrical circuit. In addition to the basic elements required in a electrical
circuit, most also contain protective devices, fuses or circuit breakers, that are designed to interrupt the current flow
should it exceed the amount the conductors or loads in the circuit are capable of handling without damage.
An electrical control scheme is comprised of three categories of devices; input devices like switches, potentiometers
and sensors, control or logic devices like relays and programmed or programmable electronic modules and output
devices like lights, motors and solenoids. Input devices provide information in the way of an electrical signal to the
logic devices. The signal provided may be a digital signal; on or off, high or low, a transition from one predefined
level to another either higher or lower which is referred to as leading or trailing edge or an analog signal which is
variable measurable levels. Logic or control devices use the signals provided by the input devices to determine how
the output devices should be controlled, energized or de-energized and to what level and polarity. Programmed and
programmable logic devices often use the system source voltage, battery voltage, to create other voltages which are
referred to as reference voltages. The reference voltage or reference source as well as a reference ground or control
module ground is provided by the logic or control device to inputs and outputs. This means the control or logic device
is capable of switching, sensing or varying different signal levels and types.
Configuring the electrical control scheme is done in a variety of ways. The input devices may use:
• system source, which is the battery, or
• system ground, which is the frame or chassis, or
• a reference voltage, which is created by the control module, or
• a reference ground, which is provided by the control module,
to provide a digital or analog signal to the control or logic device.
• A single input device may provide a signal directly or

• two or more input devices sharing the same signal wire, in parallel, may provide the signal or
• two or more input devices may provide the signal through one another, in series,
to the control or logic device.
47540694 28/04/2014
55.1 [55.000] / 3
Electrical system Electronic Service Tool (EST) - H1 - Calibration

procedures – Requirements
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Calibration involves setting correct hardware parameters for joysticks, ground drive pumps, loader valve, and throttle
mechanism.
Unless noted otherwise, the operator has 30 seconds to complete each calibration step. The calibration procedure
will have to be restarted if a step times out.
The parameters associated with each calibration procedure will be saved when that particular procedure completes
successfully. If there are problems completing one of the five calibration procedures, only that procedure will need to
be repeated, not all five.
The audible alarm and calibration messages will not be displayed if any error codes are active.
If any calibration fails, see Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Trou-
bleshooting (55.000) for troubleshooting steps.
1. The following software will be required

• CNH Electronic Service Tool (EST), version 6.3.0.0
or later.
• If downloading new application software -
SL57 UCM Application Software (SSL_SL57_x-x-x-
x.hx1),
and SL57 Instrument Cluster software (SSLClus-
ter_Vx_x_x_x.hx1)
2. If new software is available, download it before calibrat-
ing using the following steps.
• Connect the EST hardware to the machine diagnos-
tic connector and laptop.
• Flash the new SL57 Application Software onto the
machine controller (UCM) with the Electronic Service
Tool (EST) programming menu.
• Flash the new instrument cluster (IC) software to the
IC with the EST configuration menu.
• Set the machine configurations (serial number,
model, door, etc.) in the EST configuration menu.
3. Calibration Preparation Steps
• Connect the EST hardware to the machine diagnos-
tic connector and laptop.
• Open the EST configuration menu.
• Clear any fault codes from the IC display by cycling
the Aux Override button until the display is clear.
47540694 28/04/2014
55.1 [55.000] / 4

procedures – Troubleshooting
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
These are the codes that may be encountered during calibration. If seen, check condition description and compare
to calibration procedure prerequisite conditions.
Display Text Condition Name Condition Description Software Reaction

CD01 Calibration Enable Fail Calibration Enable Condition(s) Exit calibration and use old values
not met at time of initiation
CD02 Calibration Sustain Fail Calibration Sustain Condition(s) Exit calibration and use old values
not met during cal routine
CD03 Device Fault Device Fault Calibration Sustain Exit calibration and use old values
Condition(s) not met during cal
routine
CD04 Calibration Timeout Calibration Step was not Exit calibration and use old values
completed within allotted time
CD05 Operator Interrupt Calibration interrupted by Operator Exit calibration and use old values
via cluster Cal button
CD06 Calibration Value High Calibration value higher than Beep and flash code - give
upper-end of acceptance range operator a chance to retry cal step
CD07 Calibration Value Low Calibration value lower than Beep and flash code - give
lower-end of acceptance range operator a chance to retry cal step
CD08 Signal Unstable Signal being calibrated outside of Beep and flash code - give
settling noise tolerance operator a chance to retry cal step
1. Troubleshooting Suggestions
1. For CD01 - CD05, restart calibration procedure
with the 'START CALIBRATION' button. If this
does not work, Press 'Exit' on EST calibration
procedure and re-enter the calibration state and
the individual calibration procedure.
2. For CD-06 - CD-08, try 'Retry' button on EST. If
this does not work, Press 'Exit' on the calibration
procedure and re-enter the calibration state and
the individual calibration procedure.
3. Occasionally closing and reopening the EST is re-
quired to restart a calibration.
47540694 28/04/2014
55.1 [55.000] / 5

procedures – Joystick
The purpose of the Joystick Calibration is to calibrate the main axis of the left and right joystick and the proportional
thumbwheel.
1. Ensure the prerequisite requirements are complete per

Electrical system Electronic Service Tool (EST) - H1
- Calibration procedures – Requirements (55.000).
2. Ensure the following conditions are met
• Joysticks in Neutral
• Proportional Auxiliary Roller Switch in Neutral
• Key ON
• Engine ON
• Hydraulics OFF
• Operator Present
• No Joystick Related Fault Codes
3. In the EST configuration menu, open the 'Calibration -
Joystick' item.
4. Press the 'SET UP CONTROLLER FOR CALIBRA-
TION' button.
• Ensure 'START CALIBRATION' is now active.
5. Press the 'START CALIBRATION' button.
• Ensure that the text "C-J1" is displayed on the cluster
screen.
6. Press and release the loader float button to start cap-
turing step 1 values.
• Verify that an audible beep is heard from the instru-
ment cluster and the text "C-J2" is displayed on the
cluster screen upon completion of step 1.
7. Move the proportional auxiliary roller switch to the up-
per or left detent (toward the smaller icon). Move both
joysticks to the front right corner. Press and release the
loader float button to start capturing step 2 values.
ment cluster and the text "C-J3" is displayed on the
8. Move the proportional auxiliary roller switch to the lower
or right detent (towards the larger icon). Move and hold
both joysticks to the back left corner. Press and release
the loader float button to start capturing step 3 values.
ment cluster upon completion of step 3.
• Verify that the instrument cluster screen returns to
normal message display.
47540694 28/04/2014
55.1 [55.000] / 6

procedures – Ground Drive
The purpose of the Ground Drive Calibration is to calibrate the command current to a nominal pressure and calibrate
the neutral position of the ground drive swashplate angles. This is a semi-automatic procedure, therefore most of the
operator interaction is via the cluster display screen only.
NOTE: It is not unusual to see a small amount of machine movement during calibrations the UCM finds the command
current that brings the pump on stroke.
Significant machine movement during calibration (more than 1 foot) is not expected and is a symptom of a problem
in the system.
• No Ground Drive Related Fault Codes
• Key ON
• Engine ON
• Hydraulics ON
• Hydraulic Oil Temperature between 15 °C (59.0 °F)
and 80 °C (176.0 °F)
• Engine RPM less than 1200 RPM
Ground Drive' item.
TION' button.
• Ensure that the text "C-G1" is displayed on the clus-
ter screen.
6. Move the right joystick to the front right corner (away
from the operator) and press and release the loader
float button. Keep the right joystick in the top right cor-
ner for the entirety of the ground drive calibration.
ment cluster and the text "C-G2" is displayed on the
7. Keep the right joystick at the top right corner (away from
the operator).
47540694 28/04/2014
55.1 [55.000] / 7
the operator).
the operator).
10. Keep the right joystick at the top right corner (away
from the operator).
ment cluster upon completion of step 5.
11. Release the right joystick.
• Verify that the EST Calibration Operation Status
window says "Calibration Completed Successfully."
Verify that the instrument cluster screen returns to
12. Exit out of the Calibration - Ground Drive screen
47540694 28/04/2014
55.1 [55.000] / 8

procedures – Throttle
The purpose of the Throttle Calibration is to calibrate the six key throttle position points to improve robustness of the
load control algorithm.

• Key ON
• Engine ON
• Hydraulics OFF
• No Throttle Related Fault Codes
Hand Throttle' item.
TION' button.
• Ensure that the text "C-T1" is displayed on the cluster
screen.
6. Move the hand throttle lever to the maximum throttle
end-stop position. Step on the foot throttle until it is fully
depressed. Press and release the loader float button.
ment cluster and the text "C-T2" is displayed on the
7. Very slowly reduce the throttle to approximately 150
RPM below maximum engine RPM until audible alarm
sounds and display changes to "C-T3".
8. Pull the hand throttle lever to the minimum end-stop
position. Ensure that the foot throttle is not depressed.
Press and release the loader float button.
9. Very slowly increase the throttle to approximately 150
RPM above low idle until audible alarm sounds and
display changes to "C-T5".
47540694 28/04/2014
55.1 [55.000] / 9
10. Adjust the hand throttle lever position such that the
engine RPM display flashing on the instrument clus-
ter screen is at 1750 +/- 150 RPM for ISM, 1600 +/-
150 RPM for F5C. Press and release the loader float
button.
11. Adjust the hand throttle lever position such that the
engine rpm display flashing on the instrument clus-
ter screen is at 2400 +/- 150 RPM for ISM, 2100 +/-
150 RPM for F5C. Press and release the loader float
button.
• Verify that an audible beep is heard from the in-
strument cluster upon completion of step 6. Verify
that the EST Calibration Operation Status window
says "Calibration Completed Successfully." Verify
that the instrument cluster screen returns to normal
message display.
47540694 28/04/2014
55.1 [55.000] / 10

procedures – Loader valve
The purpose of the Loader Calibration Procedure is to calibrate the command current to a nominal pressure for each
spool and calibrate the neutral position of the loader attachment spool sensors. This is a semi-automatic procedure,
therefore most of the operator interaction is via the cluster display screen only.
NOTE: It is not unusual to see a small amount of loader or bucket movement during calibration as the UCM finds the
command current that shifts the valve spools. Significant implement movement during calibration (more than 1 foot)
should not be expected and is a symptom of a problem in the system.
• Key ON
• Engine ON
• Hydraulics ON
• Park Brake Engaged (park brake light on) with the
park brake switch, not the OPERATE Button on the
IC
• Hydraulic Oil Temperature between 15 - 80 °C (59.0
- 176.0 °F)
• Engine RPM less than 1200 RPM
• No Loader Related Fault Codes
Loader Valve' item.
TION' button.
• Ensure that the text "C-L1" is displayed on the cluster
screen.
6. Move the right joystick to the top right corner (away
from the operator) and press and release the loader
float button. Keep the right joystick in the top right cor-
ner for the entirety of the loader calibration.
ment cluster and the text "C-L2" is displayed on the
cluster screen upon completion of the previous step.
47540694 28/04/2014
55.1 [55.000] / 11
the operator).
the operator).
the operator).
from the operator).
strument cluster and the text "C-L6" is displayed on
the cluster screen upon completion of the previous
step.
from the operator).
strument cluster and the text "C-L7" is displayed on
step.
from the operator).
ment cluster upon completion of the previous step.
14. Exit out of the Calibration - Loader Valve screen.
47540694 28/04/2014
55.1 [55.000] / 12

procedures – Loader start pressure
The purpose of the Loader Calibration Procedure is to calibrate the command current to a nominal pressure for each
spool and calibrate the neutral position of the loader attachment spool sensors. This is a semi-automatic procedure,
therefore most of the operator interaction is via the cluster display screen only.

• Key ON
• Engine ON
• Hydraulics ON
• Park Brake Engaged
• Hydraulic Oil Temperature between 15 - 80 °C (59.0
- 176.0 °F)
• Engine RPM less than xxxx RPM
• Loader Calibration Complete Electrical system
Electronic Service Tool (EST) - H1 - Calibration
procedures – Loader valve (55.000)
• No Loader Related Fault Codes
Loader Start Pressures' item.
TION' button.
• Ensure that the text "C-S1" is displayed on the clus-
ter screen.
6. Move the right joystick to the top right corner (away
from the operator) and press the loader float button.
Keep the right joystick in the top right corner for the
entirety of the loader start pressure calibration.
ment cluster and the text "C-S2" is displayed on the
7. Watch for loader raise motion. When detected, imme-
diately toggle that float button. This process is to be
repeated tree times for the calibration step.
47540694 28/04/2014
55.1 [55.000] / 13
8. Watch for loader lower motion. When detected, imme-

9. Watch for bucket dump motion. When detected, imme-
from the operator).
strument cluster and the text "C-S6" is displayed on
step.
11. Watch for bucket curl motion. When detected, imme-
ment cluster upon completion of the previous step.
13. Exit out of the Calibration - Loader Start Pressures
screen.
47540694 28/04/2014
55.1 [55.000] / 14
Electrical system - Testing - Diode

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA

1 Condition Result Result
Disconnect the connector from the diode. The reading should be near the If the reading is the same in both
Using a multi-meter on the diode setting, range of 0.3 V to 0.7 V one way, directions, the diode is shorted.
measure the diode from pin to pin in both and infinite the other. If reading is near 3 V or infinite in
directions. both directions, the diode is open.
Action
Replace diode.
47540694 28/04/2014
55.1 [55.000] / 15
Electrical system - Testing - Wires

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA

Circuit not functioning. Wire not broken. Wire is broken.
Check Action Action
Check the wire for an open circuit. Go to test 2 Follow Wire harnesses - Repair
(55.100)
Circuit not functioning. Wire not shorted. Wire is shorted.
Check Action Action
Check wire run for a short circuit to Go to test 3 Follow Wire harnesses - Repair
ground by following Electrical sys- (55.100)
tem - Electrical test Short to Ground
(55.000).
Circuit not functioning. Wire not shorted. Wire is shorted.
Check Action Action
Check wire run for a short circuit to The fault may be intermittent. Follow Wire harnesses - Repair
voltage by following Electrical sys- Visually inspect the relevant har- (55.100)
tem - Electrical test Short to Voltage nesses and connectors for dam-
(55.000). age, bent or dislocated pins, cor-
roded terminals, or broken wires.
Verify that the connectors are
fully installed. Flex the harnesses
involved to reveal intermittent
breaks or shorts in the wiring con-
cerned. If no damage is found,
continue operation.
47540694 28/04/2014
55.1 [55.000] / 16
Electrical system - Testing - Relay

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
NOTE: See Fuse and relay box Relay - Overview (55.100) for general relay information.
NOTE: For 4-pin relays, follow steps 1–2. For 5-pin relays, follow steps 3–5.
Relay removed from fuse and relay panel. There should be approximately 75 If there is 0.0 Ω or infinite resis-
Check - 105 Ω. tance, the coil is open or shorted
Use a multi-meter to measure the resis- Action internally.
tance from pin 86 to pin 85. Go to test 2 Action
Replace the relay.
For Normally Open (NO) relays There should be no continuity. If there is continuity, the relay is
Check shorted.
Use a multi-meter to check for continuity Action
between pin 30 to pin 87. Replace the relay.
Relay removed from fuse and relay panel. There should be approximately 75 If there is 0.0 Ω or infinite resis-
Check - 105 Ω. tance, the coil is open or shorted
Use a multi-meter to measure the resis- Action internally.
tance from pin 86 to pin 85. Go to test 4 Action
Replace the relay.
Relay removed from fuse and panel relay. There should be no continuity. If there is continuity, the relay is
Check Action shorted.
Use a multi-meter to check for continuity Go to test 5 Action
between pin 30 to pin 87. Replace the relay.
Relay removed from fuse and panel relay. There should be continuity. If there is no continuity, the relay is
Check open.
Use a multi-meter to check for continuity Action
between pin 30 to pin 87a. Replace the relay.
47540694 28/04/2014
55.1 [55.000] / 17
Index

Electrical system - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electrical system - Testing - Diode (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical system - Testing - Relay (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical system - Testing - Wires (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Ground Drive (*) . . . . . . . . . . . . . 7
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Joystick (*) . . . . . . . . . . . . . . . . . . 6
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Loader start pressure (*) . . . . . 13
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Loader valve (*) . . . . . . . . . . . . . 11
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Requirements (*) . . . . . . . . . . . . . 4
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Throttle (*) . . . . . . . . . . . . . . . . . . 9
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Troubleshooting (*) . . . . . . . . . . . 5
47540694 28/04/2014
55.1 [55.000] / 18
Fuel injection system - 010
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.2 [55.010] / 1
Contents
FUNCTIONAL DATA
Fuel shutoff solenoid

Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
55.2 [55.010] / 2
Electrical systems - Fuel injection system
Fuel shutoff solenoid - Overview

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1Z0O2004112133 1
Solenoids work in much the same way as relays, except that the iron core is not fixed in place. As a result, the
windings in the control circuit cause the iron core to move. In the starting system, for example, the movement of this
core is used to send large amounts of current to the starter motor.
A solenoid is basically a winding around an iron core. In the centre of the core there is a plunger which is free to
move through the core. When an electrical current passes through the winding an electro-magnetic force is produced
which causes the plunger to move through the core. If the current is switched off, the magnetic force is stopped and
the plunger is returned by a spring.
The solenoid plunger may have different uses: the most common are moving a hydraulic spool or a mechanical lever.
The MOST COMMON FAULTS that can occur are:

• Short circuit winding: if a section of the winding allows the current to pass directly from positive (+) to negative (-)
terminals without passing through the winding, this will cause the relevant circuit fuse to blow.
• Broken winding: causing an open circuit, it will not allow the current to pass through the winding, so the solenoid
will not operate.
• Seized plunger (and/or connected components): the solenoid will only move the plunger if all components are free
to move.
47540694 28/04/2014
55.2 [55.010] / 3
Index

Fuel shutoff solenoid - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
55.2 [55.010] / 4
Fuel tank system - 011
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.3 [55.011] / 1
Contents
TECHNICAL DATA
Fuel level sensor

FUNCTIONAL DATA
Fuel level sensor

Overview Potentiometers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47540694 28/04/2014
55.3 [55.011] / 2
Electrical systems - Fuel tank system
Fuel level sensor - General specification

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Conversion table
Instrument panel display Resistance of the fuel level sensor
8 bars 0 - 32 Ω
7 bars 33 - 67 Ω
6 bars 68 - 87 Ω
5 bars 88 - 131 Ω
4 bars 132 - 171 Ω
3 bars 172 - 200 Ω
2 bars 201 - 230 Ω
1 bar 231 - — Ω
47540694 28/04/2014
55.3 [55.011] / 3
Fuel level sensor - Overview Potentiometers

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Potentiometers are also a vital part of an electric circuit.
Typically potentiometers are configured to provide operator or operational information to an electronic controller.
Unlike switches, which are used to provide digital input (on or off type of signal), potentiometers provide an analog
input (variable type of signal).
Some potentiometers are operator controlled, like the radio volume control knob or the temperature and fan speed
control knobs on the HVAC control module, but the majority use of potentiometers is to provide operational information,
such as fluid levels or product flow (volume) or device location (position) information.
20095585 1
The Fuel level sensing device contains a potentiometer (1) that is attached to the fuel return (2) and supply (not used)
(3) tubes and controlled by the movement of a float (4) attached to the potentiometer actuator arm (5).
93095586 2
Rotary to linear actuators contain a potentiometer used to provide position information.
1Z0O2004112130 3
Like operator and mechanically controlled switches, checking the operation of potentiometers can be accomplished
by disconnecting the potentiometer from the electrical circuit and using a multi-meter to measure resistances. Poten-
47540694 28/04/2014
55.3 [55.011] / 4
tiometers are three-wire devices. Typically a source voltage is connected to one of the pins attached to the stationary
(fixed contact) resistive component of the potentiometer and reference ground to the other while the signal is taken
from the pin attached to the wiper (movable contact). First measure the resistance across the full range of the poten-
tiometer, the pins attached to the stationary (fixed contact) resistive component of the potentiometer and then from
either end to the pin attached to the wiper (movable contact). In the latter test the resistance value should change,
continuously and smoothly, as the wiper is manually moved. As the resistance varies with temperature, the test spec-
ifications are usually given at 20 °C (68 °F).
NOTE: Like switches a growing number of potentiometers, as well as other variable resistive devices, are incorporat-
ing electronics. These devices are referred to as Sensors rather than Potentiometers or Varistors and often cannot
be continuity tested with a multi-meter.
Potentiometer Adjustment
When installing potentiometers, it is important to ensure that they do not bottom out in either direction, to prevent
damage. Most potentiometers have slotted mounting holes to allow some adjustment. Before tightening the mounting
hardware, operate the attaching linkage fully in both directions to confirm proper potentiometer positioning.
47540694 28/04/2014
55.3 [55.011] / 5
Index

Fuel level sensor - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel level sensor - Overview Potentiometers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47540694 28/04/2014
55.3 [55.011] / 6
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.4 [55.012] / 1
Contents
TECHNICAL DATA
Engine coolant temperature sensor

47540694 28/04/2014
55.4 [55.012] / 2
Electrical systems - Engine cooling system
Engine coolant temperature sensor - General specification

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Conversion chart
Sensor resistance Coolant temperature Sensor resistance Coolant temperature
>128318 Ω <-40 °C (<-40 °F) 1801.2 Ω 35 °C (95 °F)
128318 Ω -40 °C (-40 °F) 1457.5 Ω 40 °C (104 °F)
88806.4 Ω -35 °C (-31 °F) 1187.3 Ω 45 °C (113 °F)
63399.2 Ω -30 °C (-22 °F) 973.3 Ω 50 °C (122 °F)
44472.7 Ω -25 °C (-13 °F) 802.8 Ω 55 °C (131 °F)
32123.4 Ω -20 °C (-4 °F) 665.9 Ω 60 °C (140 °F)
23479.7 Ω -15 °C (5 °F) 465.8 Ω 70 °C (158 °F)
17393.7 Ω -10 °C (14 °F) 392.6 Ω 75 °C (167 °F)
13020.7 Ω -5 °C (23 °F) 332.5 Ω 80 °C (176 °F)
9851.1 Ω -0 °C (32 °F) 79.2 Ω 130 °C (266 °F)
7528.2 Ω 5 °C (41 °F) 70 Ω 135 °C (275 °F)
5807.9 Ω 10 °C (50 °F) 62 Ω 140 °C (284 °F)
4521.3 Ω 15 °C (59 °F) 55.1 Ω 145 °C (293 °F)
3550 Ω 20 °C (68 °F) 49.1 Ω 150 °C (302 °F)
2810 Ω 25 °C (77 °F) > 49.1 Ω >150 °C (>302 °F)
2241.5 Ω 30 °C (86 °F)
Conversion chart
Coolant temperature Instrument panel display
<21 °C (<70 °F) 1 bar
21 °C (70 °F) 1 bar
37 °C (99 °F) 2 bars
60 °C (140 °F) 3 bars
82 °C (180 °F) 4 bars
98 °C (208 °F) 5 bars
101 °C (214 °F) 6 bars
104 °C (219 °F) 7 bars
108 °C (226 °F) 8 bars
>108 °C (>226 °F) 8 bars
47540694 28/04/2014
55.4 [55.012] / 3
Index

Engine coolant temperature sensor - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
55.4 [55.012] / 4
Engine intake and exhaust system - 014
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.5 [55.014] / 1
Contents
SERVICE
Air cleaner restriction sensor

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
47540694 28/04/2014
55.5 [55.014] / 2
Electrical systems - Engine intake and exhaust system
Air cleaner restriction sensor - Remove

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Locate and open rear engine hood (1) and service door
(2).
93107449A1 1
2. Remove hardware (1) from air filter housing (2).
931002032 2
3. Remove hose clamp (1) from air cleaner assembly (2).
931002030 3
47540694 28/04/2014
55.5 [55.014] / 3
4. Remove clip (1) securing connector X-508. Discon-

nect connector X-508 from the air filter restriction switch
B-016 (2).
931002030 4
5. Unscrew the air filter restriction switch B-016 (1) by

hand from air cleaner assembly (2).
931002030 5
47540694 28/04/2014
55.5 [55.014] / 4
Air cleaner restriction sensor - Install

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Install the air filter restriction switch (1) into the air
cleaner assembly.
931002030 1
2. Connect the connector (1) to the air filter switch, and

insert clip (2).
931002030 2
3. Place hose clamp (1) over hose and connect to air

cleaner assembly (2). Tighten the hose clamp.
931002030 3
47540694 28/04/2014
55.5 [55.014] / 5
4. Insert hardware (1), and attach air cleaner assembly

(2) to mount.
931002032 4
47540694 28/04/2014
55.5 [55.014] / 6
Index

Air cleaner restriction sensor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air cleaner restriction sensor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
55.5 [55.014] / 7
47540694 28/04/2014
55.5 [55.014] / 8
Engine control system - 015
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.6 [55.015] / 1
Contents
FUNCTIONAL DATA
Engine timing sensors

Overview Speed and position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
55.6 [55.015] / 2
Electrical systems - Engine control system
Engine timing sensors - Overview Speed and position sensors

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Most of the speed and position sensors used are 2 and 3-wire active devices (requires an electrical source to function).
Therefore, a source and ground are supplied to the sensor. Non-contact sensing of a target (ferrous material) is
performed by the sensor in different ways, generally electro-magnetic coupling, which affects the source (typically a
switch like affect, from one level to another). The altered source may or may not be conditioned by the sensor.
The controller monitoring the sensor uses the sensor signal (affected source) to produce on and off signals for digital
processing. For speed sensing this would relate to how many pulses (off to on or on to off transitions) during an
established period of time and for position sensing the level of the signal (on or off).
These sensors can not be effectively checked out-of-circuit with only a DVOM. If the sensor is faulty and the sensor
circuit is complete, use the diagnostic capability of the display monitor to test the sensor functionality in the circuit.
40011026 1
Sensor Adjustment
When installing a new sensor, adjust the sensor to obtain a clearance of 3 mm (1/8 in) to the target metal.
47540694 28/04/2014
55.6 [55.015] / 3
Index

Engine timing sensors - Overview Speed and position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
55.6 [55.015] / 4
Hydrostatic drive control system - 019
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.7 [55.019] / 1
Contents
FUNCTIONAL DATA
Hydrostatic drive control sensors

Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydrostatic control solenoids
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Hydrostatic drive control sensors

Remove – Right hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install – Right hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove Left hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install Left hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydrostatic control solenoids
Remove – Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install – Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove – Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install – Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
47540694 28/04/2014
55.7 [55.019] / 2
Electrical systems - Hydrostatic drive control system
Hydrostatic drive control sensors - Overview

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1Z0O2004112130 1
47540694 28/04/2014
55.7 [55.019] / 3
Hydrostatic control solenoids - Overview

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1Z0O2004112134 1
Whenever it is necessary to provide proportional control to the solenoid valves, it is much better to use a principle
of operation called pulse width modulation (PWM). PWM is a variable DC voltage signal that is used to control the
solenoid valves. The voltage signal is pulsed on and off many times a second (at a constant frequency of 500 Hz) at
a constant supply voltage of 12 volts.
The CM modules contain transistors that are supplied with a constant input voltage which is switched on and off
to achieve the variable input range. In this way the control module is able to limit the armature movement, so the
hydraulic output flow of the solenoid is proportional to the average DC voltage. The lower voltage also allows the
solenoid to operate with less residual magnetism and so the entire circuit will operate smoother.
The variable DC voltage signal level is determined by varying the duration of the ON pulse relative to the OFF pulse.
The ratio between the ON time and the cycle time is called duty cycle and is stated as a percentage of one complete
cycle.
1Z0O2004112135 2
Diagrams (1) to (3) show the normal operating range of the PWM valve, and diagram (4), shows the initial 12 volts
programming and fill time only. The diagrams in column A show the voltage signal that is sent to the valve, whereas
column B shows the relevant spring pressure and column B the reading on a voltmeter connected to the solenoid
valve.
Diagram (1) shows the OFF position: no signal is directed to the valve, which means no spring pressure in the valve
at all and results in a zero voltage reading. Increasing the duty cycle causes some pressure to be made on the circuit
(Diagram (2)), which results in a voltmeter reading increase. Diagram (3), shows the maximum signal that is used
during the normal activity of the valve: its duty cycle is around 0.5, which results in a spring pressure for the half of
its run and in an indication of a 6 volts average DC current.
The electrical circuit to the solenoids can be checked by using a digital or analogue DC voltmeter, which will indicate
the average voltage readings.
47540694 28/04/2014
55.7 [55.019] / 4
Hydrostatic drive control sensors - Remove – Right hand swash

plate sensor
L223 TIER 4 [NDM474381 - ] NA
1. Locate the right hand swash plate sensor on the bottom

of the electro-hydraulic hydrostatic pump (1).
931001814 1
2. Label and disconnect the connector from the swash

plate sensor. The right hand swash plate sensor (1) is
located on the input shaft side of the hydrostatic pump.
931001961 2
3. Remove the two screws (1) holding the swash plate

shield (2) and sensor.
931001961 3
4. Remove the swash plate sensor.
47540694 28/04/2014
55.7 [55.019] / 5
Hydrostatic drive control sensors - Install – Right hand swash plate

sensor
L223 TIER 4 [NDM474381 - ] NA
1. Install the right hand swash plate sensor (1).
931001961 1
2. Place the swash plate shield (2) over the right hand
swash plate sensor. Insert the two screws (1) and
tighten to proper torque.
931001961 2
47540694 28/04/2014
55.7 [55.019] / 6
Hydrostatic drive control sensors - Remove Left hand swash plate

sensor
L223 TIER 4 [NDM474381 - ] NA
1. Locate the left hand swash plate sensor on the bottom

of the electro-hydraulic hydrostatic pump (1).
931001814 1
2. Label and disconnect the connector from the swash

plate sensor. The left hand swash plate sensor (1) is
located near the auxiliary pump.
931001961 2
3. Remove the two screws (1) holding the swash plate

shield (2) and sensor.
931001961 3
4. Remove the swash plate sensor.
47540694 28/04/2014
55.7 [55.019] / 7
Hydrostatic drive control sensors - Install Left hand swash plate

sensor
L223 TIER 4 [NDM474381 - ] NA
1. Install the left hand swash plate sensor (1).
931001961 1
2. Place the swash plate shield (2) over the left hand
swash plate sensor. Insert the two screws (1) and
tighten to proper torque.
931001961 2
47540694 28/04/2014
55.7 [55.019] / 8
Hydrostatic control solenoids - Remove – Right-hand side

L223 TIER 4 [NDM474381 - ] NA
NOTE: This procedure covers how to remove the right hand forward and right hand reverse drive solenoids located
on the electro-hydraulic hydrostatic pump.
1. Locate the electro-hydraulic hydrostatic pump (1).
931001814 1
2. Locate the drive solenoid that needs to be removed.

The right hand reverse (1) and right hand forward (2)
solenoids are located on the input shaft side of the hy-
drostatic pump.
931001814 2
3. Disconnect the connector (2) from the solenoid. Un-

screw the cap (1).
931001814 3
4. Slide the solenoid off.
47540694 28/04/2014
55.7 [55.019] / 9
Hydrostatic control solenoids - Install – Right-hand side

L223 TIER 4 [NDM474381 - ] NA
NOTE: This procedure covers how to install the right hand forward and right hand reverse drive solenoids located on
the electro-hydraulic hydrostatic pump.
1. Place the solenoid on to the valve body. See picture
for location of solenoids. The right hand reverse (1)
and right hand forward (2) solenoids are located on the
input shaft side of hydrostatic pump.
931001814 1
2. Screw the cap (1) onto valve body. Connect the con-
nector (2) to the solenoid.
931001814 2
47540694 28/04/2014
55.7 [55.019] / 10
Hydrostatic control solenoids - Remove – Left-hand side

L223 TIER 4 [NDM474381 - ] NA
NOTE: This procedure covers how to remove the left hand forward and left hand reverse drive solenoids located on
the electro-hydraulic hydrostatic pump.
1. Locate the electro-hydraulic hydrostatic pump (1).
931001814 1
2. Locate the drive solenoid that needs to be removed.

The left hand forward (1) and left hand reverse (2)
solenoids are located near the auxiliary pump.
931001814 2
3. Disconnect the connector (1) from the solenoid. Un-

screw the cap (2).
931001814 3
4. Slide the solenoid off.
47540694 28/04/2014
55.7 [55.019] / 11
Hydrostatic control solenoids - Install – Left-hand side

L223 TIER 4 [NDM474381 - ] NA
NOTE: This procedure covers how to install the left hand forward and left hand reverse drive solenoids located on the
electro-hydraulic hydrostatic pump.
1. Place the solenoid on to the valve body. See picture
for location of solenoids. The left hand reverse (1) and
left hand forward (2) solenoids are located near the
auxiliary pump.
931001814 1
2. Screw the cap (1) onto valve body. Connect the con-
nector (2) to the solenoid.
931001814 2
47540694 28/04/2014
55.7 [55.019] / 12
Index

Hydrostatic control solenoids - Install – Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydrostatic control solenoids - Install – Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydrostatic control solenoids - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydrostatic control solenoids - Remove – Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydrostatic control solenoids - Remove – Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydrostatic drive control sensors - Install – Right hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydrostatic drive control sensors - Install Left hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydrostatic drive control sensors - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydrostatic drive control sensors - Remove – Right hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydrostatic drive control sensors - Remove Left hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
47540694 28/04/2014
55.7 [55.019] / 13
47540694 28/04/2014
55.7 [55.019] / 14
Parking brake electrical system - 031
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.8 [55.031] / 1
Contents
FUNCTIONAL DATA
Brake control solenoids

Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Pressure sensor
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
47540694 28/04/2014
55.8 [55.031] / 2
Electrical systems - Parking brake electrical system
Brake control solenoids - Overview

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1Z0O2004112133 1
Solenoids work in much the same way as relays, except that the iron core is not fixed in place. As a result, the
windings in the control circuit cause the iron core to move. In the starting system, for example, the movement of this
core is used to send large amounts of current to the starter motor.
A solenoid is basically a winding around an iron core. In the centre of the core there is a plunger which is free to
move through the core. When an electrical current passes through the winding an electro-magnetic force is produced
which causes the plunger to move through the core. If the current is switched off, the magnetic force is stopped and
the plunger is returned by a spring.
The solenoid plunger may have different uses: the most common are moving a hydraulic spool or a mechanical lever.
The MOST COMMON FAULTS that can occur are:

• Short circuit winding: if a section of the winding allows the current to pass directly from positive (+) to negative (-)
terminals without passing through the winding, this will cause the relevant circuit fuse to blow.
• Broken winding: causing an open circuit, it will not allow the current to pass through the winding, so the solenoid
will not operate.
• Seized plunger (and/or connected components): the solenoid will only move the plunger if all components are free
to move.
47540694 28/04/2014
55.8 [55.031] / 3
Pressure sensor - Remove

L223 TIER 4 [NDM474381 - ] NA
WARNING
Crushing hazard!
If you service the machine with the loader lift arms raised, always use the support strut. Remove the
retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support
strut. Lower the lift arms onto the support strut.
W0230A
NOTE: Removing the charge pressure switch is the same procedure for the EH brake valve and EH 2speed brake
valve. This procedure uses the EH 2speed brake valve.
1. Locate the brake valve.
931002289 1
2. Locate the charge pressure switch, port PS1. Discon-

nect the connector (1) from the harness.
931001731 2
3. Unscrew the pressure sensor from the valve body.
47540694 28/04/2014
55.8 [55.031] / 4
Pressure sensor - Install

L223 TIER 4 [NDM474381 - ] NA
NOTE: Installing the charge pressure switch is the same procedure for the EH brake valve and EH 2speed brake
valve. This procedure uses the EH 2speed brake valve.
1. Thread and tighten the charge pressure switch into the
brake valve body port PS1.
2. Connect the charge pressure connector to the electrical
harness.
931001731 1
47540694 28/04/2014
55.8 [55.031] / 5
Index

Brake control solenoids - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure sensor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure sensor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47540694 28/04/2014
55.8 [55.031] / 6
Hydraulic system control - 036
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.9 [55.036] / 1
Contents
TECHNICAL DATA
Hydraulic fluid temperature control sensor

47540694 28/04/2014
55.9 [55.036] / 2
Electrical systems - Hydraulic system control
Hydraulic fluid temperature control sensor - General specification

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Conversion chart
Sensor resistance Oil temperature Sensor resistance Oil temperature
>128318 Ω <-40 °C (<-40 °F) 1801.2 Ω 35 °C (95 °F)
128318 Ω -40 °C (-40 °F) 1457.5 Ω 40 °C (104 °F)
88806.4 Ω -35 °C (-31 °F) 1187.3 Ω 45 °C (113 °F)
63399.2 Ω -30 °C (-22 °F) 973.3 Ω 50 °C (122 °F)
44472.7 Ω -25 °C (-13 °F) 802.8 Ω 55 °C (131 °F)
32123.4 Ω -20 °C (-4 °F) 665.9 Ω 60 °C (140 °F)
23479.7 Ω -15 °C (5 °F) 465.8 Ω 70 °C (158 °F)
17393.7 Ω -10 °C (14 °F) 392.6 Ω 75 °C (167 °F)
13020.7 Ω -5 °C (23 °F) 332.5 Ω 80 °C (176 °F)
9851.1 Ω -0 °C (32 °F) 79.2 Ω 130 °C (266 °F)
7528.2 Ω 5 °C (41 °F) 70 Ω 135 °C (275 °F)
5807.9 Ω 10 °C (50 °F) 62 Ω 140 °C (284 °F)
4521.3 Ω 15 °C (59 °F) 55.1 Ω 145 °C (293 °F)
3550 Ω 20 °C (68 °F) 49.1 Ω 150 °C (302 °F)
2810 Ω 25 °C (77 °F) > 49.1 Ω >150 °C (>302 °F)
2241.5 Ω 30 °C (86 °F)
Conversion chart
Oil temperature Instrument panel display
<21 °C (<70 °F) 1 bar
21 °C (70 °F) 1 bar
37 °C (99 °F) 2 bars
60 °C (140 °F) 3 bars
82 °C (180 °F) 4 bars
90 °C (194 °F) 5 bars
98 °C (208 °F) 6 bars
104 °C (219 °F) 7 bars
110 °C (230 °F) 8 bars
>110 °C (>230 °F) 8 bars
47540694 28/04/2014
55.9 [55.036] / 3
Index

Hydraulic fluid temperature control sensor - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
55.9 [55.036] / 4
Heating, Ventilation, and Air-Conditioning (HVAC) control system -

050
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.10 [55.050] / 1
Contents
Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050
FUNCTIONAL DATA
Heating, Ventilation, and Air-Conditioning (HVAC) control system

Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
55.10 [55.050] / 2
Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
Heating, Ventilation, and Air-Conditioning (HVAC) control system

- Overview
C232 TIER 4 [NDM451672 - ] NA
NOTE: See X-HVC1 and X-HVC2 for connector information

NOTE: See Air conditioning - Overview – Electrical system (50.200)for electrical flowpath description.
Components in HVAC BOX A-003

Designation Component
(1) Compressor Relay
(2) Auxiliary Relay for Electric Fan
(3) Resistor
(4) Electric Fan Motor
(5) No-Frost Electronic Thermostat
(6) Single-Level Pressure Switch
(7) Connector X-HVC2
HVACBOXSCHEMSL5 1
HVAC BOX A-003 Schematic
HVAC Box Pin Information (numbered from top to bottom on schematic)

Pin Number Wire Description
3 Power to Low Speed portion of Resistor from BLOWER
SWITCH S-020
4 Power to Medium Speed portion of Resistor from
BLOWER SWITCH S-020
5 High Speed power to Electric Fan Motor from BLOWER
SWITCH S-020
2 Power to Compressor Relay from COMPRESSOR FUSE
F-002
47540694 28/04/2014
55.10 [55.050] / 3
Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
10 Power to BLOWER SWITCH S-020, TEMPCONTROL Z-017

potentiometer, and WATER VALVE Z-019 from Auxiliary
Relay for Electric Fan
14 Power to Auxiliary Relay for Electric Fan from HVAC
FUSE F-001
9 Ground path from Thermostat
12 Power to A/C COMPRESSOR from Compressor Relay
11 Power to Auxiliary Relay for Electric Fan coil from
ACCESSORY RELAY K-018
6 Power to Single-Level Pressure Switch and Thermostat
from AC SWITCH S-017
1 Ground for Compressor Relay coil
Ground for Auxiliary Relay for Electric Fan coil
Ground for Electric Fan Motor
13 not used
8 Power to Compressor Relay coil from HVAC HIGH
PRESSURE SWITCH
7 Power to HVAC HIGH PRESSURE SWITCH from Thermostat
47540694 28/04/2014
55.10 [55.050] / 4
Index
Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050

Heating, Ventilation, and Air-Conditioning (HVAC) control system - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
55.10 [55.050] / 5
47540694 28/04/2014
55.10 [55.050] / 6
Harnesses and connectors - 100
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.11 [55.100] / 1
Contents
FUNCTIONAL DATA
Wire harnesses
Electrical schematic sheet 01 Main Power Distribution, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical schematic sheet 02 Accessory Power Distribution, Mechanical Units (*) . . . . . . . . . . . . . . . . . . 8
Electrical schematic sheet 03 Ignition Charging System, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . 10
Electrical schematic sheet 04 System Power and Ground, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . 12
Electrical schematic sheet 05 Engine Power Distribution and Fuel Pump, Mechanical Units (*) . . . . . . 14
Electrical schematic sheet 06 Engine F5C T4 (Vehicle), Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . 16
Electrical schematic sheet 07 Engine F5C T4 (Engine), Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . 18
Electrical schematic sheet 08 Throttle Sensor, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical schematic sheet 09 Control Valve Interlock & 2nd Aux Hydraulics, Mechanical Units (*) . . . . 22
Electrical schematic sheet 10 Cab to Chassis Interface, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . 24
Electrical schematic sheet 11 Cab Console Switches, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 26
Electrical schematic sheet 12 Left Hand Control Handle, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . 28
Electrical schematic sheet 13 Right Hand Control Handle, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . 30
Electrical schematic sheet 14 Seat, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Electrical schematic sheet 15 Std Aux Hydraulics, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Electrical schematic sheet 16 Lamps, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Electrical schematic sheet 17 Indicators, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Electrical schematic sheet 18 Turn Signal and Work Lights, Mechanical Units (*) . . . . . . . . . . . . . . . . . . 40
Electrical schematic sheet 19 Roading Lights, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Electrical schematic sheet 20 Wipers and Washers, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . 44
Electrical schematic sheet 21 Instrument Cluster, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Electrical schematic sheet 22 HVAC, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Electrical schematic sheet 23 Radio, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Electrical schematic sheet 24 Multi-Function Loader Arm, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . 52
Electrical schematic sheet 25 Telematics, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Electrical schematic sheet 26 Case Front Lights, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Electrical schematic sheet 27 Diagnostic Connector, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 58
Electrical schematic sheet 28 Fuel Filter Jumper, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Electrical schematic sheet 29 NH Front Lights, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Electrical schematic sheet 30 Boom Lock Valve, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
47540694 28/04/2014
55.11 [55.100] / 2
Electrical schematic sheet 01 Main Power Distribution, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Electrical schematic sheet 02 Accessory Power Distribution, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . 68
Electrical schematic sheet 03 Ignition Charging System, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Electrical schematic sheet 04 System Power and Grounds, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Electrical schematic sheet 05 Engine F5C T4 (Vehicle), EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electrical schematic sheet 06 Engine F5C T4 (Engine), EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Electrical schematic sheet 07 Engine Power Distribution and Fuel Pump, EH Units (*) . . . . . . . . . . . . . . 78
Electrical schematic sheet 08 Throttle Sensors, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Electrical schematic sheet 09 EH Pump/ Hydraulics, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Electrical schematic sheet 10 Hydraulic Interlocks, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Electrical schematic sheet 11 Loader Valve and Sensors, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Electrical schematic sheet 12 Cab to Chassis Interface, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Electrical schematic sheet 15 Cab Console Switches, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Electrical schematic sheet 16 Left Hand Control Handle, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Electrical schematic sheet 17 Right Hand Control Handle, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Electrical schematic sheet 18 Seat Switch, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Electrical schematic sheet 19 Unit Control Module, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Electrical schematic sheet 20 Unit Control Module, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Electrical schematic sheet 21 Lamps, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Electrical schematic sheet 22 Indicators, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Electrical schematic sheet 23 Turn Signal and Work Lights, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . 110
Electrical schematic sheet 24 Roading Lights, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Electrical schematic sheet 25 Wipers and Washers, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Electrical schematic sheet 26 Instrument Cluster, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Electrical schematic sheet 27 HVAC, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Electrical schematic sheet 28 Radio, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Electrical schematic sheet 29 Case Front Lights, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Electrical schematic sheet 30 Multi-Function Loader Arm, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Electrical schematic sheet 31 Telematics, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Electrical schematic sheet 32 Enhanced High Flow, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Electrical schematic sheet 33 Multi-Function ON/OFF, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Electrical schematic sheet 34 2nd Aux, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Electrical schematic sheet 35 Diagnostic Connector, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Electrical schematic sheet 36 Fuel Filter Jumper, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Electrical schematic sheet 37 NH Front Lights, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Wire connectors
Component localisation - Deluxe cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Component Diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
47540694 28/04/2014
55.11 [55.100] / 3
Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Component diagram – Connectors A – Z (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Component diagram – Grounds (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Component localisation - Deluxe cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Component Diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
47540694 28/04/2014
55.11 [55.100] / 4
Component diagram – Connectors A – Z (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Component diagram – Grounds (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Fuse and relay box
Relay - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Fuse - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
SERVICE
Wire harnesses
Repair (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
DIAGNOSTIC
Fuse and relay box

Testing – Universal Control Module (UCM) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
47540694 28/04/2014
55.11 [55.100] / 5
Electrical systems - Harnesses and connectors
Wire harnesses - Electrical schematic sheet 01 Main Power

Distribution, Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 6
RAIL14SSL0175JA 1
47540694 28/04/2014
55.11 [55.100] / 7
Wire harnesses - Electrical schematic sheet 02 Accessory Power

Distribution, Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 8
RAIL14SSL0176JA 1
47540694 28/04/2014
55.11 [55.100] / 9
Wire harnesses - Electrical schematic sheet 03 Ignition Charging

System, Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 10
RAIL14SSL0177JA 1
47540694 28/04/2014
55.11 [55.100] / 11
Wire harnesses - Electrical schematic sheet 04 System Power and

Ground, Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 12
RAIL14SSL0178JA 1
47540694 28/04/2014
55.11 [55.100] / 13
Wire harnesses - Electrical schematic sheet 05 Engine Power

Distribution and Fuel Pump, Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 14
RAIL14SSL0179JA 1
47540694 28/04/2014
55.11 [55.100] / 15
Wire harnesses - Electrical schematic sheet 06 Engine F5C T4 (Vehicle),

Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 16
RAIL14SSL0247JA 1
47540694 28/04/2014
55.11 [55.100] / 17
Wire harnesses - Electrical schematic sheet 07 Engine F5C T4 (Engine),

Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 18
RAIL14SSL0181JA 1
47540694 28/04/2014
55.11 [55.100] / 19
Wire harnesses - Electrical schematic sheet 08 Throttle Sensor,

Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 20
RAIL14SSL0182JA 1
47540694 28/04/2014
55.11 [55.100] / 21
Wire harnesses - Electrical schematic sheet 09 Control Valve Interlock &

2nd Aux Hydraulics, Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 22
RAIL14SSL0183JA 1
47540694 28/04/2014
55.11 [55.100] / 23
Wire harnesses - Electrical schematic sheet 10 Cab to Chassis Interface,

Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 24
RAIL14SSL0184JA 1
47540694 28/04/2014
55.11 [55.100] / 25
Wire harnesses - Electrical schematic sheet 11 Cab Console Switches,

Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 26
RAIL14SSL0185JA 1
47540694 28/04/2014
55.11 [55.100] / 27
Wire harnesses - Electrical schematic sheet 12 Left Hand Control

Handle, Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 28
RAIL14SSL0186JA 1
47540694 28/04/2014
55.11 [55.100] / 29
Wire harnesses - Electrical schematic sheet 13 Right Hand Control

Handle, Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 30
RAIL14SSL0187JA 1
47540694 28/04/2014
55.11 [55.100] / 31
Wire harnesses - Electrical schematic sheet 14 Seat, Mechanical Units

47540694 28/04/2014
55.11 [55.100] / 32
RAIL14SSL0188JA 1
47540694 28/04/2014
55.11 [55.100] / 33
Wire harnesses - Electrical schematic sheet 15 Std Aux Hydraulics,

Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 34
RAIL14SSL0189JA 1
47540694 28/04/2014
55.11 [55.100] / 35
Wire harnesses - Electrical schematic sheet 16 Lamps, Mechanical Units

47540694 28/04/2014
55.11 [55.100] / 36
RAIL14SSL0190JA 1
47540694 28/04/2014
55.11 [55.100] / 37
Wire harnesses - Electrical schematic sheet 17 Indicators, Mechanical

Units
47540694 28/04/2014
55.11 [55.100] / 38
RAIL14SSL0191JA 1
47540694 28/04/2014
55.11 [55.100] / 39
Wire harnesses - Electrical schematic sheet 18 Turn Signal and Work

Lights, Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 40
RAIL14SSL0192JA 1
47540694 28/04/2014
55.11 [55.100] / 41
Wire harnesses - Electrical schematic sheet 19 Roading Lights,

Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 42
RAIL14SSL0193JA 1
47540694 28/04/2014
55.11 [55.100] / 43
Wire harnesses - Electrical schematic sheet 20 Wipers and Washers,

Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 44
RAIL14SSL0194JA 1
47540694 28/04/2014
55.11 [55.100] / 45
Wire harnesses - Electrical schematic sheet 21 Instrument Cluster,

Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 46
RAIL14SSL0195JA 1
47540694 28/04/2014
55.11 [55.100] / 47
Wire harnesses - Electrical schematic sheet 22 HVAC, Mechanical Units

47540694 28/04/2014
55.11 [55.100] / 48
RAIL14SSL0196JA 1
47540694 28/04/2014
55.11 [55.100] / 49
Wire harnesses - Electrical schematic sheet 23 Radio, Mechanical Units

47540694 28/04/2014
55.11 [55.100] / 50
RAIL14SSL0197JA 1
47540694 28/04/2014
55.11 [55.100] / 51
Wire harnesses - Electrical schematic sheet 24 Multi-Function Loader

Arm, Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 52
RAIL14SSL0198JA 1
47540694 28/04/2014
55.11 [55.100] / 53
Wire harnesses - Electrical schematic sheet 25 Telematics, Mechanical

Units
47540694 28/04/2014
55.11 [55.100] / 54
RAIL14SSL0199JA 1
47540694 28/04/2014
55.11 [55.100] / 55
Wire harnesses - Electrical schematic sheet 26 Case Front Lights,

Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 56
RAIL14SSL0200JA 1
47540694 28/04/2014
55.11 [55.100] / 57
Wire harnesses - Electrical schematic sheet 27 Diagnostic Connector,

Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 58
RAIL14SSL0201JA 1
47540694 28/04/2014
55.11 [55.100] / 59
Wire harnesses - Electrical schematic sheet 28 Fuel Filter Jumper,

Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 60
RAIL14SSL0202JA 1
47540694 28/04/2014
55.11 [55.100] / 61
Wire harnesses - Electrical schematic sheet 29 NH Front Lights,

Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 62
RAIL14SSL0203JA 1
47540694 28/04/2014
55.11 [55.100] / 63
Wire harnesses - Electrical schematic sheet 30 Boom Lock Valve,

Mechanical Units
47540694 28/04/2014
55.11 [55.100] / 64
RAIL14SSL0204JA 1
47540694 28/04/2014
55.11 [55.100] / 65
Wire harnesses - Electrical schematic sheet 01 Main Power Distribution,

EH Units
47540694 28/04/2014
55.11 [55.100] / 66
RAIL14SSL0210JA 1
47540694 28/04/2014
55.11 [55.100] / 67
Wire harnesses - Electrical schematic sheet 02 Accessory Power

Distribution, EH Units
47540694 28/04/2014
55.11 [55.100] / 68
RAIL14SSL0211JA 1
47540694 28/04/2014
55.11 [55.100] / 69
Wire harnesses - Electrical schematic sheet 03 Ignition Charging

System, EH Units
47540694 28/04/2014
55.11 [55.100] / 70
RAIL14SSL0212JA 1
47540694 28/04/2014
55.11 [55.100] / 71
Wire harnesses - Electrical schematic sheet 04 System Power and

Grounds, EH Units
47540694 28/04/2014
55.11 [55.100] / 72
RAIL14SSL0213JA 1
47540694 28/04/2014
55.11 [55.100] / 73
Wire harnesses - Electrical schematic sheet 05 Engine F5C T4 (Vehicle),

EH Units
47540694 28/04/2014
55.11 [55.100] / 74
RAIL14SSL0214JA 1
47540694 28/04/2014
55.11 [55.100] / 75
Wire harnesses - Electrical schematic sheet 06 Engine F5C T4 (Engine),

EH Units
47540694 28/04/2014
55.11 [55.100] / 76
RAIL14SSL0215JA 1
47540694 28/04/2014
55.11 [55.100] / 77
Wire harnesses - Electrical schematic sheet 07 Engine Power

Distribution and Fuel Pump, EH Units
47540694 28/04/2014
55.11 [55.100] / 78
RAIL14SSL0216JA 1
47540694 28/04/2014
55.11 [55.100] / 79
Wire harnesses - Electrical schematic sheet 08 Throttle Sensors, EH

Units
47540694 28/04/2014
55.11 [55.100] / 80
RAIL14SSL0217JA 1
47540694 28/04/2014
55.11 [55.100] / 81
Wire harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics,

EH Units
47540694 28/04/2014
55.11 [55.100] / 82
RAIL14SSL0218JA 1
47540694 28/04/2014
55.11 [55.100] / 83
Wire harnesses - Electrical schematic sheet 10 Hydraulic Interlocks,

EH Units
47540694 28/04/2014
55.11 [55.100] / 84
RAIL14SSL0219JA 1
47540694 28/04/2014
55.11 [55.100] / 85
Wire harnesses - Electrical schematic sheet 11 Loader Valve and

Sensors, EH Units
47540694 28/04/2014
55.11 [55.100] / 86
RAIL14SSL0220JA 1
47540694 28/04/2014
55.11 [55.100] / 87

EH Units
47540694 28/04/2014
55.11 [55.100] / 88
RAIL14SSL0221JA 1
47540694 28/04/2014
55.11 [55.100] / 89

EH Units
47540694 28/04/2014
55.11 [55.100] / 90
RAIL14SSL0222JA 1
47540694 28/04/2014
55.11 [55.100] / 91

EH Units
47540694 28/04/2014
55.11 [55.100] / 92
RAIL14SSL0223JA 1
47540694 28/04/2014
55.11 [55.100] / 93
Wire harnesses - Electrical schematic sheet 15 Cab Console Switches,

EH Units
47540694 28/04/2014
55.11 [55.100] / 94
RAIL14SSL0224JA 1
47540694 28/04/2014
55.11 [55.100] / 95
Wire harnesses - Electrical schematic sheet 16 Left Hand Control

Handle, EH Units
47540694 28/04/2014
55.11 [55.100] / 96
RAIL14SSL0225JA 1
47540694 28/04/2014
55.11 [55.100] / 97
Wire harnesses - Electrical schematic sheet 17 Right Hand Control

Handle, EH Units
47540694 28/04/2014
55.11 [55.100] / 98
RAIL14SSL0226JA 1
47540694 28/04/2014
55.11 [55.100] / 99
Wire harnesses - Electrical schematic sheet 18 Seat Switch, EH Units

47540694 28/04/2014
55.11 [55.100] / 100
RAIL14SSL0227JA 1
47540694 28/04/2014
55.11 [55.100] / 101
Wire harnesses - Electrical schematic sheet 19 Unit Control Module,

EH Units
47540694 28/04/2014
55.11 [55.100] / 102
RAIL14SSL0228JA 1
47540694 28/04/2014
55.11 [55.100] / 103
Wire harnesses - Electrical schematic sheet 20 Unit Control Module,

EH Units
47540694 28/04/2014
55.11 [55.100] / 104
RAIL14SSL0229JA 1
47540694 28/04/2014
55.11 [55.100] / 105
Wire harnesses - Electrical schematic sheet 21 Lamps, EH Units

47540694 28/04/2014
55.11 [55.100] / 106
RAIL14SSL0230JA 1
47540694 28/04/2014
55.11 [55.100] / 107
Wire harnesses - Electrical schematic sheet 22 Indicators, EH Units

47540694 28/04/2014
55.11 [55.100] / 108
RAIL14SSL0231JA 1
47540694 28/04/2014
55.11 [55.100] / 109
Wire harnesses - Electrical schematic sheet 23 Turn Signal and Work

Lights, EH Units
47540694 28/04/2014
55.11 [55.100] / 110
RAIL14SSL0232JA 1
47540694 28/04/2014
55.11 [55.100] / 111
Wire harnesses - Electrical schematic sheet 24 Roading Lights, EH Units

47540694 28/04/2014
55.11 [55.100] / 112
RAIL14SSL0233JA 1
47540694 28/04/2014
55.11 [55.100] / 113
Wire harnesses - Electrical schematic sheet 25 Wipers and Washers,

EH Units
47540694 28/04/2014
55.11 [55.100] / 114
RAIL14SSL0234JA 1
47540694 28/04/2014
55.11 [55.100] / 115
Wire harnesses - Electrical schematic sheet 26 Instrument Cluster, EH

Units
47540694 28/04/2014
55.11 [55.100] / 116
RAIL14SSL0235JA 1
47540694 28/04/2014
55.11 [55.100] / 117
Wire harnesses - Electrical schematic sheet 27 HVAC, EH Units

47540694 28/04/2014
55.11 [55.100] / 118
RAIL14SSL0236JA 1
47540694 28/04/2014
55.11 [55.100] / 119
Wire harnesses - Electrical schematic sheet 28 Radio, EH Units

47540694 28/04/2014
55.11 [55.100] / 120
RAIL14SSL0237JA 1
47540694 28/04/2014
55.11 [55.100] / 121
Wire harnesses - Electrical schematic sheet 29 Case Front Lights, EH

Units
47540694 28/04/2014
55.11 [55.100] / 122
RAIL14SSL0238JA 1
47540694 28/04/2014
55.11 [55.100] / 123
Wire harnesses - Electrical schematic sheet 30 Multi-Function Loader

Arm, EH Units
47540694 28/04/2014
55.11 [55.100] / 124
RAIL14SSL0239JA 1
47540694 28/04/2014
55.11 [55.100] / 125
Wire harnesses - Electrical schematic sheet 31 Telematics, EH Units

47540694 28/04/2014
55.11 [55.100] / 126
RAIL14SSL0240JA 1
47540694 28/04/2014
55.11 [55.100] / 127
Wire harnesses - Electrical schematic sheet 32 Enhanced High Flow,

EH Units
47540694 28/04/2014
55.11 [55.100] / 128
RAIL14SSL0241JA 1
47540694 28/04/2014
55.11 [55.100] / 129
Wire harnesses - Electrical schematic sheet 33 Multi-Function ON/OFF,

EH Units
47540694 28/04/2014
55.11 [55.100] / 130
RAIL14SSL0242JA 1
47540694 28/04/2014
55.11 [55.100] / 131
Wire harnesses - Electrical schematic sheet 34 2nd Aux, EH Units

47540694 28/04/2014
55.11 [55.100] / 132
RAIL14SSL0243JA 1
47540694 28/04/2014
55.11 [55.100] / 133
Wire harnesses - Electrical schematic sheet 35 Diagnostic Connector,

EH Units
47540694 28/04/2014
55.11 [55.100] / 134
RAIL14SSL0244JA 1
47540694 28/04/2014
55.11 [55.100] / 135
Wire harnesses - Electrical schematic sheet 36 Fuel Filter Jumper, EH

Units
47540694 28/04/2014
55.11 [55.100] / 136
RAIL14SSL0245JA 1
47540694 28/04/2014
55.11 [55.100] / 137
Wire harnesses - Electrical schematic sheet 37 NH Front Lights, EH Units

47540694 28/04/2014
55.11 [55.100] / 138
RAIL14SSL0246JA 1
47540694 28/04/2014
55.11 [55.100] / 139
Wire connectors - Component localisation - Deluxe cab

NOTE: Deluxe cab shown
47540694 28/04/2014
55.11 [55.100] / 140
RAPH12SSL0478KA 1
47540694 28/04/2014
55.11 [55.100] / 141
47540694 28/04/2014
55.11 [55.100] / 142
RAPH12SSL0479GA 2
Detail 1
Connector title Component Pin information

X-30 Cab/right hand jumper interface Wire connectors - Component
diagram 03 (55.100)
X-9 Ignition switch Wire connectors - Component
Diagram 00 (55.100)
X-C23 Instrument cluster Wire connectors - Component
diagram – Connectors A – Z
(55.100)
X-365 Park brake switch Wire connectors - Component
diagram 36 (55.100)
X-CTS Turn signal switch Not available
X-311 Light selector switch Not available
X-20A Hand throttle Wire connectors - Component
diagram 02 (55.100)
X-502 Door wiper motor Wire connectors - Component
diagram 50 (55.100)
47540694 28/04/2014
55.11 [55.100] / 143
RAPH12SSL0480GA 3
Detail 2

X-31 Cab/left hand jumper interface Wire connectors - Component
diagram 03 (55.100)
X-252 Temperature control switch Wire connectors - Component
diagram 25 (55.100)
X270 Blower fan switch Not available
X-275 A/C switch Wire connectors - Component
diagram 27 (55.100)
X-155B Turn signal (right) Not available
X-157B Turn signal (left) Not available
X175B Turn indicator (ground) Not available
X-300 Hydraulic coupler switch Wire connectors - Component
diagram 30 (55.100)
X-310 Two speed indicator Wire connectors - Component
diagram 31 (55.100)
47540694 28/04/2014
55.11 [55.100] / 144
X-301 Beacon switch Wire connectors - Component

diagram 30 (55.100)
X-302 Hazard switch Wire connectors - Component
diagram 30 (55.100)
X-317 Self level switch Not available
X-303 Hi flow switch Wire connectors - Component
diagram 30 (55.100)
X-113 FE #2 switch Not available
X-503 Wiper/washer switch Wire connectors - Component
diagram 50 (55.100)
X-306 Loader lockout switch Wire connectors - Component
diagram 30 (55.100)
X-ACC Accessory power switch Not available
X-505 Cab/door switch interface Not available
RAPH12SSL0481GA 4
Detail 3

X-2SPD Two speed valve solenoid Not available
X-DIAG CAN Diagnostic connector Wire connectors - Component
(55.100)
X-BRK Brake valve solenoid Not available
47540694 28/04/2014
55.11 [55.100] / 145
CHS_GND_FRT Ground Wire connectors - Component

diagram – Grounds (55.100)
X-CO2A Cab/chassis option 2 Wire connectors - Component
(55.100)
X-42 Mechanical backup switch Not available
X-CAB_GNDA Ground Wire connectors - Component
X-CAB_GNDB Ground Wire connectors - Component
FUSE1 Fuse box Wire connectors - Component
(55.100)
X-271 Water valve Wire connectors - Component
diagram 27 (55.100)
X-20A Foot throttle sensor Wire connectors - Component
diagram 02 (55.100)
47540694 28/04/2014
55.11 [55.100] / 146
RAPH12SSL0482GA 5
Detail 4

(55.100)
(55.100)
X-CC3A Cab/chassis 3 Wire connectors - Component
(55.100)
X-CC7A Cab/chassis 7 Not available
(55.100)
47540694 28/04/2014
55.11 [55.100] / 147

(55.100)
RAPH12SSL0483GA 6
Detail 5

X-HVC1 Cab/HVAC interconnect Wire connectors - Component
(55.100)
X-111 Condenser relay Wire connectors - Component
diagram 11 (55.100)
47540694 28/04/2014
55.11 [55.100] / 148
RAPH12SSL0484GA 7
Detail 6

X-RDCTRL Ride control valve solenoid Not available
X-318 Self level valve Not available
X-PORT_LK Port lock Not available
X-OILTMP Hydraulic oil temperature sender Not available
X-402 Right hand handle interconnect Wire connectors - Component
park/ride/brake control diagram 40 (55.100)
X-432 Proportional auxiliary valve retract Not available
X-433 Proportional auxiliary valve extend Not available
X-TELE Telematics Wire connectors - Component
(55.100)
X-430 Auxiliary PWM controller Wire connectors - Component
diagram 43 (55.100)
X-405 Left hand handle interlock horn/two Wire connectors - Component
speed diagram 40 (55.100)
47540694 28/04/2014
55.11 [55.100] / 149
RAPH12SSL0485GA 8
Detail 7

X-195 GCU fuse Not available
X-001 Engine relay box Wire connectors - Component
Diagram 00 (55.100)
X-5A Alternator Not available
X-126 Starter Not available
X-013 GCU Wire connectors - Component
diagram 01 (55.100)
47540694 28/04/2014
55.11 [55.100] / 150
RAPH12SSL0486GA 9
Detail 8

X-004 Air temperature sensor Not available
X-007 Exhaust gas temperature sensor 2 Not available
X-508 Air filter Not available
X-005 Differential pressure sensor Wire connectors - Component
Diagram 00 (55.100)
X-178 Beacon lamp socket Not available
X-HORN_PWR Horn power Not available
x-HORN_GND Horn ground Not available
X-77 Side lamp socket Not available
X-502A Rear window wiper motor Wire connectors - Component
diagram 50 (55.100)
X-006 Exhaust gas temperature sensor 1 Not available
X-014 Lambda sensor Wire connectors - Component
diagram 01 (55.100)
X-902 Wire connectors - Component
diagram 90 (55.100)
47540694 28/04/2014
55.11 [55.100] / 151
RAPH12SSL0487GA 10
Detail 9

X-331 Right speaker Not available
X–330 Right speaker Not available
X-332 Left speaker Not available
X-97 Cab/dome lamp jumper Not available
X-30 Cab/right hand lamp jumper interface Wire connectors - Component
diagram 03 (55.100)
Diagram 00 (55.100)
X-335 Radio connector Wire connectors - Component
diagram 33 (55.100)
X-104 Lap bar switch Not available
47540694 28/04/2014
55.11 [55.100] / 152
RAPH12SSL0488GA 11
Detail 10

X-012 ECU Wire connectors - Component
diagram 01 (55.100)
diagram 01 (55.100)
X-11 Wire connectors - Component
diagram 01 (55.100)
X-CHS_GND_RR Ground Wire connectors - Component
X-015 Electric valve Wire connectors - Component
diagram 01 (55.100)
X-NEG_TERM_A Ground Wire connectors - Component
ECU_GND Ground Wire connectors - Component
47540694 28/04/2014
55.11 [55.100] / 153
X-017 Engine interface Wire connectors - Component

diagram 01 (55.100)
Diagram 00 (55.100)
X-018 Fuel filter heater Not available
X-14 Fuel level sender Not available
RAPH12SSL0489GA 12
Detail 11

BKUP-GND Backup alarm (ground) Not available
BKUP-PWR Backup alarm (power) Not available
X-RRJMPRA Chassis/rear lamp jumper interface Wire connectors - Component
(55.100)
47540694 28/04/2014
55.11 [55.100] / 154
Wire connectors - Component Diagram 00

CONNECTOR X-001 - ENGINE RELAY BOX

PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE
A30 256 (RD) CRANK RELAY FUSE POWER
A85 161 (YE) CRANK ENABLE FROM ECU
A87 520 (WH) STARTER MOTOR POWER
C85 112 (BL) ECU MAIN RELAY ENABLE FROM ECU
C86 527C (RD) BATT+
C87 528A (OR) ECU RELAY OUTPUT TO FUSE
47540694 28/04/2014
55.11 [55.100] / 155
CONNECTOR X-005 - DIFFERENTIAL PRESSURE SENSOR

1 269 (YE) DIFF PRESSURE SUPPLY
2 266 (BK/WH) DIFF PRESSURE SENSOR GND
3 268 (YE) DIFF PRESSURE SENSOR SIGNAL
87747172 2
CONNECTOR X-9 - IGNITION SWITCH

1 140 (RD) KEY SW POWER
2 624 (WH) KEY START TO CLUSTER
3 132 (OR) KEY IGNITION TO CLUSTER
6 138 (OR) KEY ACCESSORY
87693713 3
47540694 28/04/2014
55.11 [55.100] / 156
Wire connectors - Component diagram 01

CONNECTOR X-011 - WATER IN FUEL SWITCH

1 150 (YE) WATER IN FUEL LEVEL SENSOR SIGNAL
2 908E (BK) WIF GND
3 133E (OR) WIF POWER
87709663 1
CONNECTOR X-012 - ECU

PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME
NUMBER
1 110 (OR) ECU FUSE 1 POWER
2 908B (BK) ECU GND 1
3 155B (OR) BATTERY +B VIA MAIN RELAY
4 908C (BK) ECU GND 2
5 155C (OR) BATTERY +C VIA MAIN RELAY
6 908D (BK) ECU GND 3
7 242 (YE) LAMBDA SENSOR HEATING
8 622 (WH) CRANK SIGNAL FROM CLUSTER
TO ECU
14 269 (YE) DIFF PRESSURE SUPPLY
19 257 (YE) AIR TEMP SENSOR SIGNAL
20 254 (BK/WH) AIR TEMP GND
22 235 (YE) GLOW PLUG FEEDBACK SIGNAL
24 503C (YE)
25 504C (GN)
27 121 (YE) CRANK ENABLE FROM ECU
28 112 (BL) ECU MAIN RELAY ENABLE FROM
ECU
30 150 (YE) WATER IN FUEL LEVEL SENSOR
SIGNAL
41 239 (BK) GLOW PLUG UNIT GND
52 216 (YE) GLOW PLUG UNIT COMMAND
SIGNAL
54 133D (OR) TERMINAL 15 SW BATT+
68 248 (YE) EGR ECU K-LINE
47540694 28/04/2014
55.11 [55.100] / 157

NUMBER
70 347 (BL) FUEL FILTER HEATER GROUND
79 270 (BK/WH) EXHAUST GAS TEMP GND
80 271 (YE) EXHAUST GAS TEMP SIGNAL
81 265 (BK/WH) INLET TURBINE TEMP GND
82 263 (YE) INLET TURBINE TEMP SIGNAL
83 272 (BK/WH) EXHAUST GAS TEMP GND 2
84 273 (YE) EXHAUST GAS TEMP SIGNAL 2
85 252 (BK)
86 249 (YE)
47540694 28/04/2014
55.11 [55.100] / 158
CONNECTOR X-013 - GCU

1 1112 (WH) GLOW PLUG
4 212 (OR) GCU B+
5 239A (BK) GLOW PLUG UNIT GND
8 216 (YE) GLOW PLUG UNIT COMMAND SIGNAL
84356962 3
47540694 28/04/2014
55.11 [55.100] / 159
CONNECTOR X-014 - LAMBDA SENSOR

1 245 (YE)
2 252 (BK)
4 241B (OR) LAMBDA POWER
5 249 (YE)
6 253 (PK)
84301132 4
CONNECTOR X-015 - ELECTRIC VALVE

A 274 (WH)
B 275 (GY)
C 276 (GY)
D 277 (WH)
E 278 (WH)
F 279 (GY)
G 280 (GY)
H 281 (WH)
87698252 5
47540694 28/04/2014
55.11 [55.100] / 160

1 277 (WH)
2 281 (WH)
4 294 (GY) BOOST PRESSURE ACTUATOR 1
6 658 (YE)
8 340 (PK) TVA POSITION SENSOR SUPPLY
9 318 (PK) EGR POSITION SENSOR SUPPLY
10 343 (PK) BOOST PRESSURE SENSOR SUPPLY
11 284 (PK) RAIL PRESSURE SENSOR SUPPLY
12 295 (PK) EXHAUST GAS PRESSURE SENSOR SUPPLY (UPSTREAM
TURBINE PRESSURE) P3
13 289 (PK) SEGMENT(CAMSHAFT) SPEED SENSOR SUPLY
14 287 (YE) SEGMENT(CAMSHAFT) SPEED SENSOR SIGNAL
15 299 (WH)
16 274 (WH)
17 278 (WH)
23 292 (BL) FUEL TEMPERATURE SENSOR GROUND
24 337 (BK/WH) EGR POSITION SENSOR GROUND
25 345 (BK/WH) BOOST PRESURE SENSOR GROUND
26 282 (YE)
27 296 (BK/WH) EXHAUST GAS PRESSURE SENSOR GROUND P3 (UPSTREAM
TURBINE PRESSURE)
28 288 (BL) SEGMENT(CAMSHAFT) SPEED SENSOR GROUND
31 276 (GY)
32 275 (GY)
34 339 (GY)
35 322 (GY)
37 342 (BK/WH) TVA POSITION SENSOR GROUND
38 293 (YE) FUEL TEMPERATURE SENSOR SIGNAL
39 327 (YE) EGR POSITION SENSOR SIGNAL
40 344 (YE) BOOST PRESSURE SENSOR SIGNAL
41 283 (YE)
43 297 (YE) EXHAUST GAS PRESSURE SENSOR SIGNAL P3 (UPSTREAM
TURBINE PRESSURE)
44 286 (YE)
46 280 (GY)
48 279 (GY)
49 338 (WH)
50 321 (WH)
53 341 (YE) TVA POSITION SENSOR SIGNAL
54 - -
55 346 (YE) BOOST PRESSURE TEMPERATURE SENSOR SIGNAL
57 291 (YE) COOLANT TEMPERATURE SENSOR SIGNAL
58 290 (BL) COOLANT TEMPERATURE SENSOR GROUND
59 285 (YE)
60 298 (GY)
47540694 28/04/2014
55.11 [55.100] / 161
47540694 28/04/2014
55.11 [55.100] / 162
CONNECTOR X-017 - ENGINE INTERFACE

1 299 (WH)
2 298 (GY)
3 658 (YE)
5 282 (YE)
6 283 (YE)
9 285 (YE)
10 286 (YE)
TURBINE PRESSURE)
TURBINE PRESSURE)
24 - -
27 294 (GY) BOOST PRESSURE ACTUATOR 1
28 241C (OR) ELECTRIC VALVE POWER
29 321 (WH)
30 322 (GY)
37 338 (WH)
38 339 (GY)
47540694 28/04/2014
55.11 [55.100] / 163
84154706 7
47540694 28/04/2014
55.11 [55.100] / 164
CONNECTOR X-11 - X-11

1 833 (WH) THERMOSTAT TO PRES SW
2 834 (WH) PRES SW TO COMP RLY
3 841 (WH) A/C COMP RLY PIN 87 POWER
87382911 8
47540694 28/04/2014
55.11 [55.100] / 165

CONNECTOR X-20 - FOOT THROTTLE SENSOR

A 545 (YE) FOOT THROTTLE SIGNAL
B 1066 (BK/WH) FOOT THROTTLE SENSOR GND
C 211 (PK) FOOT THROTTLE SENSOR SUPPLY
CONNECTOR X-20A - HAND TROTTLE
CONNECTOR X-20A - HAND TROTTLE

A 544 (YE) HAND THROTTLE SIGNAL
B 1071 (BK/WH) HAND THROTTLE SENSOR GND
C 260 (PK) HAND THROTTLE SENSOR SUPPLY
47540694 28/04/2014
55.11 [55.100] / 166

CONNECTOR X-30 - CAB/RH LAMP JUMPER INTERFACE

1 798 (VT) RH WORK LAMP POWER
2 793 (VT) RH SIDE LAMP POWER
3 779 (VT) RH CAB TURN SIGNAL POWER
4 926 (BK) RH CAB LAMPS GROUND
87694154 1
CONNECTOR X-31 - CAB/LH LAMP JUMPER INTERFACE

1 799 (VT) LH WORK LAMP POWER
2 794 (VT) LH SIDE LAMP POWER
3 773 (VT) LH CAB TURN SIGNAL POWER
4 927 (BK) LH CAB LAMPS GND
87694154 2
47540694 28/04/2014
55.11 [55.100] / 167

CONNECTOR X-58 - CAB/SEAT INTERFACE

1 756 (OR) SEAT ACCESSORY POWER
2 933 (BK) SEAT ACCESSORY GROUND
3 315 (RD) SEAT SW UNSWITCHED POWER
4 323 (YE) SEAT SW CLUSTER INPUT
87694154 1
47540694 28/04/2014
55.11 [55.100] / 168


A 600 (OR) FUEL PUMP
B 600A (OR) FUEL PUMP
87695580 1
47540694 28/04/2014
55.11 [55.100] / 169

CONNECTOR X-111 - CONDENSER RELAY [CAB]

1 839 (RD) CONDENSER RELAY PIN 30 POWER
2 840 (WH) CONDENSER RELAY PIN 86 SIGNAL
3 237 (WH) HVAC COND FAN POWER
5 1087 (BK) CONDENSER RELAY GROUND
CONNECTOR X-113 - FE #2 SWITCH

D 425 (VT) CONSOLE SWITCH MF #2 UP
E 359 (OR) CONSOLE SWITCH MF #2 POWER
F 427 (RD) CONSOLE SWITCH MF #2 DN
47540694 28/04/2014
55.11 [55.100] / 170
CONNECTOR X-114 - LH HANDLE INTERCONNECT

1 558 (OR) 2ND AUX SWITCH POWER
2 554 (WH) 2ND AUX EXTEND
3 552 (WH) 2ND AUX RETRACT
6 768 (VT) LH GRIP LH TURN SIGNAL OUTPUT SIGNAL
7 765 (VT) LH GRIP RH TURN SIGNAL OUTPUT SIGNAL
8 246 (OR) AUX ELEC ON/OFF SWITCH IN
9 857 (WH) AUX ELEC ON/OFF SWITCH SIGNAL
10 358 (OR) LH HANDLE MF #2/#3 POWER
11 424 (VT) LH HANDLE MULTIFUNCTION #2 UP
12 426 (RD) LH HANDLE MULTIFUNCTION #2 DOWN
13 418 (GY) LH HANDLE MULTIFUNCTION #3 UP
14 419 (LG) LH HANDLE MULTIFUNCTION #3 DOWN
87382926 3
47540694 28/04/2014
55.11 [55.100] / 171
CONNECTOR X-117 - RH HANDLE INTERCONNECT
CONNECTOR X-117 - RH HANDLE INTERCONNECT

1 352 (OR) RH HANDLE MF #1/#2 POWER
2 410 (WH) RH HANDLE MULTIFUNCTION #1 UP
3 411 (TN) RH HANDLE MULTIFUNCTION #1 DOWN
5 412 (VT) RH HANDLE MULTIFUNCTION #2 UP
6 413 (RD) RH HANDLE MULTIFUNCTION #2 DOWN
9 247 (OR) AUX ELEC ON/OFF SWITCH IN
87382924 4
47540694 28/04/2014
55.11 [55.100] / 172

CONNECTOR X-200 - CHASSIS/REAR LAMP JUMPER INTERFACE

1 766 (VT) LH REAR TURN SIGNAL POWER
2 763 (VT) RH REAR TURN SIGNAL POWER
3 717 (VT) LH REAR POSITION LAMP
4 718 (VT) RH REAR POSITION LAMP
5 725 (VT) BRAKE LAMP SIGNAL POWER
6 975 (BK) REAR LAMPS GROUND
87382918 1
47540694 28/04/2014
55.11 [55.100] / 173

CONNECTOR X-230 - CHASSIS OPTIONS/LH BOOM LIGHTS INTERCONNECT

A 712 (VT) LH BOOM ROAD LAMPS SIGNAL
B 767 (VT) LH BOOM TURN SIGNAL POWER
D 979 (BK) LH BOOM LAMPS GROUND
CONNECTOR X-231 - CHASSIS OPTION/RH BOOM LIGHTS INTERCONNECT

A 713 (VT) RH BOOM ROAD LAMPS SIGNAL
B 764 (VT) RH BOOM TURN SIGNAL POWER
D 980 (BK) RH BOOM LAMPS GROUND
47540694 28/04/2014
55.11 [55.100] / 174

CONNECTOR X-252 - TEMP CONTROL SW
CONNECTOR X-252 - TEMP CONTROL SW

1 912 (BK) HVAC TEMPERATURE SW GROUND
2 824 (YE) HVAC TEMP CTRL SIG
3 823 (PK) HVAC TEMP SW POWER
47540694 28/04/2014
55.11 [55.100] / 175

CONNECTOR X-271 - WATER VALVE

A 822 (OR) HVAC WATER VALVE POWER
C 1013 (BK) WATER GROUND
D 824 (YE) HVAC TEMP CTRL SIG
CONNECTOR X-275 - A/C SW
CONNECTOR X-275 - A/C SW

A 825 (OR) HVAC CLUTCH
B 913 (BK) HVAC COMPRESSOR CLUTCH SW GROUND
C 829 (WH) A/C SWITCH OUT
47540694 28/04/2014
55.11 [55.100] / 176

CONNECTOR X-300 - HYD COUPLER SW
CONNECTOR X-300 - HYD COUPLER SW

1 - -
2 751 (OR) HYD COUPLER SWITCH POWER
3 752 (WH) HYDRAULIC COUPLER SIGNAL
9 918 (BK) HYDRAULIC COUPLER SWITCH INDICATOR GROUND
CONNECTOR X-301 - BEACON SW
CONNECTOR X-301 - BEACON SW

A 919 (BK) BEACON SW INDICATOR GROUND
D 761 (VT) BEACON SW OUTPUT
E 796 (VT) BEACON POWER
47540694 28/04/2014
55.11 [55.100] / 177
CONNECTOR X-302 - HAZARD SW
CONNECTOR X-302 - HAZARD SW

A 776 (VT) HAZARD SW LH TURN SIGNAL OUTPUT
B 784 (OR) LH HAZARD FLASHER POWER IN
C 920 (BK) HAZARD SW INDICATOR GROUND
E 785 (OR) RH HAZARD FLASHER POWER IN
F 778 (VT) HAZARD SW RH TURN SIGNAL OUTPUT
CONNECTOR X-303 - HI FLOW SW
CONNECTOR X-303 - HI FLOW SW

NUMBER
B 753 (OR) HIGH FLOW SWITCH POWER
C 750 (WH) STANDARD HIGH FLOW SIGNAL
E 921 (BK) HIGH FLOW SW INDICATOR GND
47540694 28/04/2014
55.11 [55.100] / 178
CONNECTOR X-306 - LOADER LOCKOUT SW
CONNECTOR X-306 - LOADER LOCKOUT SW

A 312 (WH) LOADER LOCK SWITCH OUT
B 311 (WH) LOADER LOCKOUT SWITCH IN
E 924 (BK) LOADER LOCK SW INDICATOR GND
47540694 28/04/2014
55.11 [55.100] / 179

CONNECTOR X-310 - 2SPD INDICATOR
CONNECTOR X-310 - 2SPD INDICATOR

7 565 (VT) 2 SPEED INDICATOR
9 917 (BK) 2 SPEED INDICATOR GROUND
CONNECTOR X-317 - SELF LEVEL SW
CONNECTOR X-317 - SELF LEVEL SW

A 404 (WH) SELF LEVEL SW OUT
B 405 (OR) SELF LEVEL SW POWER
E 922 (BK) SELF LEVEL SW INDICATOR GROUND
47540694 28/04/2014
55.11 [55.100] / 180

CONNECTOR X-323 - CHASSIS OPTION/MULTIFUNCTION INTERCONNECT

5 416 (VT) HANDLE MULTIFUNCTION #2 UP
6 417 (RD) HANDLE MULTIFUNCTION #2 DOWN
7 982 (BK) MULTIFUNCTION GROUND
9 420 (OR) FE HOT FUSE POWER
87382922 1
47540694 28/04/2014
55.11 [55.100] / 181

CONNECTOR X-335 - RADIO CONNECTOR

2 452 (BL) LEFT SPEAKER (-)
4 451 (WH) RIGHT SPEAKER (+)
5 450 (BL) RIGHT SPEAKER (-)
6 453 (WH) LEFT SPEAKER (+)
7 934 (BK) RADIO GROUND
9 130 (OR) RADIO POWER
84257494 1
47540694 28/04/2014
55.11 [55.100] / 182

CONNECTOR X-365 - NH PARK BRAKE SW
CONNECTOR X-365 - NH PARK BRAKE SW

2 305 (YE) RH CONSOLE PARK BRAKE SW
3 306 (YE) RH CONSOLE PARK BRAKE SW OUT
47540694 28/04/2014
55.11 [55.100] / 183

CONNECTOR X-402 - RH HANDLE INTERCONNECT PARK BRAKE/RIDE CONTROL
CONNECTOR X-402 - RH HANDLE INTERCONNECT PARK BRAKE/RIDE CONTROL

1 324 (OR) RH GRIP PARK BRAKE SWITCH POWER
2 307 (YE) RH PARK BRAKE SW OUT
4 832 (OR) RIDE CONTROL VALVE FUSED POWER
5 831 (WH) RIDE CONTROL VALVE SOLENOID SIGNAL
8 699 (PK) EH AUX PROPORTIONAL SWITCH SIGNAL OUTPUT
9 1010 (BK/WH) EH AUX PROPORTIONAL SWITCH GROUND
10 331 (OR) EH AUX PROPORTIONAL SWITCH REFERENCE VOLTAGE
87382922 1
CONNECTOR X-405 - LH HANDLE INTERCONNECT HORN/TWO SPEED
CONNECTOR X-405 - LH HANDLE INTERCONNECT HORN/TWO SPEED

A 891 (OR) LH GRIP HORN / 2 SSPEED SWITCH POWER
B 892 (WH) HORN POWER SIGNAL
D 563 (WH) 2 SPEED SWITCH OUTPUT SIGNAL
47540694 28/04/2014
55.11 [55.100] / 184

CONNECTOR X-430 - EH AUX PWM CONTROLLER
CONNECTOR X-430 - EH AUX PWM CONTROLLER

1 319 (OR) EH AUX POWER
2 901 (BK/WH) AUX PWN CLEAN GROUND
3 889 (WH) EH AUX RETRACT SIGNAL
4 890 (WH) EH AUX RETRACT SIGNAL
5 1009 (BL) EH AUX VALVE SIGNAL RETURN
6 699 (PK) EH AUX PROPORTIONAL SWITCH SIGNAL OUTPUT
7 1010 (BK/WH) EH AUX PROPORTIONAL SWITCH GROUND
8 331 (OR) EH AUX PROPORTIONAL SWITCH REFERENCE VOLTAGE
47540694 28/04/2014
55.11 [55.100] / 185

CONNECTOR X-502 - DOOR WIPER MOTOR

A 227 (WH) DOOR WIPER MOTOR SIGNAL
B 929 (BK) DOOR WIPER MOTOR GROUND
C 231 (OR) DOOR WIPER MOTOR PARK
D 220 (YE) DOOR SW BYPASS
CONNECTOR X-502A - REAR WINDOW WIPER MOTOR

A 228 (WH) REAR WINDOW WIPER MOTOR SIGNAL
B 930 (BK) REAR WINDOW WIPER MOTOR GND
C 232 (OR) REAR WINDOW WIPER MOTOR PARK
87693712 2
47540694 28/04/2014
55.11 [55.100] / 186
CONNECTOR X-503 - WIPER/WASHER SW
CONNECTOR X-503 - WIPER/WASHER SW

1 931 (BK) SW GROUND
2 225 (WH) WIPER & INDICATOR POWER
3 229 (OR) WIPER/INDICATOR POWER IN
5 224 (WH) WASHER PUMP SIGNAL
6 230 (OR) WASHER MOTOR POWER IN
7 226 (VT) WIPER/WASHER LAMP SIGNAL
8 932 (BK) WIPER/WASHER SW IND GND
87716755 3
47540694 28/04/2014
55.11 [55.100] / 187


A 1095 (BK) OPTION RELAY COIL GROUND
B 1098 (BK) OPTION RELAY COIL GROUND
C 1094 (BK) CAB GND B
D 947 (BK) MAIN POWER RELAY COIL GROUND
CONNECTOR X-903 - FUSE HOLDER
CONNECTOR X-903 - FUSE HOLDER

47540694 28/04/2014
55.11 [55.100] / 188
Wire connectors - Component diagram – Connectors A – Z

CONNECTOR X-C23 - INSTRUMENT CLUSTER

2 261 HYDRAULIC OIL FILTER
3 624 KEY START TO CLUSTER
5 505 CAN LO
6 500 CAN HI
7 301 CLUSTER SW POWER
8 302 CLUSTER SW POWER
9 313 CLUSTER UNSW POWER
10 132 KEY IGNITION TO CLUSTER
AIR FILTER/ENGINE
11 267
MALFUNCTION
12 323 SEAT SW CLUSTER INPUT
13 205C TELEMATICS CRANK DISABLE
16 264 HYDRAULIC OIL TEMP SENDER
17 259 THROTTLE SENSOR SUPPLY
19 251 DOOR SW SIGNAL
LAP BAR/SEAT BELT CLUSTER
20 314
INPUT
21 754 PARK BRAKE SW
22 543 THROTTLE SIGNAL
24 234 FUEL LEVEL SENDER
25 1070 THROTTLE SENSOR GND
26 319 EH AUX POWER
28 258 PARK BRAKE VALVE SIGNAL
29 137 ACCESSORY RELAY SIGNAL
30 303 HYD LOADER INTERLOCK SIGNAL
CRANK SIGNAL FROM CLUSTER
32 622
TO ECU
33 133 MAIN POWER RELAY SIGNAL
34 1011 INSTRUMENT CLUSTER GND
47540694 28/04/2014
55.11 [55.100] / 189
82028495 1
47540694 28/04/2014
55.11 [55.100] / 190
CONNECTOR X-CC1A - CAB/CHASSIS 1

1 797 FRONT WORK LAMP FUSE PWR
2 795 SIDE LAMP POWER SIGNAL
3 248 EGR ECU K-LINE
4 503A CAN HI
5 791 LAMP SW ROAD LAMP SIGNAL
7 910 CLUSTER GROUND
9 319 EH AUX POWER
10 115 ACC/BEACON FUSE POWER
12 310 UNSW BAT FUSE POWER
13 545 FOOT THROTTLE SIGNAL
14 790 LAMP SW WORK LAMP SIGNAL
87382926 2
47540694 28/04/2014
55.11 [55.100] / 191
CONNECTOR CC2A - CAB/CHASSIS 2
CONNECTOR CC2A - CAB/CHASSIS 2

ACCESSORY RELAY FUSE
1 134
POWER
4 309 CLUSTER FUSE POWER
5 303 HYD LOADER INTERLOCK SIGNAL
AIR FILTER/ENGINE
7 267
MALFUNCTION
8 1066 FOOT THROTTLE SENSOR GND
HVAC FUSE TO HVAC BOX
9 843 - VOLTAGE DROP PARALLEL
CIRCUIT
10 622
TO ECU
FOOT THROTTLE SENSOR
13 211
SUPPLY
14 822 HVAC WATER VALVE POWER
87382927 3
47540694 28/04/2014
55.11 [55.100] / 192

1 404 SELF LEVEL SW OUT
2 565 2 SPEED INDICATOR
3 824 HVAC TEMP CTRL SIG
4 504 CAN LO
5 792 LAMP SW WORK/SIDE SIG
6 841 A/C COMP RLY PIN 87 POWER
7 833 THERMOSTAT TO PRES SW
8 844 - VOLTAGE DROP PARALLEL
CIRCUIT
9 307 RH PARK BRAKE SW OUT
10 123 LAMP SW POWER
11 237 HVAC COND FAN POWER
COMPRESSOR/CONDENSER FAN
12 836
FUSE POWER
13 834 PRES SW TO COMP RLY
14 233 WIPER/WASHER SW PWR
84394888 4
47540694 28/04/2014
55.11 [55.100] / 193
CONNECTOR CN1A - UCM CN1A

1 1075 UCM GROUND 1A.01
8 202 SENSOR SUPPLY 1
13 1018 BUCKET RETURN
14 525 UCM WAKE-UP
16 124 ENGINE RPM SIGNAL
19 1022 DRIVE REVERSE RETURN
UCM UNSWITCHED BATTERY
20 189
FUSE POWER
22 1020 PROPORTIONAL AUX RETURN
PROPORTIONAL AUX RETRACT
24 515
SIGNAL
26 240 5V REF SUPPLY FUSE
82016219 5
RAPH12SSL0240AA 6
47540694 28/04/2014
55.11 [55.100] / 194
CONNECTOR CN1B - UCM CN1B

1 1026 UCM GROUND 1B.34
13 560 RH UA2 Y SENSOR OUTPUT
15 521 CONTROL PATTERN NEUTRAL
26 128 SW POWER PROP AUX EXTEND
27 126 SW POWER PROP AUX RETRACT
29 580 BRAKE LAMP CIRCUIT OUTPUT #2
31 166 SWITCHED POWER BRAKE LAMP
PROPORTIONAL AUX EXTEND
33 514
SIGNAL
87410946 7
RAPH12SSL0240AA 8
47540694 28/04/2014
55.11 [55.100] / 195
CONNECTOR CN2A (2) - UCM CN2A

2 164 LEFT PUMP REVERSE POWER
3 165 RIGHT PUMP REVERSE POWER
4 536 LOADER PILOT INTERLOCK
5 537 LOADER PORT LOCK
SWITCHED POWER PORT/PILOT
7 159
LOCK
8 518 PUMP RIGHT REVERSE
HYDRAULIC CHARGE PRESSURE
9 262
SWITCH
13 163
LOCK
14 517 PUMP LEFT REVERSE
PATTERN INDICATOR H LS
23 1024
OUTPUT
25 750 STANDARD HIGH FLOW SIGNAL
82028493 9
47540694 28/04/2014
55.11 [55.100] / 196
RAPH12SSL0240AA 10
47540694 28/04/2014
55.11 [55.100] / 197
CONNECTOR CN2B (2) - UCM CN2B

1 503E CAN HI
PATTERN INDICATOR ISO LS
2 1023
OUTPUT
7 1019 LOADER RETURN
8 1099 EHF RETURN
SWITCHED POWER LOADER
9 154
CONTROL
10 504E CAN LO
13 535 PARK BRAKE PRESSURE SWITCH
14 562 LH UA2 X SENSOR OUTPUT
17 158
CONTROL
20 522 CONTROL PATTERN H
21 523 CONTROL PATTERN ISO
22 754 PARK BRAKE SWITCH
LOADER LOCKOUT SWITCH N.O.
23 398
OUTPUT (VALVE OFF)
START SIGNAL FROM CLUSTER
24 532
TO UCM
25 1021 DRIVE FORWARD RETURN
27 531 LOADER FLOAT SWITCH INPUT
PROPORTIONAL AUX SWITCH
28 547
OUTPUT SIGNAL #2
31 568 LH UA2 Y SENSOR OUTPUT
32 576 RH PUMP ANGLE #1
82028495 11
47540694 28/04/2014
55.11 [55.100] / 198
RAPH12SSL0240AA 12
47540694 28/04/2014
55.11 [55.100] / 199

2 168 SWITCHED POWER PARK BRAKE
6 430 EHF RETRACT SIGNAL
7 170 SWITCHED POWER TWO SPEED
9 574 LH PUMP ANGLE #1
11 548 RH UA2 X SENSOR OUTPUT
19 431 EHF EXTEND SIGNAL
21 120 PUMP FORWARD FUSE POWER
22 512 LOADER LOWER SIGNAL
HYDRAULIC LOADER INTERLOCK
23 303
SIGNAL
2 SPEED VALVE SOLENOID
25 564
SIGNAL
84130757 13
47540694 28/04/2014
55.11 [55.100] / 200
RAPH12SSL0240AA 14
47540694 28/04/2014
55.11 [55.100] / 201

UCM BACKUP ALARM FUSE

3 167
POWER
6 513 LOADER RAISE SIGNAL
8 142 SW POWER BUCKET CONTROL
HIGH PERFORMANCE HIGH FLOW
11 755
SIGNAL
CONTROL VALVE BUCKET
12 570
POSITION SENSOR
CONTROL VALVE LOADER
13 571
POSITION SENSOR
CONTROL VALVE AUX POSITION
14 572
SENSOR
17 510 BUCKET RETRACT SIGNAL
18 895 BACKUP ALARM SIGNAL
LOADER LOCK SWITCH N.C.
19 312
OUTPUT (VALVE ON)
2ND AUX EXTEND SWITCH
29 554
OUTPUT
SEAT SWITCH OPERATOR
30 526
INTERLOCK
2ND AUX RETRACT SIGNAL
31 552
POWER
32 519 PUMP RIGHT FORWARD
33 516 PUMP LEFT FORWARD
CNH_84130760AAO 15
47540694 28/04/2014
55.11 [55.100] / 202
RAPH12SSL0240AA 16
47540694 28/04/2014
55.11 [55.100] / 203

SEAT BELT / LAP BAR OPERATOR
10 524
INTERLOCK
19 511 BUCKET EXTEND SIGNAL
82028493 17
RAPH12SSL0240AA 18
47540694 28/04/2014
55.11 [55.100] / 204

13 423 EHF INTERLOCK
15 541 2 SPEED UCM INPUT
21 546
OUTPUT SIGNAL #1
82028495 19
RAPH12SSL0240AA 20
47540694 28/04/2014
55.11 [55.100] / 205
CONNECTOR X-CO1A - CAB/CHASSIS OPTIONS 1

1 782 FLASHER POWER OUTPUT
LH TURN SIGNAL CHASSIS
2 774
POWER
5 311 LOADER LOCKOUT SW IN
RH TURN SIGNAL CHASSIS
6 780
POWER
7 312 LOADER LOCK SW OUT
10 141 CLUSTER OPT RELAYS SIGNAL
SL57_87382924 21

1 425 CONSOLE SWITCH MF #2 UP
2 359 CONSOLE SWITCH MF #2 POWER
3 427 CONSOLE SWITCH MF#2 DN
4 751 HYDRAULIC COUPLER SW IN
5 752 HYDRAULIC COUPLER SIGNAL
7 753 HIGH FLOW SW IN
84257541 22
47540694 28/04/2014
55.11 [55.100] / 206
CONNECTOR X-DIAG - CAN DIAGNOSTIC CONNECTOR

A 961 DIAG CONNECTOR GND
B 162 UNSWITCHED BATTERY POWER
C 501 CAN HI
D 506 CAN LO
E 248 EGR ECU K-LINE
84497873 23
47540694 28/04/2014
55.11 [55.100] / 207
CONNECTOR ECC1B - CHASSIS/CAB INTERFACE 1

FRONT WORK LAMP FUSE
1 798
POWER
4 503A CAN HI
5 791 ROAD LAMP SIGNAL
6 205A TELEMATICS CRANK DISABLE
7 910 INSTRUMENT CLUSTER GROUND
8 234 UNSWITCHED BATTERY POWER
9 319 EH AUX POWER
10 115 ACC/BEACON FUSE POWER
UNSWITCHED BATTERY FUSE
12 310
POWER
LAMP SWITCH WORK LAMP
14 790
SIGNAL
87382927 24
47540694 28/04/2014
55.11 [55.100] / 208
RAPH12SSL0251AA 25
47540694 28/04/2014
55.11 [55.100] / 209

1 134
POWER
4 309 CLUSTER FUSE POWER
5 303 HYD INTLCK SIG
AIR FILTER / ENGINE
7 267
MALFUNCTION
8 1066
GROUND
HVAC FUSE POWER - VOLTAGE
9 843
DROP PARALLEL CIRCUIT
10 622
TO ECU
11 133A MAIN POWER RELAY SIGNAL
13 211
SUPPLY
87382926 26
47540694 28/04/2014
55.11 [55.100] / 210
RAPH12SSL0251AA 27
47540694 28/04/2014
55.11 [55.100] / 211

SELF LEVEL SWITCH OUTPUT
1 404
POWER
2 565 2 SPEED INDICATOR
3 824 HVAC TEMP CONTROL SIGNAL
4 504A CAN LO
LAMP SWITCH WORK AND SIDE
5 792
LAMP SIGNAL
A/C COMPRESSOR RELAY PIN 87
6 841
POWER
THERMOSTAT TO BINARY
7 833
PRESSURE SWITCH
HVAC FUSE POWER - VOLTAGE
8 844
DROP PARALLEL CIRCUIT
RH GRIP PARK BRAKE SWITCH
9 307
OUTPUT
ACC RELAY OUTPUT TO LAMP
10 123
SWITCH
11 237 HVAC CONDENSER FAN POWER
12 836
FUSE POWER
PRESSURE SWITCH TO
13 834 COMPRESSOR RELAY PIN
86
14 233 WIPER / WASHER FUSE POWER
84394890 28
47540694 28/04/2014
55.11 [55.100] / 212
RAPH12SSL0251AA 29
47540694 28/04/2014
55.11 [55.100] / 213
CONNECTOR FUSE1 - POWER DISTRIBUTION-CHASSIS
CONNECTOR FUSE1 - POWER DISTRIBUTION-CHASSIS

A1 830 HVAC RELAY FUSE IN
A2 820 HVAC FUSE POWER
A3 528B ECU FUSE 1 IN
A4 110 ECU FUSE 1 POWER
A5 528C ECU FUSE 2 IN
A6 155A ECU FUSE 2 POWER
LIGHT RELAY #2 SIDE & REAR
A7 707
WORK LAMP OUT
A9 945 COIL GROUND
A10 116 B+ TO LIGHT RELAY #1 PIN 87
A11 710 STD LAMP CONFIG CONTROL
A12 946 COIL GROUND
ACC RELAY OUTPUT TO
B1 243
WIPER/WASHER
B2 233 WIPER / WASHER FUSE POWER
B3 528D ENGINE SENSORS FUSE IN
B4 241A ENGINE SENSORS FUSE POWER
B7 709 SIDE LAMP FUSE OUT
B9 113 LIGHT RELAY #2 B+
B10 325 LIGHT RELAY #1 SWITCH SIGNAL
LIGHT RELAY #1 PIN 30 TO FUSE
B12 788
(FRONT WORK LAMP POWER)
C1 135 ACC FUSE IN
C2 134
POWER
C3 350 IGNITION FUSE IN
C4 351 IGNITION FUSE POWER
C5 835 COMPRESSOR RELAY FUSE IN
C6 836
FUSE POWER
C7 136 MAIN POWER RELAY OUT
MAIN POWER RELAY COIL
C9 947
GROUND
C10 125 ACC RELAY OUT
C12 948 COIL GROUND
D1 160 UNSWITCHED B+
D2 310
POWER
D3 326 INSTRUMENT CLUSTER FUSE IN
INSTRUMENT CLUSTER FUSE
D4 300
POWER
D5 114 ACC/BEACON B+
D6 196 ACC/BEACON FUSE POWER
D7 144 MAIN POWER RELAY SIGNAL
D9 118 MAIN POWER RELAY B+
D10 139 ACCESSORY RELAY SIGNAL
D12 117 ACCESSORY RELAY B+
E1 788
LIGHT RELAY #1 FRONT WORK
E2 797
LAMP POWER
E3 792
LAMP SIGNAL
E4 708 SIDE LAMP FUSE POWER
E5 705 REAR WORK LAMP FUSE IN
47540694 28/04/2014
55.11 [55.100] / 214
E6 706 REAR WORK LAMP FUSE POWER

E7 701 LH TAIL LAMP FUSE IN
E8 703 LH TAIL LAMP FUSE POWER
E9 700 RH TAIL LAMP FUSE IN
E10 704 RH TAIL LAMP FUSE POWER
E11 255 CRANK RELAY FUSE IN
E12 256 CRANK RELAY FUSE POWER
84255438 30
CONNECTOR X-HVC1 - CAB/HVAC INTERCONNECT

1 935 HVAC GND
COMPRESSOR RELAY PIN 30
2 838
POWER
3 828 HVAC FAN LOW
4 827 HVAC FAN MEDIUM
5 850 HVAC FAN HIGH
A/C SW COMPRESSOR RELAY
6 837
PIN 86 VIA PRESSURE SW
9 1012 HVAC THERMOSTAT CLEAN GND
HVAC RELAY PIN 87 OUTPUT
10 842
POWER
11 143 HVAC KEYED POWER
14 845 HVAC RELAY FUSE POWER
47540694 28/04/2014
55.11 [55.100] / 215
87382926 31
47540694 28/04/2014
55.11 [55.100] / 216
CONNECTOR RRJMPRA - CHASSIS/REAR LAMP JUMPER INTERFACE

1 706 REAR WORK LAMP FUSE POWER
2 704 RH TAIL LAMP FUSE POWER
3 703 LH TAIL LAMP FUSE POWER
4 950 REAR LAMP GROUND
87382914 32
47540694 28/04/2014
55.11 [55.100] / 217
CONNECTOR TELE - TELEMATICS

TELEMATICS UNSWITCHED
A 336
BATTERY
C 802 TELEMATICS IGNITION POWER
ALTERNATOR LAMP TELEMATICS
D 244
ENGINE ON
E 308 VEHICLE WORKING CONDITION
H 925 TELEMATICS GROUND
L 503D TELEMATICS CAN HI
M 504D TELEMATICS CAN LO
S 205A TELEMATICS CRANK DISABLE
87696550 33
RAPH12SSL0240AA 34
47540694 28/04/2014
55.11 [55.100] / 218
CONNECTOR X-UJML - UJM LH

1 215 LH UB1 X-Y SENSOR VOLTAGE
4 1045 LH OV1 X-Y SENSOR GROUND
SL57_87694583 35
CONNECTOR X-UJMR - UJM RH

1 219 RH UB1 X-Y SENSOR VOLTAGE
4 1047 RH OV1 X-Y SENSOR GROUND
SL57_87694583 36
47540694 28/04/2014
55.11 [55.100] / 219
Wire connectors - Component diagram – Grounds

Ground locations
Grounds
NEG_TERM_A (1)
Main chassis (2)
ECU (3)
RAPH12SSL0239AA 1
Ground location for the ECU, NEG_TERM_A, and the main chassis
Grounds
X-CAB_GNDA (1)
X-CAB_GNDB (2)
RAPH12SSL0248AA 2
Ground location for X-CAB_GNDA and X-CAB_GNDB
47540694 28/04/2014
55.11 [55.100] / 220
Grounds
CHS_GND_RR (1)
OPT_GND_RR (2)
RAPH12SSL0252AA 3
Ground location for CHS_GND_RR and OPT_GND_RR
Grounds
UCM_GND (1)
CHS_GND_FRT (2)
OPT_GND_FRT (3)
RAPH12SSL0251AA 4
Ground location for UCM_GND, CHS_GND_FRT, and OPT_GND_FRT
47540694 28/04/2014
55.11 [55.100] / 221
Wire connectors - Component localisation - Deluxe cab

NOTE: Deluxe cab shown.
47540694 28/04/2014
55.11 [55.100] / 222
RAPH12SSL0466KA 1
47540694 28/04/2014
55.11 [55.100] / 223
47540694 28/04/2014
55.11 [55.100] / 224
RAPH12SSL0467GA 2
Detail 1

Diagram 00 (55.100)
X-C23 Instrument cluster Wire connectors - Component
(55.100)
X-365 Park brake switch Wire connectors - Component
diagram 36 (55.100)
X-015 Drive pattern selector switch Wire connectors - Component
diagram 01 (55.100)
X-CTS Turn signal switch Not available
X-311 Lamp selector switch Not available
X-20A Hand throttle Wire connectors - Component
diagram 02 (55.100)
X-502 Door wiper motor Wire connectors - Component
diagram 50 (55.100)
47540694 28/04/2014
55.11 [55.100] / 225
RAPH12SSL0468GA 3
Detail 2

X-270 Blower fan switch Not available
X-275 A/C switch Wire connectors - Component
diagram 27 (55.100)
X-155B Turn signal indicator (right) Not available
X-156B Turn signal indicator (left) Not available
X-157B Turn signal indicator (ground) Not available
X-300 Hydraulic coupler switch Wire connectors - Component
diagram 30 (55.100)
X-310 2SPD indicator Wire connectors - Component
diagram 31 (55.100)
X-301 Beacon lamp switch Wire connectors - Component
diagram 30 (55.100)
X-302 Hazard lamp switch Wire connectors - Component
diagram 30 (55.100)
X-317 Self level switch Not available
47540694 28/04/2014
55.11 [55.100] / 226
X-303 Hi flow switch Wire connectors - Component

diagram 30 (55.100)
X-113 Fe #2 switch Wire connectors - Component
diagram 11 (55.100)
X-503 Wiper/washer switch Wire connectors - Component
diagram 50 (55.100)
X-306 Loader lockout switch Wire connectors - Component
diagram 30 (55.100)
X-ACC Accessory power outlet Not available
X-505 Cab/door switch interface Not available
RAPH12SSL0469GA 4
Detail 3

X-CN1A UCM Wire connectors - Component
(55.100)
X-CN1B UCM Wire connectors - Component
(55.100)
(55.100)
47540694 28/04/2014
55.11 [55.100] / 227

(55.100)
(55.100)
(55.100)
(55.100)
(55.100)
X- F1 Fuse 1 Wire connectors - Component
(55.100)
X-F2 Fuse 2 Wire connectors - Component
(55.100)
X-AUX_RET 2nd auxiliary retract Not available
X-AUX_EXT 2nd auxiliary extend Not available
X-271 Water valve Wire connectors - Component
diagram 27 (55.100)
X-20 Foot throttle sensor Wire connectors - Component
diagram 02 (55.100)
X-DIAG CAN Diagnostic connector Wire connectors - Component
(55.100)
47540694 28/04/2014
55.11 [55.100] / 228
RAPH12SSL0470GA 5
Detail 4

X-ECC6B Wire connectors - Component
(55.100)
(55.100)
(55.100)
X-ECC3B Chassis/cab interface Wire connectors - Component
(55.100)
(55.100)
47540694 28/04/2014
55.11 [55.100] / 229

(55.100)
CHS_GND_FRT Ground Wire connectors - Component
OPT_GND_FRT Ground Wire connectors - Component
X-BRKPRS Brake pressure switch Not available
X-PLTLK Pilot interlock Not available
X-BRK Brake valve solenoid Not available
X-CHGPRS Hydraulic charge pressure switch Not available
X-2SPD 2 speed valve solenoid Not available
RAPH12SSL0471GA 6
Detail 5
47540694 28/04/2014
55.11 [55.100] / 230

X-HVC1 Cab/HVAC interconnect Wire connectors - Component
(55.100)
X-UJML UJM left hand Wire connectors - Component
(55.100)
X-408 left hand handle interconnect Wire connectors - Component
diagram 40 (55.100)
X-58 Cab/seat interface Wire connectors - Component
diagram 05 (55.100)
RAPH12SSL0472GA 7
Detail 6

X-93 Right swash plate sensor Wire connectors - Component
diagram 09 (55.100)
X-318 Self level Not available
47540694 28/04/2014
55.11 [55.100] / 231
X-403 Right hand interconnect Wire connectors - Component

FE/proportional auxiliary/float diagram 40 (55.100)
X-UJMRH UJM right hand Wire connectors - Component
(55.100)
X-506 Front washer pump Not available
X-401 Right hand handle interconnect FE Not available
X-406 Right hand handle interconnect park Wire connectors - Component
brake/ride control diagram 40 (55.100)
X-OILTMP Hydraulic oil temperature sensor Not available
X-13 Left, drive, forward Wire connectors - Component
diagram 01 (55.100)
X-16 Left, drive, reverse Wire connectors - Component
diagram 01 (55.100)
X-CPLR Hydraulic coupler Not available
X-94 Left swash plate sensor Wire connectors - Component
diagram 09 (55.100)
X-TELE Telematics Wire connectors - Component
(55.100)
X-PORT_LK Port lock Not available
47540694 28/04/2014
55.11 [55.100] / 232
RAPH12SSL0473GA 8
Detail 7

X-195 GCU fuse Not available
X-013 GCU Wire connectors - Component
diagram 01 (55.100)
Diagram 00 (55.100)
X-126 Starter Not available
X-318 Self level valve Not available
X-93 Right hand swash plate sensor Wire connectors - Component
diagram 09 (55.100)
X-RDCTRL Ride control valve solenoid Not available
47540694 28/04/2014
55.11 [55.100] / 233
RAPH12SSL0474GA 9
Group 8

NED_TERM_A Ground Wire connectors - Component
X-OILFLT Hydraulic oil filter switch Not available
SIDE LAMP Side lamp dealer installed accessory Not available
BEACON LAMP SOCKET Beacon lamp socket dealer installed Not available
accessory
X-HORN_PWR Horn power Not available
X-HORN_GND Horn ground Not available
REAR WIPER MOTOR Rear wiper motor dealer installed Not available
accessory
X-230 Chassis options/left hand boom lights Wire connectors - Component
interconnect diagram 23 (55.100)
X-323 Chassis options/multifunction Wire connectors - Component
interconnect diagram 32 (55.100)
47540694 28/04/2014
55.11 [55.100] / 234
RAPH12SSL0475GA 10
Group 9

X-104 Lap bar switch Not available
X-97 Cab/dome lamp jumper Not available
X-30 Cab/right hand jumper interface Wire connectors - Component
diagram 03 (55.100)
Diagram 00 (55.100)
X-335 Radio connector Wire connectors - Component
diagram 33 (55.100)
47540694 28/04/2014
55.11 [55.100] / 235
RAPH12SSL0476GA 11
Group 10

X-231 Chassis option right hand boom lights Wire connectors - Component
diagram 23 (55.100)
X-14 Fuel level sensor Not available
NEG_TERM_A Ground Wire connectors - Component
X-15 Electrical valve Wire connectors - Component
diagram 01 (55.100)
ECU_POS1 Battery power Not available
ECU_POS2 Battery power Not available
47540694 28/04/2014
55.11 [55.100] / 236

Diagram 00 (55.100)
diagram 01 (55.100)
RAPH12SSL0477GA 12
Group 11

X-BKUP_PWR Backup alarm power Not available
X-BKUP_GND Backup alarm ground Not available
X-200 Chassis/rear jumper interface Wire connectors - Component
diagram 20 (55.100)
X-RRJMPRA Chassis/rear lamp jumper interface Wire connectors - Component
(55.100)
47540694 28/04/2014
55.11 [55.100] / 237
ECU-GND Ground Wire connectors - Component

47540694 28/04/2014
55.11 [55.100] / 238
Wire connectors - Component Diagram 00


A30 256 (RD) CRANK FUSE POWER
A87 520 (WH) STARTER MOTOR POWER
B30 - -
B85 - -
B86 - -
B87 - -
C30 527B (RD) ECU RELAY B+
C85 112 (BL) ECU MAIN RELAY
C86 527C (RD) ECU RELAY COIL B+
C87 528A (OR) ECU RELAY OUTPUT TO ECU FUSES
A87A - -
B87A - -
C87A - -
47540694 28/04/2014
55.11 [55.100] / 239

1 269 (YE) DIFF PRESSURE SENSOR SUPPLY
87747172 2
CONNECTOR X-5A - ALTERNATOR
CONNECTOR X-5A - ALTERNATOR

1 244 (YE) ALTERNATOR LAMP TELEMATICS ENGINE ON
2 127 (OR) ALTERNATOR EXCITE
3 124 (YE) ENGINE RPM SIGNAL
47540694 28/04/2014
55.11 [55.100] / 240

1 140 (RD) KEY SWITCH INPUT POWER
2 624 (WH) KEY START OUTPUT
3 132 (OR) KEY IGNITION
6 138 (OR) KEY ACCESSORY
87693713 4
47540694 28/04/2014
55.11 [55.100] / 241


1 150 (YE) WIF LEVEL SENSOR SIGNAL
2 908E (BK) WIF GROUND
3 133E (OR) WIF SENSOR POWER
87709663 1

1 110 (OR) ECU FUSE 1 POWER
2 908B (BK) ECU GROUND 1
3 155B (OR) BATTERY +B VIA MAIN RELAY
4 908C (BK) ECU GROUND 2
5 155C (OR) BATTERY +C VIA MAIN RELAY
6 908D (BK) ECU GROUND 3
8 626 (WH) START SIGNAL FROM CLUSTER TO ECU
14 269 (YE) DIFF PRESSURE SENSOR SUPPLY
19 257 (YE) AIR TEMP SENSOR SIGNAL
20 254 (BK/WH) AIR TEMP GND
24 503C (YE)
25 504C (GN)
28 112 (BL) ECU MAIN RELAY
30 150 (YE) WIF LEVEL SENSOR SIGNAL
41 239 (BK) GLOW PLUG UNIT GND
54 133D (OR) EGR ECU SWITCHED BATTERY POWER
63 253 (PK)
64 245 (YE)
68 248 (YE) EGR ECU K-LINE
70 347 (BL) FUEL FILTER HEATER GROUND
79 270 (BK/WH) EXHAUST GAS TEMP GND
47540694 28/04/2014
55.11 [55.100] / 242

80 271 (YE) EXHAUST GAS TEMP SIGNAL
83 272 (BK/WH) EXHAUST GAS TEMP GND 2
84 273 (YE) EXHAUST GAS TEMP SIGNAL 2
85 252 (BK)
86 249 (YE)
47540694 28/04/2014
55.11 [55.100] / 243

4 212 (OR) GCU B+
5 239A (BK) GLOW PLUG UNIT GND
84356962 3
47540694 28/04/2014
55.11 [55.100] / 244

1 245 (YE)
2 252 (BK)
4 241B (OR) LAMBDA SENSOR POWER
5 249 (YE)
6 253 (PK)
84301132 4
47540694 28/04/2014
55.11 [55.100] / 245

A 274 (WH)
B 275 (GY)
C 276 (GY)
D 277 (WH)
E 278 (WH)
F 279 (GY)
G 280 (GY)
H 281 (WH)
87698252 5
47540694 28/04/2014
55.11 [55.100] / 246

1 277 (WH)
2 281 (WH)
4 294 (GY)
6 658 (YE)
15 299 (WH)
16 274 (WH)
17 278 (WH)
26 282 (BL)
TURBINE PRESSURE)
31 276 (GY)
32 275 (GY)
34 339 (GY)
35 322 (GY)
41 283 (YE)
TURBINE PRESSURE)
44 286 (YE)
46 280 (GY)
48 279 (GY)
49 338 (WH)
50 321 (WH)
59 285 (YE)
60 298 (GY)
47540694 28/04/2014
55.11 [55.100] / 247
47540694 28/04/2014
55.11 [55.100] / 248

1 299 (WH)
2 298 (GY)
3 658 (YE)
5 282 (BL)
6 283 (YE)
9 285 (YE)
10 286 (YE)
TURBINE PRESSURE)
TURBINE PRESSURE)
27 294 (GY)
28 241C (OR)
29 321 (WH)
30 322 (GY)
37 338 (WH)
38 339 (GY)
47540694 28/04/2014
55.11 [55.100] / 249
84154706 7
47540694 28/04/2014
55.11 [55.100] / 250
CONNECTOR X-10 - CHASSIS/ LOADER INTERFACE
CONNECTOR X-10 - CHASSIS/ LOADER INTERFACE

1 510 (WH) BUCKET RETRACT SIGNAL
2 1018 (BL) BUCKET RETURN
3 511 (WH) BUCKET EXTEND SIGNAL
4 570 (YE) CONTROL VALVE BUCKET POSITION SENSOR
5 512 (WH) LOADER LOWER SIGNAL
6 1019 (BL) LOADER RETURN
7 513 (WH) LOADER RAISE SIGNAL
8 571 (YE) CONTROL VALVE LOADER POSITION SENSOR
9 1060 (BK/WH) CONTROL VALVE SENSOR GROUNDS
10 515 (WH) PROPORTIONAL AUX RETRACT SIGNAL
11 1020 (BL) PROPORTIONAL AUX RETURN
12 514 (WH) PROPORTIONAL AUX EXTEND SIGNAL
13 572 (YE) CONTROL VALVE AUX POSITION SENSOR
14 236 (PK) CONTROL VALVE SENSOR REFERENCE VOLTAGE
87382926 8
47540694 28/04/2014
55.11 [55.100] / 251
CONNECTOR X-11 - A/C COMPRESSOR
CONNECTOR X-11 - A/C COMPRESSOR

1 833 (WH) THERMOSTAT TO BINARY PRESSURE SW
2 834 (WH) BINARY PRESSURE SW TO COMPRESSOR RELAY PIN 86
3 841 (WH) A/C COMPRESSOR RELAY PIN 87 POWER
87382911 9
47540694 28/04/2014
55.11 [55.100] / 252


A 545 (YE) FOOT THROTTLE SIGNAL
B 1066 (BK/WH) FOOT THROTTLE SENSOR GROUND
C 211 (PK) FOOT THROTTLE SENSOR SUPPLY
CONNECTOR X-20A - HAND THROTTLE
CONNECTOR X-20A - HAND THROTTLE

A 544 (YE) HAND THROTTLE SIGNAL
B 1071 (BK/WH) HAND THROTTLE SENSOR GROUND
C 260 (PK) HAND THROTTLE SENSOR SUPPLY
47540694 28/04/2014
55.11 [55.100] / 253


1 798 (VT) RH WORK LAMP POWER
2 793 (VT) RH SIDE LAMP POWER
3 779 (VT) RH CAB TURN SIGNAL POWER
4 926 (BK) RH CAB LAMPS GROUND
87694154 1

1 799 (VT) LH WORK LAMP POWER
2 794 (VT) LH SIDE LAMP POWER
3 773 (VT) LH CAB TURN SIGNAL POWER
4 927 (BK) LH CAB LAMPS GROUND
87694154 2
47540694 28/04/2014
55.11 [55.100] / 254


1 756 (OR) SEAT ACCESSORY POWER
2 933 (BK) SEAT ACCESSORY GROUND
3 315 (RD) SEAT SW UNSWITCHED POWER
4 323 (YE) SEAT SW CLUSTER INPUT
87694154 1
47540694 28/04/2014
55.11 [55.100] / 255

CONNECTOR X-93 - RH PUMP SWASH PLATE SENSOR
CONNECTOR X-93 - RH PUMP SWASH PLATE SENSOR

1 1055 (BK/WH) RH PUMP ANGLE SENSOR GROUND
2 223 (PK) RH PUMP ANGLE SENSOR REFERENCE
3 575 (YE) RH PUMP ANGLE #2
4 576 (YE) RH PUMP ANGLE #1
5 221 (PK) RH PUMP ANGLE SENSOR REFERENCE
6 1074 (BK/WH) RH PUMP ANGLE SENSOR GROUND #2
87694112 1
CONNECTOR X-94 - LH PUMP SWASH PLATE SENSOR
CONNECTOR X-94 - LH PUMP SWASH PLATE SENSOR

1 1054 (BK/WH) LH PUMP ANGLE SENSOR GROUND
2 222 (PK) LH PUMP ANGLE SENSOR REFERENCE
3 574 (YE) LH PUMP ANGLE #1
4 573 (YE) LH PUMP ANGLE #2
5 209 (PK) LH PUMP ANGLE SENSOR REFERENCE
6 1073 (BK/WH) LH PUMP ANGLE SENSOR GROUND #2
87694112 2
47540694 28/04/2014
55.11 [55.100] / 256
CONNECTOR X-95 - DRIVE PATTERN SELECTOR SWITCH
CONNECTOR X-95 - DRIVE PATTERN SELECTOR SWITCH

1 522 (YE) CONTROL PATTERN H
3 521 (YE) CONTROL PATTERN NEUTRAL
5 199 (OR) CONTROL PATTERN SW INPUT POWER
6 523 (YE) CONTROL PATTERN ISO
7 197 (OR) PATTERN INDICATOR H POWER
8 1024 (BL) PATTERN INDICATOR H LS OUTPUT
9 1023 (BL) PATTERN INDICATOR ISO LS OUTPUT
10 198 (OR) PATTERN INDICATOR ISO POWER
47540694 28/04/2014
55.11 [55.100] / 257


1 839 (RD) CONDENSER RELAY PIN 30 POWER
2 840 (WH) CONDENSER RELAY PIN 86 SIGNAL
3 237 (WH) HVAC CONDENSER FAN POWER
5 1087 (BK) CONDENSER RELAY GROUND

D 425 (VT) CAB CONSOLE MULTIFUNCTION #2 UP
E 359 (OR) CAB CONSOLE MULTIFUNCTION #2/#3 POWER
F 427 (RD) CAB CONSOLE MULTIFUNCTION #2 DOWN
47540694 28/04/2014
55.11 [55.100] / 258


1 766 (VT) LH REAR TURN SIGNAL POWER
2 763 (VT) RH REAR TURN SIGNAL POWER
3 717 (VT) LH REAR POSITION LAMP
4 718 (VT) RH REAR POSITION LAMP
5 721 (VT) BRAKE LAMP SIGNAL POWER
6 975 (BK) REAR LAMPS GROUND
87382918 1
47540694 28/04/2014
55.11 [55.100] / 259


A 712 (VT) LH BOOM ROAD LAMPS SIGNAL
B 767 (VT) LH BOOM TURN SIGNAL POWER
D 979 (BK) LH BOOM LAMPS GROUND

A 713 (VT) RH BOOM ROAD LAMPS SIGNAL
B 764 (VT) RH BOOM TURN SIGNAL POWER
D 980 (BK) RH BOOM LAMPS GROUND
47540694 28/04/2014
55.11 [55.100] / 260

CONNECTOR X-252 - TEMP CONTROL SWITCH
CONNECTOR X-252 - TEMP CONTROL SWITCH

1 912 (BK) HVAC TEMPERATURE SWITCH GROUND
2 824 (YE) HVAC TEMPERATURE CONTROL SIGNAL
3 823 (PK) HVAC TEMPERATURE SW POWER
47540694 28/04/2014
55.11 [55.100] / 261


A 822 (OR) HVAC WATER VALVE POWER
B - -
C 1013 (BK) WATER VALVE GROUND
D 824 (YE) HVAC TEMPERATURE CONTROL SIGNAL
CONNECTOR X-275 - A/C SWITCH
CONNECTOR X-275 - A/C SWITCH

A 825 (OR) HVAC CLUTCH
B 913 (BK) HVAC COMPRESSOR CLUTCH SW GROUND
C 829 (WH) A/C SW OUT
47540694 28/04/2014
55.11 [55.100] / 262

CONNECTOR X-300 - HYDRAULIC COUPLER SWITCH
CONNECTOR X-300 - HYDRAULIC COUPLER SWITCH

1 - -
2 751 (OR) HYDRAULIC COUPLER SW IN
3 752 (WH) HYDRAULIC COUPLER SIGNAL
9 918 (BK) HYD COUPLER IND GND
CONNECTOR X-301 - BEACON LAMP SWITCH
CONNECTOR X-301 - BEACON LAMP SWITCH

A 919 (BK) BEACON SW IND GND
D 761 (VT) BEACON SW OUTPUT
E 796 (VT) BEACON POWER
47540694 28/04/2014
55.11 [55.100] / 263
CONNECTOR X-302 - HAZARD LAMP SWITCH
CONNECTOR X-302 - HAZARD LAMP SWITCH

A 776 (VT) HAZARD SW LH TURN SIGNAL OUTPUT
B 784 (OR) LH HAZARD FLASHER POWER IN
C 920 (BK) HAZARD SW INDICATOR GROUND
E 785 (OR) RH HAZARD FLASHER POWER IN
F 778 (VT) HAZARD SW RH TURN SIGNAL OUTPUT
CONNECTOR X-303 - HI FLOW SWITCH
CONNECTOR X-303 - HI FLOW SWITCH

A 755 (WH) HIGH PERFORMANCE HIGH FLOW SIGNAL
B 753 (OR) HIGH FLOW SW IN
C 750 (WH) STANDARD HIGH FLOW SIGNAL
E 921 (BK) HIGH FLOW SW INDICATOR GROUND
47540694 28/04/2014
55.11 [55.100] / 264
CONNECTOR X-306 - LOADER LOCKOUT SWITCH
CONNECTOR X-306 - LOADER LOCKOUT SWITCH

A 312 (YE) LOADER LOCK SW N.C. OUTPUT (VALVE ON)
B 311 (OR) LOADER LOCKOUT SW PWR
C 398 (YE) LOADER LOCKOUT SW N.O. OUTPUT (VALVE OFF)
E 924 (BK) LOADER LOCK SW INDICATOR GROUND
47540694 28/04/2014
55.11 [55.100] / 265

CONNECTOR X-310 - 2 SPD INDICATOR
CONNECTOR X-310 - 2 SPD INDICATOR

7 565 (VT) 2 SPEED INDICATOR
9 917 (BK) 2 SPEED INDICATOR GROUND
CONNECTOR X-317 - SELF LEVEL SWITCH
CONNECTOR X-317 - SELF LEVEL SWITCH

A 404 (WH) SELF LEVEL SW OUTPUT POWER
B 405 (OR) SELF LEVEL SW POWER
E 922 (BK) SELF LEVEL SW IND GROUND
47540694 28/04/2014
55.11 [55.100] / 266


5 416 (VT) MULTIFUNCTION #2 UP
6 417 (RD) MULTIFUNCTION #2 DOWN
7 982 (BK) MULTIFUNCTION GROUND
8 856 (WH) AUX ELEC ON/OFF SW SIGNAL
9 420 (OR) MULTIFUNCTION FUSE POWER
10 423 (YE) EHF INTERLOCK
87382922 1
47540694 28/04/2014
55.11 [55.100] / 267

47540694 28/04/2014
55.11 [55.100] / 268

2 452 (BL) LEFT SPEAKER (-)
4 451 (WH) RIGHT SPEAKER (+)
5 450 (BL) RIGHT SPEAKER (-)
6 453 (WH) LEFT SPEAKER (+)
7 934 (BK) RADIO GROUND
9 130 (OR) RADIO POWER
84257494 1
47540694 28/04/2014
55.11 [55.100] / 269

CONNECTOR X-365 - NH PARK BRAKE SWITCH
CONNECTOR X-365 - NH PARK BRAKE SWITCH

2 194 (OR) RH CONSOLE PARK BRAKE SW PWR
3 306 (YE) RH CONSOLE PARK BRAKE SW OUT
47540694 28/04/2014
55.11 [55.100] / 270

CONNECTOR X-403 - RH HANDLE INTERCONNECT FE/PROPORTIONAL AUX/FLOAT
CONNECTOR X-403 - RH HANDLE INTERCONNECT FE/PROPORTIONAL AUX/FLOAT

1 213 (PK) PROPORTIONAL AUX SW #2 REFERENCE
2 547 (YE) PROPORTIONAL AUX SW OUTPUT SIGNAL #2
3 1052 (BK/WH) PROPORTIONAL AUX SW #2 GROUND
5 352 (OR) RH HANDLE MULTIFUNCTION #1/#2 POWER
8 412 (VT) RH HANDLE MULTIFUNCTION #2 UP
9 413 (RD) RH HANDLE MULTIFUNCTION #2 DOWN
10 214 (PK) PROPORTIONAL AUX SW #1 REFERENCE
11 546 (YE) PROPORTIONAL AUX SW OUTPUT SIGNAL #1
12 1053 (BK/WH) PROPORTIONAL AUX SW #1 GROUND
13 406 (OR) FLOAT SW INPUT VOLTAGE
14 531 (YE) LOADER FLOAT SW INPUT
87382928 1
47540694 28/04/2014
55.11 [55.100] / 271
CONNECTOR X-406 - RH HANDLE INTERCONNECT PARK BRAKE/RIDE CTRL
CONNECTOR X-406 - RH HANDLE INTERCONNECT PARK BRAKE/RIDE CTRL

A 324 (OR) RH GRIP PARK BRAKE SW POWER
B 307 (YE) RH GRIP PARK BRAKE SW OUTPUT
C 832 (OR) RIDE CONTROL VALVE SOLENOID SW POWER
D 831 (WH) RIDE CONTROL VALVE SOLENOID SIGNAL
47540694 28/04/2014
55.11 [55.100] / 272

1 558 (OR) 2ND AUX SW POWER
2 554 (WH) 2ND AUX EXTEND SW OUTPUT
3 552 (WH) 2ND AUX RETRACT SIGNAL POWER
4 891 (OR) LH GRIP HORN/2 SPEED SW POWER
5 770 (OR) LH GRIP FLASHER POWER
6 768 (VT) LH GRIP LH TURN SIGNAL OUTPUT SIGNAL
7 765 (VT) LH GRIP RH TURN SIGNAL OUTPUT SIGNAL
8 892 (WH) HORN POWER SIGNAL
9 563 (WH) 2 SPEED SW OUTPUT SIGNAL
10 353 (OR) LH HANDLE MULTIFUNCTION #2/#3 POWER
11 414 (VT) LH HANDLE MULTIFUNCTION #2 UP
12 415 (RD) LH HANDLE MULTIFUNCTION #2 DOWN
87382929 3
47540694 28/04/2014
55.11 [55.100] / 273

CONNECTOR X-411 - FLASHER MODULE
CONNECTOR X-411 - FLASHER MODULE

1 156 (RD) FLASHER/BRAKE FUSE POWER
2 981 (BK) FLASHER GROUND
3 769 (OR) FLASHER MODULE OUTPUT POWER
47540694 28/04/2014
55.11 [55.100] / 274


A 227 (WH) DOOR WIPER MOTOR SIGNAL
B 929 (BK) DOOR WIPER MOTOR GROUND
C 231 (OR) DOOR WIPER MOTOR PARK
D 220 (YE) DOOR SW BYPASS

A 228 (WH) REAR WINDOW WIPER MOTOR SIGNAL
B 930 (BK) REAR WINDOW WIPER MOTOR GROUND
C 232 (OR) REAR WINDOW WIPER MOTOR PARK
87693712 2
47540694 28/04/2014
55.11 [55.100] / 275
CONNECTOR X-503 - WIPER/WASHER SWITCH
CONNECTOR X-503 - WIPER/WASHER SWITCH

1 931 (BK) WIPER/WASHER SW GROUND
2 225 (WH) MOTOR/IND OUT
3 229 (OR) WIPER/WASHER SWITCH MOTOR POWER IN
5 224 (WH) WASHER PUMP SIGNAL
6 230 (OR) WIPER/WASHER SW PUMP POWER IN
7 226 (VT) INDICATOR SIGNAL
8 932 (BK) SW INDICATOR GROUND
87716755 3
47540694 28/04/2014
55.11 [55.100] / 276

47540694 28/04/2014
55.11 [55.100] / 277
CONNECTOR X-902 - FUSE RELAY GROUND
CONNECTOR X-902 - FUSE RELAY GROUND

C 1092 (BK) OPTION RELAY COIL GROUND
D 1097 (BK) OPTION RELAY COIL GROUND
E 1094 (BK) CAB GROUND B
F 1096 (BK) OPTION RELAY COIL GROUND
47540694 28/04/2014
55.11 [55.100] / 278
Wire connectors - Component diagram – Connectors A – Z


3 624 KEY START OUTPUT
5 505 CAN LO
6 500 CAN HI
INSTRUMENT CLUSTER
7 301
SWITCHED POWER
INSTRUMENT CLUSTER
8 302
SWITCHED POWER
INSTRUMENT CLUSTER
9 313
UNSWITCHED POWER
10 132 KEY IGNITION
AIR FILTER/ENGINE
11 267
MALFUNCTION
12 328 SEAT SW CLUSTER INPUT
17 259 THROTTLE SENSOR SUPPLY
19 251 DOOR SW SIGNAL
22 543 THROTTLE SIGNAL
25 1070 THROTTLE SENSOR GROUND
30 303
SIGNAL
32 622 START SIGNAL FROM CLUSTER
34 1011 INSTRUMENT CLUSTER GROUND
47540694 28/04/2014
55.11 [55.100] / 279
82028495 1
47540694 28/04/2014
55.11 [55.100] / 280

13 1018 BUCKET RETURN
14 525 UCM WAKE-UP
16 124 ENGINE RPM SIGNAL
19 1022 DRIVE REVERSE RETURN
20 189
FUSE POWER
22 1020 PROPORTIONAL AUX RETURN
PROPORTIONAL AUX RETRACT
24 515
SIGNAL
26 240 5V REF SUPPLY FUSE
82016219 2
RAPH12SSL0240AA 3
47540694 28/04/2014
55.11 [55.100] / 281

26 128 SW POWER PROP AUX EXTEND
27 126 SW POWER PROP AUX RETRACT
PROPORTIONAL AUX EXTEND
33 514
SIGNAL
87410946 4
RAPH12SSL0240AA 5
47540694 28/04/2014
55.11 [55.100] / 282

2 164 LEFT PUMP REVERSE POWER
3 165 RIGHT PUMP REVERSE POWER
4 536 LOADER PILOT INTERLOCK
5 537 LOADER PORT LOCK
7 159
LOCK
8 518 PUMP RIGHT REVERSE
HYDRAULIC CHARGE PRESSURE
9 262
SWITCH
13 163
LOCK
14 517 PUMP LEFT REVERSE
23 1024
OUTPUT
82028493 6
47540694 28/04/2014
55.11 [55.100] / 283
RAPH12SSL0240AA 7
47540694 28/04/2014
55.11 [55.100] / 284

1 503E CAN HI
2 1023
OUTPUT
7 1019 LOADER RETURN
8 1099 EHF RETURN
9 154
CONTROL
10 504E CAN LO
13 535 PARK BRAKE PRESSURE SWITCH
17 158
CONTROL
23 398
OUTPUT (VALVE OFF)
START SIGNAL FROM CLUSTER
24 532
TO UCM
25 1021 DRIVE FORWARD RETURN
28 547
OUTPUT SIGNAL #2
82028495 8
47540694 28/04/2014
55.11 [55.100] / 285
RAPH12SSL0240AA 9
47540694 28/04/2014
55.11 [55.100] / 286

6 430 EHF RETRACT SIGNAL
19 431 EHF EXTEND SIGNAL
21 120 PUMP FORWARD FUSE POWER
22 512 LOADER LOWER SIGNAL
23 303
SIGNAL
2 SPEED VALVE SOLENOID
25 564
SIGNAL
84130757 10
47540694 28/04/2014
55.11 [55.100] / 287
RAPH12SSL0240AA 11
47540694 28/04/2014
55.11 [55.100] / 288


3 167
POWER
6 513 LOADER RAISE SIGNAL
11 755
SIGNAL
CONTROL VALVE BUCKET
12 570
POSITION SENSOR
CONTROL VALVE LOADER
13 571
POSITION SENSOR
CONTROL VALVE AUX POSITION
14 572
SENSOR
17 510 BUCKET RETRACT SIGNAL
18 895 BACKUP ALARM SIGNAL
19 312
OUTPUT (VALVE ON)
29 554
OUTPUT
SEAT SWITCH OPERATOR
30 526
INTERLOCK
31 552
POWER
32 519 PUMP RIGHT FORWARD
33 516 PUMP LEFT FORWARD
CNH_84130760AAO 12
47540694 28/04/2014
55.11 [55.100] / 289
RAPH12SSL0240AA 13
47540694 28/04/2014
55.11 [55.100] / 290

SEAT BELT / LAP BAR OPERATOR
10 524
INTERLOCK
19 511 BUCKET EXTEND SIGNAL
82028493 14
RAPH12SSL0240AA 15
47540694 28/04/2014
55.11 [55.100] / 291

13 423 EHF INTERLOCK
21 546
OUTPUT SIGNAL #1
82028495 16
RAPH12SSL0240AA 17
47540694 28/04/2014
55.11 [55.100] / 292

1 782 FLASHER POWER OUTPUT
2 774
POWER
5 311 LOADER LOCKOUT SW IN
6 780
POWER
7 312 LOADER LOCK SW OUT
10 141 CLUSTER OPT RELAYS SIGNAL
SL57_87382924 18

1 425 CONSOLE SWITCH MF #2 UP
2 359 CONSOLE SWITCH MF #2 POWER
3 427 CONSOLE SWITCH MF#2 DN
4 751 HYDRAULIC COUPLER SW IN
7 753 HIGH FLOW SW IN
84257541 19
47540694 28/04/2014
55.11 [55.100] / 293

A 961 DIAG CONNECTOR GND
B 162 UNSWITCHED BATTERY POWER
C 501 CAN HI
D 506 CAN LO
E 248 EGR ECU K-LINE
84497873 20
47540694 28/04/2014
55.11 [55.100] / 294
CONNECTOR ECC1A - CHASSIS/CAB INTERFACE -1-
CONNECTOR ECC1A - CHASSIS/CAB INTERFACE -1-

1 797
LAMP POWER
3 503 CAN HI
4 504 CAN LO
5 791 LAMP SW ROAD LAMP SIGNAL
LAP BAR/SEAT BELT CLUSTER
6 314
INPUT
7 910 CAB/CLUSTER CLEAN GROUNDS
MAIN POWER RELAY IGNITION
9 357
FUSE
10 115 BEACON/ACC FUSE OUT
12 310
POWER
14 790 LAMP SW WORK LAMP SIGNAL
87382926 21
47540694 28/04/2014
55.11 [55.100] / 295
CONNECTOR ECC1B - UCM ECC1B
CONNECTOR ECC1B - UCM ECC1B

1 798
LAMP POWER
3 503A CAN HI
4 504A CAN LO
5 791 ROAD LAMP SIGNAL
LAP BAR / SEAT BELT CLUSTER
6 314
INPUT
7 910 CAB/CLUSTER CLEAN GROUNDS
MAIN POWER RELAY IGNITION
9 357
FUSE TO CAB
10 115 BEACON/ACC FUSE OUT
HYDRAULIC OIL TEMPERATURE
11 264
SENDER
12 310
POWER
LAMP SWITCH WORK LAMP
14 790
SIGNAL
87382927 22
47540694 28/04/2014
55.11 [55.100] / 296
RAPH12SSL0251AA 23
47540694 28/04/2014
55.11 [55.100] / 297
CONNECTOR X-ECC2A - CHASSIS/CAB INTERFACE -2-

1 134 ACCESSORY FUSE POWER
3 329 SEAT SWITCH UCM INPUT
INSTRUMENT CLUSTER
4 309
SWITCHED POWER
5 303
SIGNAL
AIR FILTER/ENGINE
7 267
MALFUNCTION
8 1066
GROUND
9 843 -VOLTAGE DROP PARALLEL
CIRCUIT
12 175 ACC & OPTION RELAY SIGNALS
13 211
SUPPLY
87382927 24
47540694 28/04/2014
55.11 [55.100] / 298
CONNECTOR ECC2B - CHASSIS/CAB INTERFACE -2-

1 134 ACCESSORY FUSE POWER
3 329 SEAT SWITCH UCM INPUT
4 309 CLUSTER SWITCHED POWER
5 303
SIGNAL
AIR FILTER / ENGINE
7 267
MALFUNCTION
8 1066 FOOT THROTTLE GROUND
HVAC FUSE - VOLTAGE DROP
9 843
PARALLEL CIRCUIT
11 133A MAIN PWR RLY SIGNAL
12 175 ACC/OPT SIGNALS
13 211
SUPPLY
87382926 25
47540694 28/04/2014
55.11 [55.100] / 299
RAPH12SSL0251AA 26
47540694 28/04/2014
55.11 [55.100] / 300

1 404 SELF LEVEL SW OUTPUT POWER
HVAC TEMPERATURE CONTROL
3 824
SIGNAL
4 1090 UJM SENSOR GROUNDS 4A.20
LAMP SW WORK AND SIDE LAMP
5 792
SIGNAL
6 1023
OUTPUT
THERMOSTAT TO BINARY
7 833
PRESSURE SW
8 1024
OUTPUT
9 754 PARK BRAKE SW
10 123 LAMP SW POWER
84394888 27
47540694 28/04/2014
55.11 [55.100] / 301

SELF LEVEL SWITCH OUTPUT
1 404
POWER
HVAC TEMPERATURE CONTROL
3 824
SIGNAL
5 792
LAMP SIGNAL
6 1023
OUTPUT
8 1024
OUTPUT
10 123 LAMP SELECTOR SW POWER
13 834 PRESS SW TO COMP RLY
HVAC FUSE - VOLTAGE DROP
14 844
PARALLEL CIRCUIT
84394890 28
47540694 28/04/2014
55.11 [55.100] / 302
RAPH12SSL0251AA 29
47540694 28/04/2014
55.11 [55.100] / 303

FLASHER MODULE OUTPUT
1 769
POWER
2 774
POWER
LOADER LOCKOUT SW N.O.
3 398
OUTPUT (VALVE OFF)
6 780
POWER
A/C COMPRESSOR RELAY PIN 87
7 841
POWER
8 836
FUSE
10 233 WIPER/WASHER FUSE POWER
LOADER LOCK SW N.C. OUTPUT
12 312
(VALVE ON)
84394890 30
CONNECTOR ECC4B - CHASSIS/INTERFACE -4-
CONNECTOR ECC4B - CHASSIS/INTERFACE -4-

FLASHER MODULE OUTPUT
1 769
POWER
47540694 28/04/2014
55.11 [55.100] / 304

2 774
POWER
3 398
OUTPUT (VALVE OFF)
6 780
POWER
7 841 A/C COMP RELAY PWR
COMPRESSOR / CONDENSER
8 836
FAN FUSE
10 233 WIPER / WASHER FUSE POWER
12 312
OUTPUT (VALVE ON)
84394888 31
RAPH12SSL0251AA 32
47540694 28/04/2014
55.11 [55.100] / 305

1 129 AUX ELEC ON/OFF FUSE POWER
2 856 AUX ELEC ON/OFF SW SIGNAL
HIGH FLOW/HYDRAULIC
4 744
COUPLER FUSE POWER
6 755
SIGNAL
RIDE CONTROL VALVE SOLENOID
7 831
SIGNAL
13 554 2ND AUX EXTEND SW OUTPUT
14 552
POWER
84398821 33
CONNECTOR ECC5B - CHASSIS/CAB INTERFACE -5- ENHANCED HIGH FLOW
CONNECTOR ECC5B - CHASSIS/CAB INTERFACE -5- ENHANCED HIGH FLOW

AUX ELEC ON/OFF SWITCH
2 856
SIGNAL
47540694 28/04/2014
55.11 [55.100] / 306
HIGH FLOW / HYDRAULIC

4 744
COUPLER FUSE POWER
6 755
SIGNAL
7 831
SIGNAL
10 1051 UJM SENSOR GROUNDS
13 554
OUTPUT
14 552
POWER
84394889 34
RAPH12SSL0251AA 35
47540694 28/04/2014
55.11 [55.100] / 307
CONNECTOR ECC5B - CHASSIS/ CAB INTERFACE -5-
CONNECTOR ECC5B - CHASSIS/ CAB INTERFACE -5-

AUX ELEC ON/OFF SWITCH
2 856
SIGNAL
4 744
COUPLER FUSE POWER
6 755
SIGNAL
7 831
SIGNAL
8 750-1 STANDARD HIGH FLOW SIGNAL
10 1051 UJM SENSOR GROUNDS
13 554
OUTPUT
13 554-1
OUTPUT
14 552-1
POWER
14 552
POWER
SL57_84394889 36
47540694 28/04/2014
55.11 [55.100] / 308
RAPH12SSL0251AA 37
47540694 28/04/2014
55.11 [55.100] / 309

HANDLE MULTIFUNCTION #1, #2,
3 354
#3 FUSE POWER
RH HANDLE MULTIFUNCTION #1
4 410
UP
5 411
DOWN
6 416 MULTIFUNCTION #2 UP
7 417 MULTIFUNCTION #2 DOWN
LH HANDLE MULTIFUNCTION #3
8 418
UP
9 419
DOWN
10 892 HORN POWER SIGNAL
PROPORTIONAL AUX SW OUTPUT
11 546
SIGNAL #1
12 210 CAB SENSOR SUPPLY 1
PROPORTIONAL AUX SW OUTPUT
14 547
SIGNAL #2
84394889 38

47540694 28/04/2014
55.11 [55.100] / 310

3 354
#3 FUSE POWER
4 410
UP
5 411
DOWN
6 416 HANDLE MULTIFUNCTION #2 UP
HANDLE MULTIFUNCTION #2
7 417
DOWN
8 418
UP
9 419
DOWN
10 892 HORN POWER SIGNAL
11 546
OUTPUT SIGNAL #1
12 210 CAB SENSOR SUPPLY 1
14 547
OUTPUT SIGNAL #2
84398821 39
47540694 28/04/2014
55.11 [55.100] / 311
RAPH12SSL0251AA 40
CONNECTOR FUSE1 - MAIN POWER DISTRIBUTION FUSE BLOCK #1

A1 830 HVAC FUSE INPUT
LIGHT RELAY #1 PIN 85 COIL
A12 946
GROUND
A2 820 HVAC RELAY FUSE POWER
A3 528B ECU FUSE 1 IN
A4 110 ECU FUSE 1 POWER
A5 528C ECU FUSE 2 IN
A6 155A ECU FUSE 2 POWER
LIGHT RLY #2 PIN 87 SIDE LMP
A7 707
SW REAR WORK LMP OUT
LIGHT RELAY #2 PIN 85 COIL
A9 945
GROUND
A10 116 LIGHT RELAY #1 PIN 87 B+
STD LAMP CONFIG FRONT WORK
A11 710
LAMP CONTROL SIGNAL
B1 183 UCM BACKUP ALARM FUSE IN
B2 167
POWER
B3 528D ENGINE SENSORS FUSE IN
B4 241A ENGINE SENSORS FUSE POWER
B7 709 LIGHT RELAY #2 COIL POWER
B9 113 LIGHT RELAY #2 B+
LIGHT RELAY #1 PIN 86 WORK
B10 325
LAMP SWITCH SIGNAL
B12 788
C1 135 ACC FUSE IN
47540694 28/04/2014
55.11 [55.100] / 312
C2 134 ACCESSORY FUSE POWER

MAIN PWR RLY TO IGNITION FUSE
C3 350
IN
C4 351 INGITION FUSE POWER
C5 835 COMPRESSOR FUSE INPUT
COMPRESSOR / CONDENSER
C6 836
FAN FUSE
C7 136 MAIN PWR RLY OUT
MAIN POWER RELAY PIN 85 COIL
C9 947
GROUND
C10 125 ACC RLY OUT
ACCESSORY RELAY PIN 85 COIL
C12 948
GROUND
D1 160 UNSWITCHED BATTERY POWER
D2 310
POWER
MAIN PWR RLY TO CLUSTER
D3 326
FUSE IN
INSTRUMENT CLUSER FUSE
D4 300
POWER
D5 114 BEACON/ACC FUSE INPUT B+
D6 196 ACC/BEACON FUSE POWER
D7 144 MAIN POWER RELAY SIGNAL
MAIN POWER RELAY PIN 30
D9 118
UNSWITCHED BATTERY
D10 139 ACCESSORY RELAY SIGNAL
D12 117 ACCESSORY RELAY PIN 30 B+
E1 788
FRONT WORK LAMPS FUSE
E2 797
POWER
E3 792
LAMP SIGNAL
E4 708 SIDE LAMPS FUSE POWER
E5 705 REAR WORK LAMP FUSE IN
E6 706 REAR WORK LAMP FUSE POWER
TAIL LAMP SPLICE LH TAIL LAMP
E7 701
FUSE IN
E8 703 LH TAIL LAMP FUSE POWER
TAIL LAMP SPLICE RH TAIL LAMP
E9 700
FUSE IN
E10 704 RH TAIL LAMP FUSE POWER
E11 255 CRANK RELAY FUSE INPUT
E12 256 CRANK FUSE POWER
47540694 28/04/2014
55.11 [55.100] / 313
84255438 41

A1 173 UCM BRAKE LAMP FUSE IN
A2 172 BRK LMP FUSE PWR
A3 184 UCM PARK BRAKE FUSE IN
A4 185 DRIVE/INT FUSE PWR
A5 187 UCM PUMP REVERSE FUSE IN
A6 122 PUMP REV FUSE PWR
UCM POWER RELAY PIN 87
A7 190
OUTPUT
UCM POWER RELAY COIL
A9 1067
GROUND
A10 743 OPT RELAY OUT TO FUSE
A12 972 OPTION RELAY COIL GROUND
B1 174 PROPORTIONAL AUX FUSE IN
B2 177 PROP AUX FUSE PWR
B3 203 UCM PUMP FORWARD FUSE IN
B4 120 PUMP FORWARD FUSE POWER
B5 181 UCM LOADER FUSE IN
B6 178 UCM BOOM FUSE PWR
B7 335 UCM PWR RLY SIGNAL
B9 193 UCM POWER RELAY B+
B10 148 OPTION RELAY COIL SIGNAL
B12 104 OPTION RELAY PIN 30 B+
C1 356 MULTIFUNCTION FUSE IN
C2 420 MULTIFUNCTION FUSE POWER
UCM PORT/PILOT INTERLOCK
C3 180
FUSE IN
C4 182 UCM INTLK FUSE PWR
47540694 28/04/2014
55.11 [55.100] / 314

C5 188
FUSE IN
C6 189
FUSE POWER
C10 149 FE RLY OUT
FRONT ELECTRIC RELAY COIL
C12 974
GROUND
D1 355 HANDLE MF #1, #2, #3 FUSE IN
D2 354
#3 FUSE POWER
D3 204 UCM BUCKET FUSE IN
D4 176 BUCKET FUSE PWR
WIPER/WASHER SWITCH POWER
D5 243
FROM ACC RELAY
D6 233 WIPER / WASHER FUSE POWER
D10 146
SIGNAL
D12 103 MULTIFUNCTION RELAY PIN 30 B+
E1 145 AUX ELEC ON/OFF FUSE IN
E2 129 AUX ELEC ON/OFF FUSE POWER
E3 186 UCM 2SPD FUSE IN
E4 179 UCM 2SPD FUSE PWR
E5 714 LH BOOM ROAD LAMPS FUSE IN
LH BOOM ROAD LAMPS FUSE
E6 716
POWER
E7 715 RH BOOM ROAD LAMPS FUSE IN
RH BOOM ROAD LAMPS FUSE
E8 719
POWER
E9 157 B+ TO FLASHER/BRAKE FUSE IN
E10 156 FLASHER/BRAKE FUSE POWER
E11 743 OPT RELAY OUT TO FUSE
E12 744
COUPLER FUSE POWER
47540694 28/04/2014
55.11 [55.100] / 315
84255438 42
CONNECTOR FUSE2 - POWER DISTRIBUTION
CONNECTOR FUSE2 - POWER DISTRIBUTION

A10 743 OPT RELAY OUT TO FUSE
A12 972 OPTION RELAY COIL GROUND
C1 356 MULTIFUNCTION FUSE IN
C2 420 MULTIFUNCTION FUSE POWER
C10 149 FE RLY OUT
C12 974
GROUND
D1 355 HANDLE MF #1, #2, #3 FUSE IN
E1 145 AUX ELEC ON/OFF FUSE IN
E5 714 LH BOOM ROAD LAMPS FUSE IN
LH BOOM ROAD LAMPS FUSE
E6 716
POWER
E7 715 RH BOOM ROAD LAMPS FUSE IN
RH BOOM ROAD LAMPS FUSE
E8 719
POWER
E11 743 OPT RELAY OUT TO FUSE

1 935 HVAC GND
COMPRESSOR RELAY PIN 30
2 838
POWER
3 828 HVAC FAN LOW
4 827 HVAC FAN MEDIUM
5 850 HVAC FAN HIGH
47540694 28/04/2014
55.11 [55.100] / 316
A/C SW COMPRESSOR RELAY

6 837
PIN 86 VIA PRESSURE SW
9 1012 HVAC THERMOSTAT CLEAN GND
HVAC RELAY PIN 87 OUTPUT
10 842
POWER
11 143 HVAC KEYED POWER
14 845 HVAC RELAY FUSE POWER
87382926 43
47540694 28/04/2014
55.11 [55.100] / 317

1 706 REAR WORK LAMP FUSE POWER
2 704 RH TAIL LAMP FUSE POWER
3 703 LH TAIL LAMP FUSE POWER
4 950 REAR LAMP GROUND
87382914 44
47540694 28/04/2014
55.11 [55.100] / 318

TELEMATICS UNSWITCHED
A 336
BATTERY
C 802 TELEMATICS IGNITION POWER
ALTERNATOR LAMP TELEMATICS
D 244
ENGINE ON
E 308 VEHICLE WORKING CONDITION
H 925 TELEMATICS GROUND
L 503D TELEMATICS CAN HI
M 504D TELEMATICS CAN LO
S 205A TELEMATICS CRANK DISABLE
87696550 45
RAPH12SSL0240AA 46
47540694 28/04/2014
55.11 [55.100] / 319

SL57_87694583 47

SL57_87694583 48
47540694 28/04/2014
55.11 [55.100] / 320
Wire connectors - Component diagram – Grounds

Ground locations
Grounds
NEG_TERM_A (1)
Main chassis (2)
ECU (3)
RAPH12SSL0239AA 1
Ground location for the ECU, NEG_TERM_A, and the main chassis
Grounds
X-CAB_GNDA (1)
X-CAB_GNDB (2)
RAPH12SSL0248AA 2
Ground location for X-CAB_GNDA and X-CAB_GNDB
47540694 28/04/2014
55.11 [55.100] / 321
Grounds
CHS_GND_RR (1)
OPT_GND_RR (2)
RAPH12SSL0252AA 3
Ground location for CHS_GND_RR and OPT_GND_RR
Grounds
UCM_GND (1)
CHS_GND_FRT (2)
OPT_GND_FRT (3)
RAPH12SSL0251AA 4
Ground location for UCM_GND, CHS_GND_FRT, and OPT_GND_FRT
47540694 28/04/2014
55.11 [55.100] / 322
Fuse and relay box Relay - Overview

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1Z0O2004112131 1
The relay is an electromagnetic switch that uses a small amount of current to switch a larger amount on and off.
Relays are electrically operated switches. They are used to switch a circuit on/off in similar way to a manual switch.
When the operator closes a switch, current flows through the relay's control circuit. In this circuit there are windings
surrounding an iron core which is fixed in place. Current turns the iron core into an electromagnet. The core then
attracts an arm which has a contact point on it. When the point on the arm contacts the stationary point, current flows
through the power circuit.
Two circuits are connected to the relay:

• A work circuit, which is switched on/off by the relay, and provides the supply for the equipment to be operated, i.e.,
bulbs, solenoids, etc.;
• A control circuit, switched on/off by switches, used to operate the relay.
The part of the relay which is connected to the control circuit consists of the winding of an electro-magnet. When
the control circuit is switched off, the contacts are kept apart by a return spring. When the control circuit is switched
on, a current flows through the coil and a magnetic force is produced. This force, which is stronger than the spring
pressure, pulls the contacts of the relay together, causing the work circuit to operate.
1Z0O2004112132 2
A switch-relay system has two main advantages over a simple switch:

• The current that flows through the switch is not the same as all the current requested by the equipment to be
operated, but usually by a smaller current: this allows the usage of smaller and less expensive switches;
• The distance from the supply, to the equipment, can be made as short as possible to minimize voltage drop.
47540694 28/04/2014
55.11 [55.100] / 323
50004701 3
On the relay cover there are 4 or 5 terminal markings:

• 3 or 30: input terminal direct from battery positive, normally live.
• 2 or 85: winding output terminal, usually to ground.
• 1 or 86: winding input terminal.
• 4 or 87: output terminal for normally closed contact.
• 5 or 87a: output terminal for normally open contact.
47540694 28/04/2014
55.11 [55.100] / 324
Fuse and relay box Fuse - Overview

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
A fuse contains a thin wire, which either melts or vaporizes when too much current flows through it. The resulting
open in the circuit stops current flow. The fuse's current rating is normally stamped on the fuse.
The purpose of a fuse is to open a circuit when current flow exceeds a certain amount, which is determined by the
rating of the fuse. Opening a circuit under high current conditions can save downstream electronic components from
damage and prevents overheating, which could cause a fire. An overload can occur as the result of a short circuit or
short to ground circuit condition or by connecting equipment that requires current greater than the circuit is designed
to carry.
There are several types of fuses, but they all consist of a metal conductor which is capable of carrying a specified
amount of current. If the specified amount of current is exceeded, the metal conductor will overheat. The overheating
causes the metal conductor to melt and break, creating an open circuit condition.
NOTE: The following is for illustration purposes only. See your Operator’s Manual for specific Fuse Block location
and layout.
50014700 1
The rating of the fuse relates to the current, in amperes, that the fuse can carry continuously.
If a fuse fails, replace the fuse with same type and amp rating. Once replaced, if it fails again, the cause for the
over-current condition must be investigated and corrected.
There are a number of methods that can be used to verify the condition of a fuse. The fuse can be removed from
the fuse and relay panel socket and visually inspected to determine if the link has been melted. A continuity test can
be performed across the fuse terminals, while the fuse is removed from the fuse and relay panel, if it is not visually
apparent that the fuse link is blown. If one of the fuse terminals is connected to battery or switched battery power,
a voltage test to ground can be performed from one of the exposed terminals (1) and then the other (1), the battery
or switched battery voltage should be seen on both tests (terminals). If battery or switched battery power is NOT
connected to either fuse terminal or the power has been disconnected and the fuse is NOT part of a continuous
electrical circuit then the fuse can be continuity tested in place in the fuse and relay panel, by checking continuity
across the fuse on the two exposed terminals (1).
NOTICE: If not certain of exact circuit conditions, performing continuity tests on fuses should be done with the fuse
removed from the fuse and relay panel. Performing the test with the fuse still installed in its socket in the fuse and
relay panel could provide false indications of the actual fuse condition.
47540694 28/04/2014
55.11 [55.100] / 325
Fuse and relay box - Component localisation

Fuses and relays located in the cab.
Remove the thumbscrews (2) on the cup holder panel to
remove the cover to expose the fuses (1).
The fuse and relay decal is located at lower left as seen
from the operators seat.
NOTE: Not all machines have two fuse blocks.
93106923 1
93107475 2
Fuse and relay configuration for the fuse block located in the cab area.
RAIL13SSL0618EA 3
RAIL13SSL0619EA 4
47540694 28/04/2014
55.11 [55.100] / 326
Fuses and relays located in the engine area.

Remove the battery access cover at the rear, lower left
of the machine. Remove the battery (1). The relay block
(2) for the crank, burner glow plug, and engine control
unit (ECU) relays and the ECU fuse are located inside
the engine compartment and forward the battery (1). The
60 A glow plug unit (GCU) fuse (4) (not shown) is located
under the relay box (2). The flasher relay (3) (if equipped
with a flasher system) is located forward the relay block
(2). Please see image 5 for details.
RAIL13SSL0095AA 5
The 2 A ground fuses (1) are located near the left, rear of
the machine, between the engine and the hydraulic tank.
RAPH13SSL0908BA 6
Relay configuration for the relay block located in the engine area.
1. Crank relay
2. ECU relay
RAIL13SSL0094AA 7
47540694 28/04/2014
55.11 [55.100] / 327
How to open fuse and relay block:

Rotate the box up toward the cab and slide the red release
tab (1) away from the cover.
NOTE: There are two red locking tabs; one on top and
one on the bottom of the fuse block cover (2).
Once both of the red locking tabs (1) are in the released
position, squeeze the clasps on top and bottom to re-
mover cover.
To install the cover (2), align the locking tabs and then
slide both red locking tabs (1) toward the cover.
63107475 8
47540694 28/04/2014
55.11 [55.100] / 328
Wire harnesses - Repair

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
NOTE: For Wiring Harness replacement, see Wire harnesses - Replace (55.100)
1. Temporary Wiring Harness Repair
The following method to repair wiring is a temporary
expedient only. Wiring should be replaced as soon as
possible. Do not attempt to repair the wire on any sys-
tem sensors as these are sealed and should only be
replaced with a new component.
NOTE: When conducting a cable repair it is important that
only RESIN CORED SOLDER is used. Use of other types
of solder may result in further cable damage.
2. To carry out a temporary repair, proceed as follows:-
Locate damaged portion of cable then cut away outer
protective cover on both sides of the damaged area.
1Z0O2004112111 1
3. Peel back the cable from both ends of the damaged

area and carefully cut away the inner cable cover at
the damaged area and strip about 13 mm ( 1/2 in) of
insulation from the wires. Do not cut away any wire
strands.
Using a suitable solvent, clean about 2 in ( 50 mm)
from each cover end. Clean the grey cable cover and
the individual leads.
Twist two bare leads together for each damaged lead,
being careful to match wire colours, then solder the
leads using resin cored solder. Tape each repaired lead
with vinyl insulation tape.
1Z0O2004112112 2
47540694 28/04/2014
55.11 [55.100] / 329
4. Wind a layer of vinyl insulation tape up to the grey cable

cover at each end of the repair section. Make a paper
trough, then apply silicon rubber compound (non hard-
ening sealant) over the repaired section up to the cover
ends. Sufficient sealant must be used to fill the ends of
the cut away area.
1Z0O2004112113 3
5. Allow the compound to cure then cover the area with

insulating tape taking the tape well over each end of
the repair. An overlap of at least 2 in ( 50 mm) of tape
at each end is necessary.
Check to ensure the repair is satisfactory and secure
the repaired cable so that repeat damage is avoided.
NOTE: This is a temporary repair only. Ensure the dam-
aged cable is replaced as soon as possible to prevent
ingress of water or chemicals.
1Z0O2004112114 4
47540694 28/04/2014
55.11 [55.100] / 330
Wire harnesses - Replace

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
NOTE: For Wiring Harness repair, see Wire harnesses - Repair (55.100)
1. If a wire within the harness is found to be beyond repair
or is open circuit, a jumper wire may be installed as a
temporary repair until such time when a new harness
assembly can be installed. Use the following procedure
to install an additional wire:
Locate the faulty wire using the procedures described
in the fault code charts.
Disconnect the affected connectors.
If fitted carefully roll back the seal between the connec-
tor and harness outer covering.
Remove the pins from the connector blocks of the af-
fected wire using the appropriate removal tool found in
the harness repair kit.
NOTE: Use the instructions supplied with the kit to ensure
correct pin removal.
1Z0O2004112115 1
47540694 28/04/2014
55.11 [55.100] / 331
2. From the harness repair kit select the correct pin for the
connectors. Obtain locally the correct cross-sectional
size wire and measure out the length required by fol-
lowing the harness routing.
Join the new wire to the new pins as described in the
harness repair kit and install one of the pins into its
connector.
If possible attempt to run the new wire within the exist-
ing harness outer covering, if this is not possible run the
wire along the harness, securing regularly with suitable
ties. With the wire correctly routed instal the second ter-
minal into its connector block. Replace the connector
seal if removed.
To ensure that the repair has been effective check for
continuity of the new wire using a suitable multi-meter.
NOTE: This is a temporary repair only. Ensure the dam-
aged cable is replaced as soon as possible to prevent
ingress of water or chemicals.
1Z0O2004112116 2
47540694 28/04/2014
55.11 [55.100] / 332
Fuse and relay box - Testing – Universal Control Module (UCM)

L223 TIER 4 [NDM474381 - ] NA

1 Condition Result Action
Turn the key switch OFF. The connections are secure. The The connections are not secure
Check connections are free of corrosion, or the connections show signs of
Verify all wiring connections to the UCM abrasion and damage. Go to Next corrosion, abrasion and damage.
Power Relay are tight and secure. All Step. Repair as required.
connections should be free of corrosion,
abrasion and damage. Verify that the
chassis ground frame connections are
secure and tight and free of oil, paint, dirt,
damage and debris.
Turn the key switch OFF. The resistance is less than 10 Ω. The resistance is greater than
Check Go to Next Step. 10 Ω there is a problem in the
Measure the resistance between UCM ground circuit to the relay. Repair
Power Relay connection pin 85 (A9) to as required.
chassis ground. Wiggle the harness
during measurement to reveal an inter-
mittent condition. The chassis ground
connection should be clean and free of
oil, dirt paint and rust.
Turn the key switch OFF. The resistance is less than 10 Ω. The resistance is greater than
Check Go to Next Step. 10 Ω there is a problem in the
Measure the resistance between UCM wiring from the Ignition Switch to
Power Relay connection pin 87 (B7) to the UCM Power Relay. Repair as
the Ignition Switch connector X-9 pin 6. required.
Wiggle the harness during measurement
to reveal an intermittent condition.
Turn the key switch ON. The voltage is approximately 12 V. The voltage is less than 10 V there
Check Go to Next Step. is a problem in the battery supply
Measure the voltage from UCM Power to the relay. Repair as required.
Relay connection pin 30 (B9) to chassis
ground. Measure the voltage from UCM
Power Relay connection pin 86 (B7) to
chassis ground.
Turn the key switch ON. The voltage should be approxi- The voltage is less than 10 V there
Check mately 12 V. There is a problem is a problem in the UCM Power
Measure the voltage from UCM Power in the wiring from the UCM Power Relay. Temporarily replace the re-
Relay connection pin 87 (A7) to chassis Relay to the suspect component. lay and retest.
ground. Repair as required. Refer to Fuse
and relay box - Overview UCM
Power Relay Fuses and Fault
Codes (55.100)
47540694 28/04/2014
55.11 [55.100] / 333
Index

Wire harnesses - Electrical schematic sheet 02 Accessory Power Distribution, Mechanical Units (*) . . . . . . . . . . . 8
Wire harnesses - Electrical schematic sheet 03 Ignition Charging System, Mechanical Units (*) . . . . . . . . . . . . . 10
Wire harnesses - Electrical schematic sheet 04 System Power and Ground, Mechanical Units (*) . . . . . . . . . . . . 12
Wire harnesses - Electrical schematic sheet 05 Engine Power Distribution and Fuel Pump, Mechanical Units (*) 14
Wire harnesses - Electrical schematic sheet 06 Engine F5C T4 (Vehicle), Mechanical Units (*) . . . . . . . . . . . . . . 16
Wire harnesses - Electrical schematic sheet 07 Engine F5C T4 (Engine), Mechanical Units (*) . . . . . . . . . . . . . . 18
Wire harnesses - Electrical schematic sheet 08 Throttle Sensor, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . 20
Wire harnesses - Electrical schematic sheet 09 Control Valve Interlock & 2nd Aux Hydraulics, Mechanical Units (*)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wire harnesses - Electrical schematic sheet 10 Cab to Chassis Interface, Mechanical Units (*) . . . . . . . . . . . . . . 24
Wire harnesses - Electrical schematic sheet 11 Cab Console Switches, Mechanical Units (*) . . . . . . . . . . . . . . . . 26
Wire harnesses - Electrical schematic sheet 12 Left Hand Control Handle, Mechanical Units (*) . . . . . . . . . . . . . 28
Wire harnesses - Electrical schematic sheet 13 Right Hand Control Handle, Mechanical Units (*) . . . . . . . . . . . . 30
Wire harnesses - Electrical schematic sheet 14 Seat, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wire harnesses - Electrical schematic sheet 15 Std Aux Hydraulics, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . 34
Wire harnesses - Electrical schematic sheet 16 Lamps, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Wire harnesses - Electrical schematic sheet 17 Indicators, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Wire harnesses - Electrical schematic sheet 18 Turn Signal and Work Lights, Mechanical Units (*) . . . . . . . . . . . 40
Wire harnesses - Electrical schematic sheet 19 Roading Lights, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . 42
Wire harnesses - Electrical schematic sheet 20 Wipers and Washers, Mechanical Units (*) . . . . . . . . . . . . . . . . . 44
Wire harnesses - Electrical schematic sheet 21 Instrument Cluster, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . 46
Wire harnesses - Electrical schematic sheet 22 HVAC, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Wire harnesses - Electrical schematic sheet 23 Radio, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Wire harnesses - Electrical schematic sheet 24 Multi-Function Loader Arm, Mechanical Units (*) . . . . . . . . . . . . 52
Wire harnesses - Electrical schematic sheet 25 Telematics, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Wire harnesses - Electrical schematic sheet 26 Case Front Lights, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . 56
Wire harnesses - Electrical schematic sheet 27 Diagnostic Connector, Mechanical Units (*) . . . . . . . . . . . . . . . . . 58
Wire harnesses - Electrical schematic sheet 28 Fuel Filter Jumper, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . 60
Wire harnesses - Electrical schematic sheet 29 NH Front Lights, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . . . 62
Wire harnesses - Electrical schematic sheet 30 Boom Lock Valve, Mechanical Units (*) . . . . . . . . . . . . . . . . . . . . 64
Wire harnesses - Electrical schematic sheet 01 Main Power Distribution, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . 66
Wire harnesses - Electrical schematic sheet 02 Accessory Power Distribution, EH Units (*) . . . . . . . . . . . . . . . . . 68
Wire harnesses - Electrical schematic sheet 03 Ignition Charging System, EH Units (*) . . . . . . . . . . . . . . . . . . . . . 70
47540694 28/04/2014
55.11 [55.100] / 334
Wire harnesses - Electrical schematic sheet 04 System Power and Grounds, EH Units (*) . . . . . . . . . . . . . . . . . . 72
Wire harnesses - Electrical schematic sheet 05 Engine F5C T4 (Vehicle), EH Units (*) . . . . . . . . . . . . . . . . . . . . . 74
Wire harnesses - Electrical schematic sheet 06 Engine F5C T4 (Engine), EH Units (*) . . . . . . . . . . . . . . . . . . . . . . 76
Wire harnesses - Electrical schematic sheet 07 Engine Power Distribution and Fuel Pump, EH Units (*) . . . . . . 78
Wire harnesses - Electrical schematic sheet 08 Throttle Sensors, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Wire harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 82
Wire harnesses - Electrical schematic sheet 10 Hydraulic Interlocks, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Wire harnesses - Electrical schematic sheet 11 Loader Valve and Sensors, EH Units (*) . . . . . . . . . . . . . . . . . . . . 86
Wire harnesses - Electrical schematic sheet 12 Cab to Chassis Interface, EH Units (*) . . . . . . . . . . . . . . . . . . . . . 88
Wire harnesses - Electrical schematic sheet 15 Cab Console Switches, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . 94
Wire harnesses - Electrical schematic sheet 16 Left Hand Control Handle, EH Units (*) . . . . . . . . . . . . . . . . . . . . . 96
Wire harnesses - Electrical schematic sheet 17 Right Hand Control Handle, EH Units (*) . . . . . . . . . . . . . . . . . . . 98
Wire harnesses - Electrical schematic sheet 18 Seat Switch, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Wire harnesses - Electrical schematic sheet 19 Unit Control Module, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 102
Wire harnesses - Electrical schematic sheet 20 Unit Control Module, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 104
Wire harnesses - Electrical schematic sheet 21 Lamps, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Wire harnesses - Electrical schematic sheet 22 Indicators, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Wire harnesses - Electrical schematic sheet 23 Turn Signal and Work Lights, EH Units (*) . . . . . . . . . . . . . . . . . 110
Wire harnesses - Electrical schematic sheet 24 Roading Lights, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Wire harnesses - Electrical schematic sheet 25 Wipers and Washers, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 114
Wire harnesses - Electrical schematic sheet 26 Instrument Cluster, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Wire harnesses - Electrical schematic sheet 27 HVAC, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Wire harnesses - Electrical schematic sheet 28 Radio, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Wire harnesses - Electrical schematic sheet 29 Case Front Lights, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Wire harnesses - Electrical schematic sheet 30 Multi-Function Loader Arm, EH Units (*) . . . . . . . . . . . . . . . . . . . 124
Wire harnesses - Electrical schematic sheet 31 Telematics, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Wire harnesses - Electrical schematic sheet 32 Enhanced High Flow, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 128
Wire harnesses - Electrical schematic sheet 33 Multi-Function ON/OFF, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . 130
Wire harnesses - Electrical schematic sheet 34 2nd Aux, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Wire harnesses - Electrical schematic sheet 35 Diagnostic Connector, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . 134
Wire harnesses - Electrical schematic sheet 36 Fuel Filter Jumper, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Wire harnesses - Electrical schematic sheet 37 NH Front Lights, EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Fuse and relay box - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Fuse and relay box - Testing – Universal Control Module (UCM) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Fuse and relay box Fuse - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Fuse and relay box Relay - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Wire connectors - Component Diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Wire connectors - Component Diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
47540694 28/04/2014
55.11 [55.100] / 335
Wire connectors - Component diagram – Connectors A – Z (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Wire connectors - Component diagram – Connectors A – Z (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Wire connectors - Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
47540694 28/04/2014
55.11 [55.100] / 336
Wire connectors - Component diagram – Grounds (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Wire connectors - Component diagram – Grounds (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Wire connectors - Component localisation - Deluxe cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Wire connectors - Component localisation - Deluxe cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Wire harnesses - Electrical schematic sheet 01 Main Power Distribution, Mechanical Units (*) . . . . . . . . . . . . . . . . 6
Wire harnesses - Repair (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Wire harnesses - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
47540694 28/04/2014
55.11 [55.100] / 337
47540694 28/04/2014
55.11 [55.100] / 338
Battery - 302
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.12 [55.302] / 1
Contents
Battery - 302
SERVICE
Battery
Check Maintenance Free (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disconnect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
47540694 28/04/2014
55.12 [55.302] / 2
Electrical systems - Battery
Battery - Check Maintenance Free

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
During normal use of a vehicle the battery is constantly being discharged, and recharged by the vehicle electrical
systems. This process causes evaporation of the battery electrolyte. Maintenance free batteries have condenser
channels that allow the gases to condense into liquids again. This prevents the gases from escaping through vent
holes so there is no requirement to top off the electrolyte.
The following procedure will tell if a battery is fit for service or if it must be replaced.
1. Inspect the battery before testing. Many conditions can

be seen and corrected before battery problems occur.
Inspect the battery case for cracks and leaks. Inspect
the battery posts, cables and clamps for broken wires,
loose connections and corrosion. Make sure the top
of the battery is clean and dry. Dirt or electrolyte on
top of a battery can cause the battery to discharge.
This material on the top of a battery provides a path
for current to flow, permitting the battery to discharge.
2. Remove the battery from the vehicle. Clean the outside
of the battery. Also, clean the battery tray. When clean-
ing a battery, use a solution of baking soda and water.
Check and clean the battery cables if necessary.
3. Check the battery carrier to make sure the carrier is
in good condition. Check the battery brackets for the
correct tension. A loose battery bracket will allow the
battery to vibrate. Vibration will damage the battery.
Battery brackets which are too tight can buckle or crack
the battery case.
4. Check the battery for raised cell covers or a warped
case. This may indicate that the battery has been over-
heated or overcharged.
5. Using a multi-meter check the battery voltage. A read-
ing of less than 11.6 volts indicates the battery should
be charged using a battery charger. If battery voltage
is unable to be raised to approximately 12.4 volts, the
battery should be replaced.
47540694 28/04/2014
55.12 [55.302] / 3
Battery - Disconnect
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Heavy objects!
W0398A
WARNING
Hazardous chemicals!
Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation
and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash
hands after handling.
W0006A
WARNING
Chemical hazard!
When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spill
through the vent caps. Lift a plastic-cased battery with a battery carrier or with your hands positioned
on opposite corners of the battery. Always wash your hands after handling.
W0385A
Disconnect battery
1. Remove battery access cover (2) by removing the
mounting bolts (1).
931001637 1
2. Turn battery disconnector (1) —if equipped— to the off

position (2).
931001638 2
47540694 28/04/2014
55.12 [55.302] / 4
3. Disconnect negative battery cable connection (1).
931001641 3
4. Disconnect positive battery connection (1).
931002054 4
47540694 28/04/2014
55.12 [55.302] / 5
Battery - Remove
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Heavy objects!
W0398A
WARNING
W0006A
WARNING
Chemical hazard!
W0385A
Battery removal
1. Remove the battery cover hardware (1) and the battery
cover (2).
931001637 1

position (2).
931001638 2
47540694 28/04/2014
55.12 [55.302] / 6
3. Disconnect the negative cable connection (1).
931001641 3
4. Disconnect the positive cable connection (1).
931002054 4
5. Loosen the nuts (1), and remove the battery hold-down

(2).
931001639 5
6. Remove the battery (1) in direction of the arrow.
931001642 6
47540694 28/04/2014
55.12 [55.302] / 7
Battery - Install
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Heavy objects!
W0398A
WARNING
W0006A
WARNING
Chemical hazard!
W0385A
Battery installation
1. Confirm that the battery quick disconnector (1) is in the
off position (2), as shown.
NOTE: The battery disconnector is optional.
931001638 1
2. Place the battery (1) in the compartment, in the direc-

tion of the arrow.
931001642 2
47540694 28/04/2014
55.12 [55.302] / 8
3. Install the battery hold-down (1), and secure with the

nuts (2).
931001640 3
4. Insure that the hold-down (1) is square to the battery

(2).
931001639 4
5. Connect the positive cable connection (1).
931002054 5
6. Connect the negative cable connection (1).
931001641 6
47540694 28/04/2014
55.12 [55.302] / 9
7. Turn the battery quick disconnector (1) to the on posi-

tion (2) as shown.
NOTE: The battery disconnector is optional.
931001828 7
8. Install the battery cover (2) and secure with the hard-
ware (1).
931001637 8
47540694 28/04/2014
55.12 [55.302] / 10
Battery - Connect
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Heavy objects!
W0398A
WARNING
W0006A
WARNING
Chemical hazard!
W0385A
Connect battery
position (2).
931001638 1
2. Connect the positive battery connection (1).
931002054 2
47540694 28/04/2014
55.12 [55.302] / 11
3. Connect the negative battery connection (1).
931001641 3
4. Turn the battery disconnector (1)— if equipped— to the

on position (2).
931001828 4
47540694 28/04/2014
55.12 [55.302] / 12
Index
Battery - 302
Battery - Check Maintenance Free (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery - Connect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery - Disconnect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
47540694 28/04/2014
55.12 [55.302] / 13
47540694 28/04/2014
55.12 [55.302] / 14
External lighting - 404
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.13 [55.404] / 1
Contents
FUNCTIONAL DATA
Work light
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview Resistance devices (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47540694 28/04/2014
55.13 [55.404] / 2
Electrical systems - External lighting
Work light - Overview

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
Switches are a vital part of an electric circuit.
Switches may be configured to provide operator or operational information to an electronic controller or switches may
be used to control circuit operation indirectly by energizing a control relay or switches may control the operation of a
functional device directly by completing the power or ground side of the control circuit.
Switches can be configured to control a number of different functional devices at the same time and / or multiple
functional devices one at a time. This is achieved by having several separate functional devices connected to a single
switch terminal or by having each of the separate functional devices connected to a different terminal (multiple switch
positions).
RAPH12SSL0690BA 1
Operator controlled switches are typically toggle, rocker or potentiometer type devices. They may contain momentary
and / or maintained contact arrangements, they may have more than two positions and may incorporate warning,
position and / or backlighting.
Switches can be as simple as a two position maintained contact rocker type used to turn on or turn off the hazard
warning lights (switch also incorporates a warning light which illuminates when the hazard warning position is ac-
tuated) or as complex as the multi-position, multifunction, maintained and momentary contact selector type used to
operate the parking lights, head lights to include high and low beam control, direction indicators and horn operation.
Checking the operation of most of the operator controlled switches can be accomplished by using a multi-meter to
test for continuity through the appropriate switch contacts, once the switch connector has been disconnected and the
switch has been actuated or de-actuated.
NOTE: A growing number of mechanically controlled devices are incorporating electronics to replace mechanical
contacts and to allow for non-contact sensing. These devices are referred to as Sensors rather than Switches and
often cannot be continuity tested with a multi-meter.
47540694 28/04/2014
55.13 [55.404] / 3
Electrical systems - External lighting
Work light - Overview Resistance devices

C232 NA
C238 NA
L223 TIER 4 [NDM474381 - ] NA
L225 NA
L230 NA
1Z0O2004112128 1
A number of electrical components alter or make use of electricity through their resistance to current flow. Resistors
are components which are generally used to regulate the supply of voltage and current to other electrical components.
In some cases, the purpose of resistance in an electrical circuit is to provide light or heat. Lamps and cigar lighters
(where equipped) are examples. Lamps convert electricity into light, and cigar lighters convert it into heat. Both lamps
and lighters make use of the same physical principle, that is Ohms Law.
Where applicable, the engine grid heater and heated cab mirrors are other examples of resistance devices designed
to convert electricity into heat.
47540694 28/04/2014
55.13 [55.404] / 4
Index

Work light - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Work light - Overview Resistance devices (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47540694 28/04/2014
55.13 [55.404] / 5
47540694 28/04/2014
55.13 [55.404] / 6
Cab controls - 512
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.14 [55.512] / 1
Contents
Cab controls - 512
TECHNICAL DATA
Instrument cluster
Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Cigarette lighter
Overview Resistance devices (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
47540694 28/04/2014
55.14 [55.512] / 2
Electrical systems - Cab controls
Instrument cluster - Configure

Use the four switch buttons to navigate through the instrument cluster Menu by following the setup menu functions.
(1) TEXT DISPLAY
Displays the menu text.
(2) START
Navigates selections on every menu level.
Certain menus will prompt the user to enter an access
code or allow the user to change a numerical value.
NOTE: Pushing the Start button will increment the flash-
ing digit 1,2,3 for number entry.
(3) OPERATE
Increments the flashing digit 7,8,9,0 for number entry.
(4) AUX OVERRIDE

Exits the sub-menu and moves top level to the next
option.
Increments the flashing digit 4,5,6 for number entry.
(5) POWER
For number entry, moves flashing digit to the next place.
Saves entry.
Enters the sub-menu.
931002267 1
Top level menu options

• EXIT - Exit the setup menu.
• EH - Customize the speed of the machine’s Electro hydraulic controls (if equipped).
• dSPLY - Alternate method to select between the selected display parameters.
• UNITS - Allows the operator to select between Fahrenheit/Imperial units and Celsius/SI units.
• JTIME - Job timer. Timer that displays engine operating hours since last reset. Ideal for rentals or job tracking.
• dPF or REGEN - Used to Inhibit regeneration of the Diesel Particulate Filter (DPF) for one key cycle.
• OIL - Used to reset the oil life monitoring status after an oil change.
• LOCK - Used to create/change owner and user codes
NOTE: The Advanced Instrument Cluster (AIC) images are shown in this section for the four switch buttons (2), (3),
(4) and (5) used to navigate through the instrument cluster. The top two switch buttons on the Electronic Instrument
47540694 28/04/2014
55.14 [55.512] / 3
Cluster (EIC) are function buttons and function the same as the POWER (5) and START (2) switch buttons on the
AIC instrument panel for the setup menu functions.
Entering the SETUP mode

1. Place the machine on firm, level ground with the lift
arm and bucket down.
NOTE: For machines with the Electronic Instrument
Cluster (EIC); you will need the key for these proce-
dures.
2. Before sitting in the seat, push and hold the OPERATE
button (3) and the AUX OVERRRIDE button (4) for five
seconds until the display (1) shows the word SETUP.
3. You may now sit down and navigate through the
SETUP menu. Familiarize yourself with the use of
the switch buttons in order to help prevent erroneous
settings.
931002267 2
Text display
The operator may choose a continuous display of one of the four following parameters or select cycle from the
dSPLY top level menu and momentarily display all four of the parameters in a cycle for a few seconds each.
• ENHRS - Engine hours.
• ENRPM - Engine RPM.
• COOLT - Engine coolant temperature.
• HOILT - Hydraulic fluid temperature.
• CYCLE - Cycle though all four parameters.
Change or select from the dSPLY level menu

NOTE: The instrument cluster is programmed to display the last setting selected when you sit in the seat.
47540694 28/04/2014
55.14 [55.512] / 4
Once in the SETUP menu, press the START button until

dSPLY appears on the screen.
1. Push the POWER button (5) to display the current se-
lection.
2. Push the START button (2) to toggle through the se-
lections.
3. Once the desired selection appears on the text display,
push the POWER button (5) to save the selection.
931002267 3
47540694 28/04/2014
55.14 [55.512] / 5
Setting controllability for Electro Hydraulic (EH)

All changes must be made with the engine in the off position and the electronics asleep.
1. Before sitting in the seat, press and hold the AUX
OVERRIDE button (4) and the OPERATE button (3) at
the same time for five to seven seconds until SETUP
(1) appears in the display. After seeing setup in the
display, you may sit in the operator’s seat and make
changes.
2. Press the START button (2) to scroll between the dif-
ferent menus until EH (1) appears on the display.
3. Press the POWER button (5) to enter the next menu.
4. Press the START button (2) to scroll to the setting se-
lection you want to adjust (Speed: Drive, Lift, or Tilt)
or (CTLR: Drive or L-ARM), then press the POWER
button (5) to save the entry. For DFLT, press the
POWER button (5) to save the settings back to the fac-
tory default settings. The default settings are shown in
tables for each model on the following pages.
NOTE: Use the AUX OVERRIDE button (4) when you
want to go up a level.
5. Press the START button (2) to scroll to the desired
speed level (High, Med-2, Med-1, or Low) or (DRV1,
DRV2, or DRV3) or (LDR1, LDR2, or LDR3), then
press the POWER button (5) to save the entry.
6. After you have saved your selection; the monitor will
revert back to step 3 so you can make another ad-
justment. If no other adjustments are needed, use the
AUX OVERRRIDE button (4) to exit the machine func-
tion menu. You will now be in the main SETUP menu;
use the START button (2) to scroll to EXIT and then
push the POWER button (5) again to exit the setup
menu.
7. Leave the operator’s seat for ten seconds before trying
to start the unit.
931002267 4
47540694 28/04/2014
55.14 [55.512] / 6
Setting controllability with Easy-Electro Hydraulic (EZ-EH)

The Easy Electro Hydraulic ( EZ-EH) machines have the
EZ-EH information sign (A) located at the top of the in-
strument cluster on the right-hand column. The following
instructions are for the shortcut to the Electro Hydraulic
(EH) setup. Use these settings to set the speed of the
drive , lift and tilt. Also the drive and loader lift arm set-
tings.
NOTE: All changes must be made with the hydraulics dis-
abled and the operator in the operator’s seat.
RAIL13SSL0751BA 5
RAIL13SSL0990EA 6
EZ-EH guide
EZ-EH settings
C = custom M = medium
L = low H = high
47540694 28/04/2014
55.14 [55.512] / 7
1. Press and hold the AUX OVERRIDE button (1) for two
seconds to enter the EH shortcut menu.
2. SPEEd will display on the display (2). Press the AUX
OVERRRIDE button (1) to select a different menu item
( DRIVE, EXIT, HOUR, HOILT, COOLT, RPM, or CY-
CLE).
3. Press the OPERATE button (3) to enter the SPEEd
menu. The current setting will be displayed.
4. Press the AUX OVERRRIDE button (1) to change the
SPEEd setting.
5. Press the OPERATE button (3) to save a new setting.
If EXIT is selected, you will exit back to the top menu
level.
NOTE: If a new setting is saved, SAVEd will be dis-
played and you will exit to the top level shortcut menu.
NOTE: The CTRL menu works the same as the above
SPEEd menu.
Customize settings
• Custom settings SP-C and CR-C allow you to fully cus-
tomize the EH settings using the setup menu.
• SP-C sets to the SETUP menu SPEEd settings:
DRIVE, LIFT, and TILT. CR-C sets to setup menu
CRTL settings DRIVE and L-ARM.
• If you do not use the SETUP menu to customize set-
tings, SP-C and CR-C will be set by default to:
For a new machine from the factory, the custom settings
will be set to the factory default settings from before
August 2013. Shown in the following table.
For a machine updated in the field, the custom settings
will be set to the customer’s EH settings at the time of
the software upgrade.
931002267 7
47540694 28/04/2014
55.14 [55.512] / 8
Select Celsius or Fahrenheit temperature scales

UNITS appears on the screen.
1. Push the POWER button (5) to drop down into the

sub-menu. Fahrenheit or Celsius will appear in the
display.
2. Push the START button (2) to select the temperature
scale desired.
3. Once the selected scale appears on the display (1),
push the POWER button (5). The display (1) will blink
OFF then ON and show the selected temperature
scale.
4. To exit, press START button (2) until the display (1)
shows the word EXIT.
5. With EXIT in the display (1) press the POWER button
(5) to return to normal operation.
931002267 8
47540694 28/04/2014
55.14 [55.512] / 9
Select a job timer

The operator may choose to set a timer that will run independent from the machine hours. To view or reset the timer:
JTIME appears on the screen.
1. Push the POWER button (5) to view the current timer.
2. Push the START button (2) to reset or view the timer.
3. Use the POWER button (5) to save the selection.
931002267 9
47540694 28/04/2014
55.14 [55.512] / 10
Inhibit Diesel Particulate Filter (DPF) regeneration

The regeneration inhibit selection display allows the operator to turn off the auto regeneration procedure during the
current key cycle.
NOTE: The regeneration inhibit feature returns to the enable setting by default at the next key cycle.
NOTE: Operators that continue to disable the regeneration procedure will eventually de-rate the engine’s performance.
NOTE: The LCD display reads dPF INHIb or REGEN INHIb for five seconds every five minutes with an audible alarm.
dPF or REGEN appears on the screen.
1. Push the POWER button (5) to view INHIB on the dis-
play (1) .
2. Push the START button (2) to toggle between the
choices.
3. Push the POWER button (5) to save the current dis-
play selection.
931002267 10
47540694 28/04/2014
55.14 [55.512] / 11
Oil life reset

To reset the oil life monitoring feature.
OIL appears on the screen.
1. Push the POWER button (5) to view RESET on the
display.
2. Push the START button (2) to reset the oil life.
3. Push the POWER button (5) to save.
931002267 11
47540694 28/04/2014
55.14 [55.512] / 12
Anti-theft operation
Locking the instrument panel

If a lock code has been entered; immediately after shutting off the engine the display will show lock? and the AUX
OVERRIDE button will flash. Anti-theft is set by pressing the AUX OVERRIDE button. The panel is now locked
and LOCKd is displayed. Restarting requires entering the code. If the AUX OVERRIDE button is not pressed, the
machine can be started without a code. The panel does not automatically lock. If a lock code has not been entered;
when the engine is shut off the display will not show “ lock?” and the engine can be started without a code until a lock
code is entered.
Unlocking the instrument panel
1. Sit in the seat to power the instrument panel. The
warning lamps will illuminate and there will be an au-
dible beep.
2. Press the flashing POWER button (5). The display (1)
will show unloc.
3. Enter code by using multiple presses of the START
button (2), AUX OVERRIDE button (4), and OPER-
ATE button (3) . Press the POWER button (5) to save
each digit and move to the next.
NOTE: For numbers 1, 2, 3 use the START button.
For numbers 4, 5, 6 use the AUX OVERRIDE button.
For numbers 7, 8, 9, 0 use the OPERATE button.
4. Press the POWER button (5) after the fifth digit to enter
the code. The engine preheat lamp will illuminate and
the display (1) will begin the thirty second countdown.
NOTE: If the incorrect code is entered, ERROR is dis-
played, followed by 00000 prompting the operator to
enter the correct code.
931002267 12
If no owner code has been created

If you decide you do not want to create a code, enter all 0s. You will return to OWNCR.
Creating codes
The panel cannot be locked until a code is created. The instrument panel has one owner code and up to ten user
codes. The owner code will always unlock the panel. The owner code will be required to create or change user codes
and to modify the owner code.
47540694 28/04/2014
55.14 [55.512] / 13
Owner code
Once in the SETUP menu, press the START button to move to the LOCK menu. Press the POWER button to enter
the LOCK menu.
Create an owner code

If no owner code exists, the display will show the word OWNCR (Owner Create), followed by 00000 . Write down the
planned 5 digit code or use a code you already know.
NOTICE: Once the code is created, the panel cannot be unlocked with out the code. If the panel cannot be unlocked,
contact your Dealer.
1. Enter code by using multiple presses of the START
button (2), AUX OVERRIDE button (4), and OPER-
ATE button (3). Press the POWER button (5) to save
each digit and move to the next.
2. Press the POWER button (5) after the fifth digit to enter
the code. The engine preheat lamp will illuminate and
the display will begin the thirty second countdown.
3. Press the START button (2) to move to the exit menu,
and press the POWER button (5) to exit the SETUP
menu. The panel is not locked at this point.
931002267 13
If an owner code has been created and LOCK function is disabled

NOTE: You can turn the lock function ON and OFF by pressing the POWER button.
If you cannot remember or enter an incorrect code, you will return to OWNCR.
47540694 28/04/2014
55.14 [55.512] / 14
Modify the owner code

Once in the LOCK menu, the display will show OWNER.
Press the POWER button to enter the OWNER menu.
The display will show open followed by 00000.
1. Enter the current owner code by using multiple
presses of the START button (2), AUX OVERRIDE
button (4), and OPERATE button (3). Press the
POWER button (5) to save each digit and move to the
next.
2. Press the POWER button (5) after the fifth digit to save
the code. The display (1) will show the word OWNCR
followed by the saved owner code.
3. Enter a new owner code to overwrite the existing code.
The panel will return to the SETUP menu.
931002267 14
47540694 28/04/2014
55.14 [55.512] / 15
User codes
Once in the SETUP menu, press the START button to move to the LOCK menu. Press the POWER button to enter
the LOCK menu.
Create or modify a user code

NOTE: An owner code must be saved before a user code.
Once in the LOCK menu, the display will show the word
OWNER. Press the START button to move to the USER
menu.
1. Use the START button (2) to move to user0 through
user9. Press the POWER button (5) to create or
change that user code. The display (1) will show the
word USRCR (user create) followed by 00000 .
2. Enter the owner code. 00000 or the existing user code
will be displayed.
3. Enter a new user code to enter or overwrite the existing
code. The panel will return to the SETUP menu.
4. Press the START button (2) to move to the EXIT menu,
and press the POWER button (5) to exit the SETUP
menu. The panel is not locked at this point.
931002267 15
47540694 28/04/2014
55.14 [55.512] / 16
Cigarette lighter - Overview Resistance devices

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1Z0O2004112128 1
A number of electrical components alter or make use of electricity through their resistance to current flow. Resistors
are components which are generally used to regulate the supply of voltage and current to other electrical components.
In some cases, the purpose of resistance in an electrical circuit is to provide light or heat. Lamps and cigar lighters
(where equipped) are examples. Lamps convert electricity into light, and cigar lighters convert it into heat. Both lamps
and lighters make use of the same physical principle, that is Ohms Law.
Where applicable, the engine grid heater and heated cab mirrors are other examples of resistance devices designed
to convert electricity into heat.
47540694 28/04/2014
55.14 [55.512] / 17
Index
Cab controls - 512

Cigarette lighter - Overview Resistance devices (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Instrument cluster - Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
55.14 [55.512] / 18
Cab engine controls - 525
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.15 [55.525] / 1
Contents
FUNCTIONAL DATA
Throttle control
Overview Potentiometers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
55.15 [55.525] / 2
Electrical systems - Cab engine controls
Throttle control - Overview Potentiometers

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
20095585 1
The Fuel level sensing device contains a potentiometer (1) that is attached to the fuel return (2) and supply (not used)
(3) tubes and controlled by the movement of a float (4) attached to the potentiometer actuator arm (5).
93095586 2
1Z0O2004112130 3
47540694 28/04/2014
55.15 [55.525] / 3
Electrical systems - Cab engine controls
47540694 28/04/2014
55.15 [55.525] / 4
Index

Throttle control - Overview Potentiometers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
55.15 [55.525] / 5
47540694 28/04/2014
55.15 [55.525] / 6
FAULT CODES - DTC
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
55.16 [55.DTC] / 1
Contents
FAULT CODES - DTC
DIAGNOSTIC
1002-Engine Coolant Temperature Sender - Over Temperature >110° C . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1004-Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1009-Hydraulic Oil Temperature Sender - Over Temperature >210° F . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1014-Cluster Battery Monitor: Over Voltage > 16.5 volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1015-Cluster Battery Monitor: Under Voltage < 11.5 volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1025-Throttle Sensor - Out Of Range Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1026-Hand Throttle Signal Out Of Range - Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1030-Throttle Sensor - Out Of Range Short to Ground/ Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1031-Hand Throttle Sensor - Short To Ground/ Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1040-Engine overspeed warning, Engine speed greater than 2750 RPM for 5 seconds . . . . . . . . . . . . . 44
1041-RPM Monitoring - Over Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1045-Fuel Level Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1051-Timeout of CAN message EEC1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1053-Timeout of CAN message CM1BC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1054-Timeout of CAN message engine temperature, 5 seconds without message . . . . . . . . . . . . . . . . . 55
1056-Timeout of CAN message DPFC1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1058-Timeout of CAN message EDC2BC, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1059-Timeout of CAN message DM1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1201-Hydraulic oil filter switch open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1202-RPM Monitoring - Over Speed (Max) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1203-RPM Monitoring - Open Circuit/ Short to Ground/ Short to Power Mechanical Units (*) . . . . . . . . 62
1203-RPM Monitoring - Open Circuit/ Short to Ground/ Short to Power EH Units (*) . . . . . . . . . . . . . . . . 65
1205-Hydraulic Enable (EH Machines) - Hydraulic Enable Output, Short to Power (*) . . . . . . . . . . . . . . 67
1206-CAN Connection: Configuration Response Timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1207-Memory Parameters - Invalid Configuration Between IC and UCM (*) . . . . . . . . . . . . . . . . . . . . . . . 70
1208-Seat Switch - Plausibility Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1211-Calibration Functions - Joystick Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1212-Calibration Functions - Ground Drive Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1213-Calibration Functions - Loader Valve Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 77
47540694 28/04/2014
55.16 [55.DTC] / 2
1214-Calibration Functions - Throttle Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1221-Health Monitor Functions - UCM - UCM Temperature / Current Draw Over Limit (*) . . . . . . . . . . . 79
1222-Health Monitor Functions - UCM - UCM Sustained Over Temperature Limit (*) . . . . . . . . . . . . . . . 80
1223-Health Monitor Functions - UCM - UCM Sustained Over Current Limit (*) . . . . . . . . . . . . . . . . . . . . 81
1224-Health Monitor Functions - UCM - Internal Memory or Core Monitoring Fault (*) . . . . . . . . . . . . . . 82
1225-Health Monitor Functions - UCM - EEPROM Memory Checksum Fault (*) . . . . . . . . . . . . . . . . . . . 83
1350-Hyd Enable Switch - Implausible State (Hardwire vs CAN) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1511-Right Brake Lights Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1512-Right Brake Lights Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1513-Right Brake Lights Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1521-Left Brake Lights Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1522-Left Brake Lights Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1523-Left Brake Lights Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1532-Backup Alarm - Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1533-Backup Alarm - Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1900-UCM - UCM Ground Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1901-UCM - UCM Supply Voltage High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1902-UCM - UCM Supply Voltage Low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1903-UCM - UCM Supply Voltage Below Operational Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1904-UCM - Rail 12VB: 5V Regulators Supply Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1905-UCM - 5VREF1 Sensor Supply Voltage Out of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1906-UCM - 5VREF3 Sensor Supply Voltage Out of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1907-UCM - Rail 12VF1: Aux Retract Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1908-UCM - Rail 12VF2: Bucket Extend Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1909-UCM - Rail 12VF3: Boom Raise/Lower Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1910-UCM - Rail 12VH: Ldr Plt Interlk & Port Lock Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1911-UCM - Rail 12VH1: Left & Right Pump Reverse Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . 121
1912-UCM - Rail 12VM: Left & Right Brake Lights & Aux Extend Input Power Off (*) . . . . . . . . . . . . . . 123
1913-UCM - Rail 12VS1: Bucket Curl Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1914-UCM - Rail 12VS2: Backup Alarm Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1915-UCM - Rail 12VT1: Two Speed Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1916-UCM - Rail 12VU1: Right & Left Pumps Forward Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . 131
1917-UCM - Rail 12VU2: Park Brake Solenoid Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3007-Engine Coolant Temperature Sender - Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3008-Engine Coolant Temperature Sender - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3010-Air intake temperature sensor signal above maximum range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3011-Air intake temperature sensor signal below minimum range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3027-Oil pressure signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3051-Battery Voltage To Engine Controller - Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3052-Battery Voltage To Engine Controller - Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3059-ECM afterrun was interrupted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
47540694 28/04/2014
55.16 [55.DTC] / 3
3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3088-Crankshaft Sensor - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3089-Crankshaft Sensor - Invalid Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3090-Camshaft Sensor - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3091-Camshaft sensor - Invalid signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3093-Offset Between Camshaft And Crankshaft - Outside Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3096-ECM Busoff on vehicle CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3104-Rail Pressure Relief Valve - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3105-Rail Pressure Relief Valve - Pressure Shock Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3106-Rail Pressure Relief Valve - Did Not Open After Pressure Shock . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3107-Fuel Metering Unit - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3108-Fuel Metering Unit - Short Circuit to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3137-Metering Unit - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3139-Metering Unit Signal Range Check - Signal Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
3140-Metering Unit Signal Range Check - Signal Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3141-Set point of fuel volume flow through metering unit is lower than calculated limit . . . . . . . . . . . . . 187
3146-Water detected in fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3157-CAN Engine Timeout SCH Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3158-Engine controller configuration error anti-tamper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3166-Fuel filter heater relay - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3167-Fuel Filter Heater Relay - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3168-Fuel filter heater relay - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3169-Fuel filter heater relay - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3176-Setpoint of metering unit not plausible in overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3177-Engine overspeed detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3179-Timeout of CAN Message BC2EDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
3180-Timeout of CAN Message VCM2EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3182-Timeout Of CAN Message RxCCVS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3188-Cylinder 1 Warning - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3210-Bank 1 - General Short Circuit To Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3218-Bank 2 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3230-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3235-Number of Injections Limited - by Charge Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3236-Number of Injections Limited - by Quantity Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
47540694 28/04/2014
55.16 [55.DTC] / 4
3237-Number of Injections Limited - by Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3238-Communication error of CJ940 processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3239-Engine Controller EEPROM - Read Operation Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
3240-Engine controller EEPROM - Write operation failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3241-Engine controller EEPROM - Default value used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3242-Engine Controller (Locked) Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3243-Engine Controller Recovery (Suppressed) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3244-Engine Controller Recovery (Visible) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3245-Engine Controller - Watchdog Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3252-Controller Watchdog - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3253-ADC Monitoring - Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3255-ADC Monitoring Test Impulse Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
3256-ADC Monitoring Queue Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3260-Low side power - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
3261-Low side power - short circuit to battery or excess temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3262-Low side power - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
3265-Overrun Monitoring - Injection Time Too Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3266-Error in engine speed check, speed signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3283-Sensor Supply Voltage 2 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3285-Sensor Supply Voltage 3 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3293-Fuel Metering Unit: maximum positive deviation of rail pressure exceeded . . . . . . . . . . . . . . . . . . 246
3301-Fuel high pressure pump is at minimum delivery and the Rail pressure is not reducing . . . . . . . 247
3305-Cannot maintain rail pressure above the minimum pressure of 200 Bar . . . . . . . . . . . . . . . . . . . . . 248
3309-Maximum Fuel rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
3334-Timeout of CAN Message TSC1 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
3335-Timeout of CAN message TSC1-PE torque (when inactive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
3338-Timeout of CAN message TSC1-VE speed (when inactive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3339-Timeout of CAN message TSC1-VE speed (when active) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
3350-Terminal 50 - always on, starting circuit signal is active for an excessive time period . . . . . . . . . 257
3358-CAN transmit timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3361-ECM EEPROM - General Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
3362-Torque to Quantity Map - Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3368-Torque limitation due to performance limiter, may be triggered by inducement . . . . . . . . . . . . . . . 261
3369-Torque reduction due to smoke reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
3370-Torque limitation due to engine protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3371-Torque limitation due to Fuel quantity Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
3374-Unit injector NEMA codes are invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
3390-Engine Air Filter Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3390-Engine Air Filter Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
3402-Rail pressure sensor: maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
3403-ECU Power Stages: Starter relay HS power stage over temperature . . . . . . . . . . . . . . . . . . . . . . . 271
3405-ECU Power stages: Open load temperature error on the Turbocharger PWM output power stage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
47540694 28/04/2014
55.16 [55.DTC] / 5
3406-ECU Power stages: Over temperature error on the Turbocharger PWM output power stage . . . 275
3408-Lambda sensor: Oxygen concentration implausibly high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3409-Oil pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
3410-Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
3414-Short circuit in cylinder 1 glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3418-ECU Power stages: SCB error on the Turbocharger PWM output power stage . . . . . . . . . . . . . . 291
3419-ECU Power stages: SCG error on the Turbocharger PWM output power stage . . . . . . . . . . . . . . 293
3420-CAN Bus Received frames: DFC of Auxiliary Engine Shutdown Switch Message . . . . . . . . . . . . 295
3425-Turbocharger: Over boost deviation at P2 too high in pressure charger regulator . . . . . . . . . . . . 296
3426-Low efficiency in DPF filter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
3427-Diesel particulate filter (DPF): Signal range check flow resistance of the particulate filter - low (*) 298
3428-Diesel Particulate Filter Pressure sensor: not plausibility error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 299
3429-Diesel Particulate filter Pressure sensor: hoseline plausibility error (*) . . . . . . . . . . . . . . . . . . . . . . 300
3430-EGR Inducement less severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3431-Exhaust Gas Recirculation (EGR) inducement most severe derating level . . . . . . . . . . . . . . . . . . 302
3432-Exhaust Gas Recirculation (EGR) inducement warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
3433-Diesel Particulate Filter (DPF) inducement less severe derating level . . . . . . . . . . . . . . . . . . . . . . 304
3434-Diesel Particulate Filter (DPF) inducement most severe derating level . . . . . . . . . . . . . . . . . . . . . . 305
3435-Diesel Particulate Filter (DPF) inducement warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
3517-Ambient air temperature sensor failure (of humidity sensor) - signal too high . . . . . . . . . . . . . . . . 307
3518-Ambient air temperature sensor failure (of humidity sensor) - signal too low . . . . . . . . . . . . . . . . . 308
3616-Torque limitation due to turbo charger protection high altitude operation related . . . . . . . . . . . . . 309
3648-EVGT Boost pressure monitoring for over boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3650-Battery voltage: SRC high for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
3651-Battery voltage: SRC low for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3652-CAN Bus: Bus off of CAN node A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3655-Torque limitation, Engine protection: General report of the event of torque limitations . . . . . . . . 317
3656-Torque limitation, Engine protection: Torque limitation caused by particulate filter . . . . . . . . . . . . 318
3657-Timeout Error of CAN-Receive-Frame CM1BC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3659-Battery voltage: Power stage diagnosis could be disabled due to high battery voltage . . . . . . . . 320
3660-Battery voltage: Power stage diagnosis could be disabled due to low Battery voltage . . . . . . . . 321
3663-EGR command saturation over higher threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3664-EGR command saturation over lower threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
3667-Open load error for power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3668-Over temperature error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
47540694 28/04/2014
55.16 [55.DTC] / 6
3669-Short circuit to battery on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
3671-Short circuit to ground on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3673-Short circuit over load error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3674-Under voltage error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
3675-DFC for long time valve drift at closed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
3676-DFC for valve position sensor voltage SRC high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
3677-DFC for valve position sensor voltage SRC low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
3680-Injection cut off: Injection cut off demand (ICO) for shut off coordinator . . . . . . . . . . . . . . . . . . . . . 344
3688-Water sensor in the fuel filter: WIF sensor check is failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
3689-Faulty diagnostic data transmission or protocol error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
3691-No load error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
3692-Over temperature error on ECU power stage for glow plug low voltage system . . . . . . . . . . . . . . 349
3693-Short circuit to battery error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
3694-Short circuit to ground error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3695-Failure in glow plug cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
3699-EEPROM: Error in EEPROM block EEPData1, SD correction can not be calculated . . . . . . . . . 362
3702-Injection control: Detection of failed engine start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
3703-Injection control: check of minimum rail pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
3704-Injector adjustment programming: Check of missing injector adjustment value programming . . 365
3705-Injector adjustment programming: check of missing injector adjustment value programming . . . 366
3706-Injector adjustment programming: check of missing injector adjustment value programming . . . 367
3707-Lambda sensor: Open circuit at the lambda sensor Nernst cell pin . . . . . . . . . . . . . . . . . . . . . . . . . 368
3708-Lambda sensor: Open circuit at the lambda sensor pump current pin . . . . . . . . . . . . . . . . . . . . . . 370
3709-Lambda sensor: Open circuit at the lambda sensor virtual ground pin . . . . . . . . . . . . . . . . . . . . . . 372
3710-Lambda sensor: Fault to indicate dynamics of the sensor signal too small . . . . . . . . . . . . . . . . . . 374
3711-SCB error of the LSU Heater Power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
3712-Lambda sensor: SCG error of the LSU heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
3713-Lambda sensor: Open Load error of the LSU Heater Power stage . . . . . . . . . . . . . . . . . . . . . . . . . 380
3714-Lambda sensor: Fault code to indicate SRC High error for O2 calibration . . . . . . . . . . . . . . . . . . . 381
3715-Lambda sensor: SRC Low error for O2 calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
3716-Lambda sensor: O2 value above the max threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
3720-Lambda sensor: Low battery voltage at the SPI chip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
3721-Lambda sensor: Fault check to indicate SPI chip error of lambda sensor . . . . . . . . . . . . . . . . . . . 388
3722-Lambda sensor: LSU sensor temperature Ri exceeds the maximum limit . . . . . . . . . . . . . . . . . . . 389
3723-Lambda sensor: LSU sensor temperature Ri is below the minimum limit . . . . . . . . . . . . . . . . . . . . 390
3724-Lambda sensor: Short to battery at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
3725-Lambda sensor: Short to ground at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
47540694 28/04/2014
55.16 [55.DTC] / 7
3727-Low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
3728-Too low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
3735-Fuel Metering Unit: over temperature of device driver of metering unit . . . . . . . . . . . . . . . . . . . . . . 395
3736-O2 concentration is outside the predefined window during Heater coupling detection . . . . . . . . . 397
3737-Lambda sensor: Over temperature error of the LSU Heater Power stage . . . . . . . . . . . . . . . . . . . 398
3738-ECU Internal: Diagnostic fault check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
3739-Power stages, Injector: Loss of synchronization sending bytes to the MM from CPU . . . . . . . . . 400
3740-Power stages, Injector: DFC to set a torque limitation once an error is detected before MoCSOP's
error reaction is set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3741-Power stages, Injector: Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3742-Power stages, Injector: Too many SPI errors during MoCSOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3743-Power stages, Injector : Diagnostic fault check to report the error in under voltage monitoring . 404
3745-Power stages, Injector: Diagnostic fault check to report that WDA is not working . . . . . . . . . . . . 405
3746-Power stages, Injector: OS timeout in shutoff path test. Failure setting the alarm task period. . 406
3747-Power stages, Injector: Diagnostic fault check to report that the positive test failed . . . . . . . . . . . 407
3748-Power stages, Injector: Diagnostic fault check to report the timeout in the shutoff path test . . . . 408
3750-Injection control: Error in the plausibility of the injection energizing time . . . . . . . . . . . . . . . . . . . . 409
3751-Injection control: Error in the plausibility of the start of energizing angles . . . . . . . . . . . . . . . . . . . 410
3752-Zero Fuel Calibration (ZFC): Error in the plausibility of the energizing times of the zero fuel quantity
calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
3753-Level 2 Monitoring: Diagnostic fault check to report the error due to injection quantity correction 412
3754-Level 2 Monitoring: Diagnostic fault check to report the plausibility error in rail pressure monitoring
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
3755-Level 2 Monitoring: Diagnostic fault check to report the error due to torque comparison . . . . . . 414
3756-Level 2 Monitoring: Diagnosis fault check to report the demand for normal mode due to an error in
the post injection 2 quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
3757-Level 2 Monitoring: Diagnosis fault check to report the error to demand for an ICO due to an error
in the post injection 2 shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
3758-Level 2 Monitoring: Diagnosis fault check to report the error to demand for an ICO due to an error
in the post injection 3 efficiency factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
3759-Level 2 Monitoring: Diagnosis of current path limitation forced by Engine Control Unit (ECU) moni-
toring level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
3760-Level 2 Monitoring: Diagnosis air path limitation due to a functional control unit monitoring forced by
Engine Control Unit (ECU) monitoring level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
3761-Level 2 Monitoring: Diagnosis quantity path limitation due to a functional control unit monitoring (level
2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
3762-Level 2 monitoring: Reported overvoltage of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
3763-Level 2 monitoring: Reported under voltage of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
3764-Main Relay: Early opening defect of main relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
3766-Diesel particulate filter pressure sensor: Fault check for the pressure sensor plausibility (*) . . . 427
3767-ECU internal: Diagnostic fault check to report 'WDA active' due to errors in query-/response com-
munication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
3768-ECU Internal: Diagnostic fault check to report 'ABE active' due to under voltage detection . . . . 429
3769-ECU Internal: Diagnostic fault check to report 'ABE active' due to overvoltage detection . . . . . . 430
47540694 28/04/2014
55.16 [55.DTC] / 8
3770-ECU internal: Diagnostic fault check to report 'WDA/ABE active' due to unknown reason . . . . . 431
3771-Oxidation Catalyst: Up and down stream temperature sensors in Oxidation catalysts exchanged 432
3772-Turbocharger: Over boost deviation at P2 too high in pressure charge regulator . . . . . . . . . . . . . 434
3773-Turbocharger: Underboost detected in pressure charger regulator . . . . . . . . . . . . . . . . . . . . . . . . . 435
3786-Diesel particulate filter signal range check is high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
3787-Diesel particulate filter (DPF) : Signal range check flow resistance of the particulate filter - very high
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
3789-Regeneration duration exceeds maximum allowed duration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
3790-Diesel particulate filter: Signal range check flow resistance of the particulate filter - max (*) . . . 440
3794-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
3795-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
3796-Diesel particulate filter pressure sensor hose line error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
3797-Diesel particulate filter pressure sensor: SRC high for differential pressure sensor (*) . . . . . . . . 445
3798-Diesel particulate filter pressure sensor: SRC low for differential pressure sensor (*) . . . . . . . . . 447
3799-Pressure Relief valve: pressure relief valve is forced to open, perform pressure shock . . . . . . . 449
3800-Pressure relief valve: Quantity balance check if a successful PRV opening is ensured . . . . . . . 450
3801-Turbine upstream pressure sensor: SRC high for turbine upstream pressure sensor . . . . . . . . . 451
3802-Turbine upstream pressure sensor: SRC low for turbine upstream pressure sensor . . . . . . . . . . 453
3803-ECU internal: Error R2S2 module (low level chip driver for the power stage chips) . . . . . . . . . . . 455
3808-Fuel Metering Unit: set point of metering unit in idle mode not plausible . . . . . . . . . . . . . . . . . . . . 456
3810-Fuel pressure sensor: Rail pressure raw value is intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
3811-ECU sensor supply monitor : ECU internal: Error sensor supplies 1 . . . . . . . . . . . . . . . . . . . . . . . . 458
3812-Physical range check high for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
3813-Physical range check low for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
3814-ECU temperature sensor: SPI error ECU temperature sensor (LM71) . . . . . . . . . . . . . . . . . . . . . . 462
3815-Low efficiency in DPF filter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
3818-Open load error for power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
3820-Over temperature error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
3825-Short circuit over load error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
3826-Temperature dependent over current error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
3827-Under voltage error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
3830-DFC for valve position sensor physical SRC high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
3831-DFC for valve position sensor physical SRC low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
3834-ECU Power stages: Throttle valve actuator power stage: SRC High . . . . . . . . . . . . . . . . . . . . . . . 483
47540694 28/04/2014
55.16 [55.DTC] / 9
3835-ECU Power stages: Throttle valve actuator power stage: SRC low . . . . . . . . . . . . . . . . . . . . . . . . 484
3838-Oxidation catalyst upstream temperature shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . 485
3839-Oxidation catalyst upstream temperature shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
3840-Diesel particulate filter upstream temperature sensor shorted to high source (*) . . . . . . . . . . . . . 489
3841-Diesel particulate filter upstream temperature sensor shorted to low source (*) . . . . . . . . . . . . . . 491
3842-Turbine upstream temperature sensor shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
3843-Turbine upstream temperature sensor shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
3844-Zero fuel calibration by lambda (ZFL) : DFC reporting error state on comparing energizing time to
max value injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
min value injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
3852-Lambda sensor: The maximum allowed time for blow out is exceeded . . . . . . . . . . . . . . . . . . . . . 505
3870-CAN message not received from Vehicle Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
3899-Info: Engine temperature exceeded pre-warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
3900-Info: Engine temperature exceeded warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
3906-Injector: Number of injections is limited by quantity balance of high pressure pump . . . . . . . . . . 509
3910-Fuel metering unit: Error check for loose contact between metering unit and ECU . . . . . . . . . . . 510
3915-Pressure Relief Valve: Averaged rail pressure is outside the expected range with open PRV . . 511
4043-Hydraulic Oil Temperature Sender Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
4044-Hydraulic Oil Temperature Sender Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
4055-Park Brake Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
4056-Park Brake Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 519
4057-Park Brake Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
4061-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . . . . . 523
4062-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*) . . . 525
4071-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . . . . . 527
4072-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) . . . . 529
4081-Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*) . . . . 531
4082-Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground (*) . . 533
4083-Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . . . . . . 535
4309-Park Brake Button - Park Brake Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
4361-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . . . . . 539
47540694 28/04/2014
55.16 [55.DTC] / 10
4362-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*) . . . 541
4371-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . . . . . 543
4372-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) . . . . 545
4381-Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*) . . . . 547
4382-Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground (*) . . 549
4383-Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . . . . . . 552
4401-Park Brake (Mechanical Machines) - Park Brake Solenoid - Open Circuit (*) . . . . . . . . . . . . . . . . 554
4402-Park Brake (Mechanical Machines) - Park Brake Solenoid - Short to Power (*) . . . . . . . . . . . . . . 557
4431-Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) (*) . . . 559
4731-Right Swash Plate Sensor - Pin A Short to Ground/ Open Circuit Right Hand Pump Angle #1 (*) 562
4732-Right Swash Plate Sensor - Pin A Short to Power Right Hand Pump Angle #1 (*) . . . . . . . . . . . . 565
4734-Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit Right Hand Pump Angle #2
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
4735-Right Swash Plate Angle Sensor - Pin B Short to Power Right Hand Pump Angle #2 (*) . . . . . . 570
4737-Right Swash Plate Angle Sensor - In Range Fault Right Hand Pump Angle #1 and Right Hand Pump
Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
4741-Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit Left Hand Angle #1 (*) . 575
4742-Left Swash Plate Angle Sensor - Pin A Short to Power Left Hand Angle #1 (*) . . . . . . . . . . . . . . . 578
4744-Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit Left Hand Pump Angle #2 (*)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580
4745-Left Swash Plate Angle Sensor - Pin B Short to Power Left Hand Pump Angle #2 (*) . . . . . . . . . 583
4747-Left Swash Plate Angle Sensor - In Range Fault Left Hand Pump Angle #1 and Left Hand Pump
Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
4752-Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash
Plate Angle Left Hand Pump Angle #1 and Left Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . . . 588
4754-Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash
Plate Angle Right Hand Pump Angle #1 and Right Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . 590
4781-Solenoid Valve - Solenoid Supply Open Circuit Two Speed Solenoid (*) . . . . . . . . . . . . . . . . . . . . 592
4782-Solenoid Valve - Solenoid Supply Short to Ground Two Speed Solenoid (*) . . . . . . . . . . . . . . . . . 594
4783-Solenoid Valve - Solenoid Supply Short to Power Two Speed Solenoid (*) . . . . . . . . . . . . . . . . . . 596
4951-Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid, Short to Power (*) . . . 598
4952-Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid Open Circuit (*) . . . . . . 600
5051-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 602
5052-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . 604
5053-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . 606
5061-Port Lock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
5062-Port Lock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
5063-Port Lock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
5121-Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . 614
5122-Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . 618
5124-Right Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
5131-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . 627
5132-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . 631
47540694 28/04/2014
55.16 [55.DTC] / 11
5134-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . 635
5135-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . 639
5137-Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
5141-Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 648
5142-Aux Thumbwheel Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
5144-Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
5145-Aux Thumbwheel Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656
5147-Aux Thumbwheel Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
5201-Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . 661
5202-Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . 665
5204-Left Joystick L-R Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 669
5211-Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
5212-Left Joystick F-B Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
5214-Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 682
5215-Left Joystick F-B Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686
5217-Left Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 690
5221-Loader Arm Valve (Directional) - Solenoid Raise A Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . 695
5222-Loader Arm Valve (Directional) - Solenoid Raise A Supply Short to Ground (*) . . . . . . . . . . . . . . 697
5231-Loader Arm Valve (Directional) - Solenoid Lower B Supply Open Circuit (*) . . . . . . . . . . . . . . . . . 699
5232-Loader Arm Valve (Directional) - Solenoid Lower B Supply Short to Ground (*) . . . . . . . . . . . . . . 701
5241-Boom Valve (Directional) - Common Solenoid (C) Return Short to Power (*) . . . . . . . . . . . . . . . . 703
5242-Loader Arm Valve (Directional) - Loader Arm Solenoids Short to Ground (*) . . . . . . . . . . . . . . . . . 705
5243-Boom Valve (Directional) - Common Solenoid (C) Return Open Circuit (*) . . . . . . . . . . . . . . . . . . 707
5251-Loader Bucket Valve (Directional) - Solenoid Rollback (A) Supply Open Circuit (*) . . . . . . . . . . . 709
5252-Loader Bucket Valve (Directional) - Solenoid Rollback (A) Supply Short to Ground (*) . . . . . . . . 711
5261-Bucket Valve (Directional) - Solenoid Dump (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 713
5262-Bucket Valve (Directional) - Solenoid Dump (B) Supply Short to Ground (*) . . . . . . . . . . . . . . . . . 715
5271-Bucket Valve (Directional) - Common Solenoid (C) Return Short to Power (*) . . . . . . . . . . . . . . . 717
5272-Loader Bucket Valve (Directional) - Loader Bucket Solenoids Short to Ground (*) . . . . . . . . . . . . 719
5273-Bucket Valve (Directional) - Common Solenoid (C) Return Open Circuit (*) . . . . . . . . . . . . . . . . . . 721
5281-Aux Valve (Directional) - Solenoid Forward (A) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . 723
5282-Aux Valve (Directional) - Solenoid Forward (A) Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . 725
5291-Aux Valve (Directional) - Solenoid Reverse (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . 727
5292-Aux Valve (Directional) - Solenoid Reverse (B) Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . 729
5309-Float Button - Float Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731
5371-EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Open Circuit (*) . . . . . . . 733
5372-EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Short to Ground (*) . . . . 736
5381-EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Open Circuit (*) . . . . . . . 738
5382-EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Short to Ground (*) . . . . 741
5391-EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . 743
5392-EHF Pump Control PRV's (Directional) - EHF Pumps Solenoids Short to Ground (*) . . . . . . . . . 746
47540694 28/04/2014
55.16 [55.DTC] / 12
5393-EHF Pump Control PRV's (Directional) - EHF Pumps Solenoids Short to Power (*) . . . . . . . . . . 749
5409-CAN Message Error - Aux Override Disabled Due To Aux Override Button Timeout (30 sec) (*) 752
5501-Loader Arm Spool Sensor - Sensor Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . 753
5502-Loader Arm Spool Sensor - Sensor Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755
5503-Hydraulic Enable (Mechanical Machines) - EH AUX Output, Short to Power (*) . . . . . . . . . . . . . . 757
5504-Bucket Valve Spool Sensor - Sensor Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . 759
5505-Bucket Valve Spool Sensor - Sensor Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761
5507-Auxiliary Valve Spool Sensor - Sensor Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 764
5508-Auxiliary Valve Spool Sensor - Sensor Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 767
5511-Loader Arm Spool Sensor - Implausible State Sensor vs. Loader Arm Command, Stuck Spool/ PRV
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 770
5512-Bucket Valve Spool Sensor - Implausible State Sensor vs. Loader Bucket Command (*) . . . . . . 773
5513-Auxiliary Valve Spool Sensor - Implausible State Sensor vs. Auxiliary Command (*) . . . . . . . . . 776
5601-Aux Valve (Directional) - Common Solenoid Return Short to Power (*) . . . . . . . . . . . . . . . . . . . . . 779
5602-Loader Auxiliary Valve (Directional) - Loader Auxiliary Solenoids Short to Ground (*) . . . . . . . . . 782
5603-Loader Auxiliary Valve Solenoid Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 784
5701-Pattern Switch - Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 786
5703-Pattern Switch - Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 789
5811-Loader Lockout Switch - Implausible State (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792
9004-Memory Error - Triple Redundant: Hour Meter - Location 1 Corrupt . . . . . . . . . . . . . . . . . . . . . . . . 795
9151-CAN Connection: CAN Communication Timed Out After 5 Seconds . . . . . . . . . . . . . . . . . . . . . . . 798
9152-CAN Connection - CAN Communication Timed Out After 5 Seconds . . . . . . . . . . . . . . . . . . . . . . . 799
9153-CAN Connection - EEC1 Message Timed Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800
9154-CAN Connection - TSC1 Message Timed Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
9156-Hyd Enable Switch - Hyd Enable Button Error from AIC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
9158-H-Pattern Indicator Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
9159-ISO-Pattern Indicator Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
9160-H-Pattern Indicator Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
9161-ISO-Pattern Indicator Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
9401-Memory Error - Double Redundant: Memory Corruption Detected and Repaired . . . . . . . . . . . . . 813
9403-Memory Error - Double Redundant: Unrecoverable Memory Corruption Operable . . . . . . . . . . . 814
9404-Memory Error - Triple Redundant: Hour Meter - Hour Meter Failure . . . . . . . . . . . . . . . . . . . . . . . . 816
9405-CAN - DM1 (EH Machines): Loss Of DM1 Message From UCM (*) . . . . . . . . . . . . . . . . . . . . . . . . 817
9406-CAN - Can Communication Lost (EH Machines): Loss Of All CAN Communication From UCM (*)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 818
9407-Memory Error - ID Errors: Unrecoverable Hardware ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 819
9408-Memory Error - ID Errors: Unrecoverable Panel ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820
9410-Loss of EGR inducement status message from EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 821
47540694 28/04/2014
55.16 [55.DTC] / 13
Electrical systems - FAULT CODES
1002-Engine Coolant Temperature Sender - Over Temperature

>110° C
Context:
Diagnostic Trouble Code 1002 has an error priority of Engine-Amber.
There are no restrictions with Diagnostic Trouble Code 1002.
Cause:
Instrument Cluster has sensed that the Engine Coolant Temperature is high. The fault is active while code 3007 is
not active, Ignition is On, Start input is low, and the coolant temperature is greater than 110 °C (230.0 °F).
Possible failure modes:
1. Low coolant level.

2. Failed instrument cluster
3. Shorted wire in circuit.
4. Failed ENGINE COOLANT TEMPERATURE SENDER.
5. Failed INSTRUMENT CLUSTER.
Solution:
1. Verify that the fault code is still active
(1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes,
number of occurrences, and engine hours at last occurrence.
(2) To check for fault code: Start and operate machine.
A. Fault code is not recorded again. OK to return the machine to service.
B. Fault code 1002 is recorded again. Go to Step 2.

2. Visually inspect cooling system.
(1) Run engine at 1500 RPM.
(2) Check for proper fan operation.
(3) Check cooling core for clogs.
A. The fan is operating properly and there are no clogs in the system. Go to Step 3.
B. The fan is not operating properly or the radiator is clogged. Repair as required. Return to Step 1 to confirm
elimination of fault.
3. Verify that the wiring and connectors are free of damage.
47540694 28/04/2014
55.16 [55.DTC] / 14
RAPH12SSL0302FA 1
Schematic Legend
(1) Coolant Temperature Sender (3) ECU connector X-016
Sender ground, pin 58
Coolant Temperature signal pin 57
(2) Connector X-017
(1) Inspect the ECU and the Coolant Temperature sender. All connections should be secure, tight, free of corro-
sion, abrasion and damage.
(2) Inspect the harness from the ECU to the Coolant Temperature sender. Verify that the harness is free of damage,
corrosion, abrasion and incorrect attachment.
A. The connectors are secure and the harness is free of damage. Go to Step 4.
B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return
to Step 1 to confirm elimination of fault.
4. Measure the voltage of the signal wire to chassis ground
(1) Turn the key switch OFF. Disconnect ECU connector X-016.
(2) Turn the key switch ON.
(3) Measure the voltage from X-016 pin 57 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
the harness during measurement to reveal an intermittent condition.
A. The voltage is less than 0.5 volts. Go to Step 5.
B. The voltage is greater than 0.5 volts. There is a short circuit to another voltage source. Repair or replace the
harness as required. Return to Step 1 to confirm elimination of the fault.
5. Measure the resistance through the harness
(2) Measure the resistance across X-016 pin 58 and X-016 pin 57. The resistance should be greater than 10 ohms
but less than 20,000. Wiggle the harness during measurement to reveal an intermittent condition.
Coolant Temperature Resistance Value

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
47540694 28/04/2014
55.16 [55.DTC] / 15

100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
A. The resistance measurement is greater than 10 ohms but less than 20,000 ohms. Temporarily replace the
ECU and retest. Return to Step 1 to confirm elimination of the fault.
B. The resistance is greater than 20,000 ohms. Go to Step 6.

6. Measure the resistance across the sender
(1) Turn the key switch OFF. Disconnect Coolant Temperature sender from the harness.
(2) Measure the resistance across Coolant Temperature sender pin 1 and pin 2. The resistance should be greater
than 10 ohms but less than 20,000 ohms.

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
A. The resistance measurement is greater than 10 ohms but less than 20,000 ohms. There is an open circuit
in the coolant temperature harness. Repair or replace the harness as required. Return to Step 1 to confirm
elimination of the fault.
B. The resistance is greater than 20,000 ohms. There is an open circuit in the coolant temperature sender. Tem-
porarily replace the sender and retest. Return to Step 1 to confirm elimination of the fault.
F5H engine
Wire harnesses - Electrical schematic sheet 06 (55.100.DP-C.20.E.06)
Small mechanical machines ISM engine
Small EH machines ISM engine
Medium mechanical machines ISM engine
Medium EH machines ISM engine
47540694 28/04/2014
55.16 [55.DTC] / 16
1004-Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted

Context:
The Instrument Cluster measures an open circuit on the hydraulic oil filter input, X-C23 pin 2.
Cause:
The Instrument Cluster measures an open circuit on the hydraulic oil filter input, X-C23 pin 2.
1. Clogged hydraulic filter.

2. Signal wire has an open circuit.
3. Faulty reading from the switch.
4. Faulty instrument cluster.
Solution:
1. Verify that the fault code is still active.

Prior to clearing fault codes, write down all fault codes, number of occurrences and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
A. Fault is not recorded again. OK to return the machine to service.

2. Inspect the hydraulic oil filter.
(1) Inspect the hydraulic filter. Replace the filter if needed.
A. The filter is OK and does not need to be replaced. Go to 3.
B. The filter is in poor condition or is clogged. Replace the filter. Go to Step 3 to confirm elimination of the fault.
3. Verify the harness and connectors are not damaged.
(1) Inspect the Instrument Cluster and Hydraulic Filter Restriction Switch connections. All connections should be
secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster to the Hydraulic Filter Restriction Switch. Verify that the har-
ness is free of damage, corrosion, abrasion or incorrect attachment.
RAPH12SSL0143FA 1
47540694 28/04/2014
55.16 [55.DTC] / 17
Schematic Legend
(1) Instrument Cluster connector (2) Hydraulic filter restriction sensor
X-C23 pin 2
A. The wiring is free of corrosion, damage, abrasion and incorrect attachment. Go to Step 3.
B. The wiring is not free of corrosion, damage, abrasion or incorrect attachment. Repair or replace the harness
as required. Go to Step 1 to confirm elimination of the fault.
4. Measure the resistance through the filter restriction switch.
(1) Disconnect the oil filter switch from the harness.
(2) Measure the resistance between the oil filter switch pin and chassis ground. The chassis ground connection
must be clean and free of paint, oil, and dirt. The resistance should be less than 10 Ω.
A. The resistance is less than 10 Ω. Go to Step 5.
B. The resistance is greater than 10 Ω. Replace hydraulic filter restriction switch and retest. Return to Step 1 to
confirm elimination of fault.
5. Measure the resistance through the signal wire.
(1) Disconnect Instrument Cluster Connector X-C23.
(2) Use a jumper wire with alligator clips on both end to connect X-C23 pin 2 to chassis ground. The chassis
ground connection must be clean and free of paint, oil, and dirt.
(3) Measure the resistance from the oil filter connector X-OILFFT to chassis ground. The resistance should be
less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent short condition.
RAPH12SSL0426EA 2
Schematic Legend
(1) Digital voltmeter set to measure resis- (3) Jumper wire with alligator clips connected
tance. to chassis ground.
(2) Instrument cluster connector X-C23. (4) Instrument cluster
A. The resistance is less than 10 Ω. Temporarily replace the Instrument Cluster and retest. Return to Step 1 to
confirm elimination of the fault.
B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the signal
wire as required. Return to Step 1 to confirm elimination of fault.
Mechanical Units F5H
EH Units F5H
47540694 28/04/2014
55.16 [55.DTC] / 18

47540694 28/04/2014
55.16 [55.DTC] / 19
1009-Hydraulic Oil Temperature Sender - Over Temperature >210° F

Context:
The Instrument Cluster monitored a Hydraulic Oil Temperature greater than 110 °C (230 °F) for a period greater than
3 seconds.
Cause:
The Hydraulic Oil Temperature is above 110 °C (230 °F) for a period greater than 3 seconds.
1. Low hydraulic oil level.

2. Faulty fan operation.
3. Clogged cooling core.
4. Faulty reading from sensor.
Solution:
A. Fault is not recorded again. Return the machine to service.

2. Verify hydraulic oil level.
(1) Check hydraulic oil level, add oil as required. Refer to Operator's Manual for more details.
A. The oil level is correct and the fault is not recorded again. Return the machine to service.
B. The oil level is correct but the fault is recorded again, go to Step 3
3. Check fan operations.
(1) Run engine at 1500 RPM.
(2) Check fan operation.
(3) Check cooling core for clogs.
A. The cooling system is operating properly. Go to Step 4.
B. The cooling system is not operating properly or the cooling core is clogged. Repair fan or clear clogs from
cooling core. Repair as required. Return to Step 1 to confirm elimination of fault.
4. Check temperature sender.
(1) Disconnect terminal connector from the hydraulic oil temperature sender.
(2) Measure the resistance from the hydraulic oil temperature sender ground connection to chassis ground. The
resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
(3) Measure the resistance across the temperature sender.
Hydraulic Oil Temperature Sensor Open Circuit Resistance Measurements

Temperature Resistance in ohms (± 10%)
110 °C (230 °F) 130 Ω
47540694 28/04/2014
55.16 [55.DTC] / 20

105 °C (221 °F) 151 Ω
100 °C (212 °F) 175 Ω
95 °C (203 °F) 202 Ω
92 °C (198 °F) 223 Ω
88 °C (190 °F) 258 Ω
85 °C (185 °F) 280 Ω
81 °C (178 °F) 323 Ω
78 °C (172 °F) 358 Ω
74 °C (165 °F) 412 Ω
68 °C (154 °F) 511 Ω
16 °C (61 °F) 4250 Ω
A. The resistance measurement is greater than 100 Ω and less than 5,000 Ω, go to Step 5.
B. The resistance reading is not acceptable. The measured resistance is less than 100 Ω and greater than
5,000 Ω. Replace the hydraulic oil temperature sender. Return to Step 1 to confirm elimination of fault.
5. Check the wiring to the instrument cluster.
(1) Disconnect Instrument Cluster connector X-C23.
(2) Disconnect the hydraulic oil temperature sensor.
(3) Measure the resistance from hydraulic oil temperature sender connector pin 1 (signal wire) to chassis ground.
The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent
condition.
A. The resistance measurement is greater than 20,000 Ω. Temporarily replace the Instrument Cluster and retest.
Go to Step 1 to confirm elimination of the fault.
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the wire. Repair or replace
the wire as required. Return to Step 1 to confirm elimination of fault.
Mechanical Units F5H engine
EH Units F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 21
1014-Cluster Battery Monitor: Over Voltage > 16.5 volts

Context:
Diagnostic Trouble Code 1014 has an error priority of Amber.
Cause:
Instrument Cluster has sensed that the battery voltage is high. The fault is active when the engine is running and the
battery voltage is greater than 16.5 V.
1. Problem with battery or charging system.

2. Failure of the instrument cluster.
Solution:

B. Fault code 1014 is recorded again. No other fault codes are active. Go to Step 2.
C. Fault code 1014 is recorded again along with fault code 3051 and/or fault code 1901. There is a problem in the
alternator charging system. Troubleshoot the battery and alternator. Return to Step 1 to confirm elimination of
the fault.
(1) Inspect the alternator and battery connections. All connections should be secure, tight, free of corrosion, abra-
sion, and damage.
(2) Inspect the harness from the alternator and battery to the instrument cluster. Verify that the harness is free of
damage, corrosion, abrasion, or incorrect attachment.
A. All connections are secure and the harness is free of damage. Go to Step 3.
to Step 1 to confirm elimination of the fault.
3. Measure the voltage at the instrument cluster.
(1) Turn the ignition switch OFF.
(2) Disconnect instrument cluster connector X-C23.
(3) Turn the ignition switch ON.
(4) Measure the voltage between X-C23 pin 7 and chassis ground. The chassis ground connection must be clean
and free of paint, oil and dirt. The voltage should be between 11.5 V and 14.5 V. Wiggle the harness during mea-
surement to reveal an intermittent condition.
47540694 28/04/2014
55.16 [55.DTC] / 22
A. All voltage measurements are between 11.5 V and 14.5 V. Temporarily replace the instrument cluster and
retest. Return to Step 1 to confirm elimination of the fault.
B. One or more of the voltage measurement are out of range. There is a problem with the battery or alternator
charging system. Repair as required. Return to Step 1 to confirm elimination of the fault.
EH Units F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 23
1015-Cluster Battery Monitor: Under Voltage < 11.5 volts

Context:
There are no restrictions while Diagnostic Trouble Code 1015 is active.
Cause:
Instrument Cluster has sensed that the battery voltage is low. The fault is active when the engine is running and the
battery voltage is less than 11.5 V.

Solution:

B. Fault code 1015 is recorded again. No other fault codes are active. Go to Step 2.
C. Fault code 1015 is recorded again along with fault code 3052 and/or fault code 1902. There is a problem in the
alternator charging system. Troubleshoot the battery and alternator. Return to Step 1 to confirm elimination of
the fault.
(1) Inspect the alternator and battery connections. All connections should be secure, tight, free of corrosion, abra-
sion, and damage.
(2) Inspect the harness from the alternator and battery to the instrument cluster. Verify that the harness is free of
damage, corrosion, abrasion, or incorrect attachment.
A. All connections are secure and the harness is free of damage. Go to Step 3.
47540694 28/04/2014
55.16 [55.DTC] / 24
A. All voltage measurements are between 11.5 V and 14.5 V. Temporarily replace the instrument cluster and
B. One or more of the voltage measurement are out of range. There is a problem with the battery supply to
the instrument cluster. Verify that the battery and alternator charging system are working properly. Repair as
required. Return to Step 1 to confirm elimination of the fault.
EH Units F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 25
1025-Throttle Sensor - Out Of Range Short to Power

Context:
The instrument cluster has detected an problem with the throttle signal to the instrument cluster. Diagnostic Trouble
Code 1030 has an error priority of White. White errors are not displayed on the instrument cluster.
Engine speed is set to 1500 RPM while Diagnostic Trouble Code 1030 is active.
Cause:
instrument cluster has sensed higher than normal voltage on throttle input pin, X-C23 pin 22. The fault is active while
the ignition switch is on and throttle voltage is greater than 5.3 V.
1. Short circuit in the throttle wiring.

2. Failure of the throttle position sensor.
3. The instrument cluster has an internal failure.
Solution:
1. Verify that the fault code is active.
Connect the Electronic Service Tool to the service tool connector.
To check for fault codes: Start and operate the machine.
A. The fault code is not recorded again. OK to return the machine to service.
B. Fault code 1025 is recorded again. Go to step 2.

2. Verify the harness is not damaged
Turn the ignition switch OFF.
Verify the connections from the instrument cluster to the throttle position sensor are tight and secure.
Verify the harness is free of damage, abrasion, corrosion and incorrect attachment from the instrument cluster to
the throttle position sensor.
RAPH12SSL0300FA 1
47540694 28/04/2014
55.16 [55.DTC] / 26
Schematic Legend
(1) Hand throttle position sensor (4) Connector XCC1A/1B pin 13
(2) Foot throttle position sensor (5) Connector XCC2A/2B pin 8
XCC2A/2B pin 13
(3) Instrument cluster
A. The throttle position sensor harness is not damaged and all connections are secure. Go to step 3.
B. The throttle position sensor harness is damaged or the connectors are loose or damaged. Repair or replace
the harness as required. Return to step 1 to confirm elimination of fault.
3. Measure the supply voltage to the throttle sensor.
Turn the ignition switch OFF. Disconnect the throttle connector and inspect pins.
Turn the ignition switch to the ON position.
Measure the voltage from pin C to pin B. The voltage should be between 4.8 volts and 5.2 volts. Wiggle the
harness during measurement to reveal an intermittent condition.
A. The voltage is correct. Go to step 4.
B. The voltage is greater than 5.2 volts or less than 4.8 volts. Go to step 7.
4. Measure the voltage on the sensor signal line.
Disconnect the throttle position sensor from the harness. Disconnect the instrument cluster Connector X-C23.
Turn the ignition switch ON.
Measure the voltage of X-20 pin A to chassis ground. The voltage should be less than 0.5 volts. Wiggle the
A. The voltage is less than 0.5 volts. Go to step 5.
B. The voltage is greater than 0.5 volts. There is a short circuit to another voltage source. Repair or repalce the
wire as required. Return to step 1 to confirm elimination of the fault.
5. Check the signal voltage from the sensor.
47540694 28/04/2014
55.16 [55.DTC] / 27
RCPH10TLB053FAM 2
Throttle Signal Legend

(1) Throttle Signal Voltage
(2) Throttle movement in degrees of travel. 0 degrees equals low idle. 20 degrees
equals WOT (Wide Open Throttle).
This step is used to monitor the throttle signal. The sensor must be connected and active in order to continue.
The dealer must build a breakout harness as shown below.
RAPH12SSL0301FA 3
47540694 28/04/2014
55.16 [55.DTC] / 28
Schematic legend
(1) Throttle position sensor (3) Breakout Tee
Connect the breakout Tee and measure the voltage from pin A to pin B (or slide Back Probes into pin A and B).
Turn the ignition switch ON, engine OFF.
Measure the voltage from pin A to pin B. Move the throttle from low idle to WOT (wide open throttle). The voltage
should change from approximately 0.55 volts at low idle to 4.2 volts at WOT.
A. The voltage changed from approximately 0.5 volts to 4.2 volts. Go to step 6.
B. The voltage did not change from 0.55 volts to 4.2 volts as the throttle moved from low idle to WOT or the
voltage was less than 0.5 volts at low idle. Temporarily replace the sensor and retest. Return to step 1 to
6. Measure the throttle signal from the sensor to the instrument cluster.
Remove the breakout harness and reconnect the sensor to the instrument cluster harness.
Remove pin 22 from connector X-C23.
Turn the ignition switch ON, engine OFF. Measure the voltage from removed wire, pin 22 to X-C25 pin 20 (chassis
ground will also work). Move the throttle from low idle to WOT (wide open throttle). The voltage should change
from approximately 0.55 volts at low idle to 4.2 volts at WOT.
A. The voltage changed from approximately 0.5 volts to 4.2 volts. Temporarily replace the instrument cluster and
retest. Return to step 1 to confirm elimination of the fault.
B. The voltage did not change from 0.55 volts to 4.2 volts as the throttle moved from low idle to WOT or the
voltage was less than 0.5 volts at low idle. There is a problem in the throttle signal wire from the sensor to the
instrument cluster. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault.
7. Measure the voltage at the instrument cluster
Turn the ignition switch OFF. Remove the wires from instrument cluster connector X-C23 pin 17 and 25.
Fabricate two jumper wires and insert them into X-C23 pin 25 and X-C23 pin 17.
Use the jumper wires to measure the voltage between X-C23 pin 25 and X-C23 pin 17.
A. The voltage is correct. There is a problem in the wiring harness from the instrument cluster to the throttle
position sensor. Repair or replace the harness as required. Return to step 1.
B. The voltage is greater than 5.2 volts or less than 4.8 volts. Temporarily replace the instrument cluster and
EH Units F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 29

47540694 28/04/2014
55.16 [55.DTC] / 30
1026-Hand Throttle Signal Out Of Range - Short to Power

Context:
Diagnostic Trouble Code 1026 has an error priority of White.
Cause:
The instrument cluster has sensed higher than normal voltage on throttle input pin, X-C23 pin 22. The fault is active
while ignition switch is on and throttle voltage is greater than 5.3 V.
1. Short circuit in the throttle wiring.

Solution:
To check for fault code: Start and operate machine.

2. Verify the harness is not damaged.
RAPH12SSL0300FA 1
47540694 28/04/2014
55.16 [55.DTC] / 31
Schematic Legend
(1) Hand throttle position sensor (4) Connector XCC1A/1B pin 13
(2) Foot throttle position sensor (5) Connector XCC2A/2B pin 8
XCC2A/2B pin 13
3. Check voltage at throttle sensor.
Turn the ignition switch OFF. Disconnect the throttle connector and inspect pins.
Measure the voltage between pin C and pin B. The voltage should be between 4.8 V and 5.2 V. Wiggle the harness
during measurement to reveal an intermittent condition.
B. The voltage is greater than 5.2 V or less than 4.8 V. Go to step 7.

4. Turn the ignition switch OFF.
Disconnect the throttle position sensor from the harness. Disconnect the instrument cluster connector X-C23.
Measure the voltage between X-20 pin A and chassis ground. The voltage should be less than 0.5 V. Wiggle the
A. The voltage is less than 0.5 V. Go to step 5.
B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the wire
as required. Return to step 1 to confirm elimination of the fault.
5. Check the throttle signal from the sensor.
RCPH10TLB053FAM 2
47540694 28/04/2014
55.16 [55.DTC] / 32

RAPH12SSL0301FA 3
Schematic legend
(1) Throttle position sensor (3) Breakout Tee
Connect the breakout Tee and measure the voltage from pin C to pin B (or slide Back Probes into pin C and B).
Measure the voltage from pin C to pin B. Move the throttle from low idle to WOT (wide open throttle). The voltage
should change from approximately 0.55 V at low idle to 4.2 V at WOT.
A. The voltage changed between 0.55 V at low idle to 4.2 V at WOT. Go to step 6.
B. The voltage did not change between 0.55 V and 4.2 V as the throttle moved between low idle and WOT or the
voltage was less than 0.5 V at low idle. Temporarily replace the sensor and retest. Return to step 1 to confirm
47540694 28/04/2014
55.16 [55.DTC] / 33
Measure the voltage between the removed wire, pin 22 and X-C25 pin 20 (chassis ground will also work). Move
the throttle from low idle to WOT (wide open throttle). The voltage should change from approximately 0.55 V at
low idle to 4.2 V at WOT.
A. The voltage changed from approximately 0.55 V at low idle to 4.2 V at WOT. Temporarily replace the instrument
cluster and retest. Return to step 1 to confirm elimination of the fault.
B. The voltage did not change between 0.55 V and 4.2 V as the throttle moved between low idle and WOT or the
voltage was less than 0.5 V at low idle. There is a problem in the throttle signal wire from the sensor to the
instrument cluster. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault.
Turn the ignition switch OFF. Remove the wires from instrument cluster connector X-C23 pin 17 and 25.
B. The voltage is greater than 5.2 V or less than 4.8 V. Temporarily replace the instrument cluster and retest.
Return to step 1 to confirm elimination of the fault.
Small mechanical machines
Small EH machines
Medium mechanical machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 34
1030-Throttle Sensor - Out Of Range Short to Ground/ Open Circuit

Context:
The instrument cluster has detected an problem with the throttle signal to the instrument cluster. Diagnostic Trouble
Code 1030 has an error priority of White. White errors are not displayed on the instrument cluster.
Cause:
The instrument cluster has sensed that the throttle signal has failed. The fault is active while the engine is on and the
throttle input voltage, X-C23 pin 22 falls below 0.2 V.

2. Open wire in circuit.
Solution:

RAPH12SSL0300FA 1
47540694 28/04/2014
55.16 [55.DTC] / 35
Schematic Legend
(1) Hand Throttle Position Sensor (4) Connector XCC1A/1B pin 13
(2) Foot Throttle Position Sensor (5) Connector XCC2A/2B pin 8
XCC2A/2B pin 13
(3) Instrument Cluster
3. Measure the supply voltage to the throttle sensor.
Disconnect the throttle connector.
Measure the voltage between pin C and pin B. The voltage should be approximately between 5 V. Wiggle the
A. The voltage is between 4.8 V and 5.2 V. Go to step 4.
47540694 28/04/2014
55.16 [55.DTC] / 36
4. Measure the throttle signal from the sensor.
RCPH10TLB053FAM 2

47540694 28/04/2014
55.16 [55.DTC] / 37
RAPH12SSL0301FA 3
Schematic legend
(1) Throttle Position Sensor (3) Breakout Tee
Connect the breakout tee and measure the voltage between pin A and pin B (or slide Back Probes into pin A and
B).
Measure the voltage between pin A to pin B. Move the throttle from low idle to WOT (wide open throttle). The
voltage should change from approximately 0.55 V at low idle to 4.2 V at WOT.
A. The voltage changed from approximately 0.55 V to 4.2 V. Go to step 5.
B. The voltage did not change from 0.55 V to 4.2 V as the throttle moved from low idle to WOT or the voltage was
less than 0.5 V at low idle. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination
of fault.
ground). Move the throttle from low idle to WOT (wide open throttle). The voltage should change from approxi-
mately 0.55 V volts at low idle to 4.2 V at WOT.
A. The voltage changed from approximately 0.5 V to 4.2 V. Temporarily replace the instrument cluster and retest.
47540694 28/04/2014
55.16 [55.DTC] / 38
B. The voltage did not change from 0.55 V to 4.2 V as the throttle moved from low idle to WOT or the voltage
was less than 0.5 V at low idle. There is a problem in the throttle signal wire from the sensor to the instrument
cluster. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault.
Turn the ignition switch OFF. Remove the wires X-C23 pin 17 and X-C23 25 from instrument cluster connector.
Use the jumper wires and measure the voltage between X-C23 pin 25 and X-C23 pin 17.
B. The voltage is greater than 5.2 V or less than 4.8 V. Temporarily replace the instrument cluster and retest.
EH Units F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 39
1031-Hand Throttle Sensor - Short To Ground/ Open Circuit

Context:
Diagnostic Trouble Code 1031 has an error priority of White. Engine speed is set to 1500 RPM while Diagnostic
Trouble Code 1031 is active.
Cause:
The instrument cluster has sensed that the throttle signal has failed. The fault is active while the engine is on and the
throttle input voltage, X-C23 pin 22 falls below 0.2 V.

Solution:
Use the Electronic Service Tool to clear all fault codes.
A. The fault is not recorded again. OK to return the machine to service.

RAPH12SSL0300FA 1
47540694 28/04/2014
55.16 [55.DTC] / 40
Schematic Legend
(1) Hand Throttle Position Sensor (4) Connector XCC1A/1B pin 13
(2) Foot Throttle Position Sensor (5) Connector XCC2A/2B pin 8
XCC2A/2B pin 13
3. Check voltage at throttle sensor.
Disconnect the throttle connector.
Measure the voltage between pin C and pin B. The voltage should be between 4.8 V and 5.2 V. Wiggle the harness

4. Measure the throttle signal from the sensor.
RCPH10TLB053FAM 2

47540694 28/04/2014
55.16 [55.DTC] / 41
RAPH12SSL0301FA 3
Schematic legend
(1) Throttle Position Sensor (3) Breakout Tee
Connect the breakout tee and measure the voltage between pin C and pin B (or slide Back Probes into pin C and
B).
Measure the voltage between pin C to pin B. Move the throttle from low idle to WOT (wide open throttle). The
voltage should change from approximately 0.55 V at low idle to 4.2 V at WOT.
A. The voltage changed from approximately 0.55 V to 4.2 V. Go to step 5.
B. The voltage did not change from 0.55 V to 4.2 V as the throttle moved from low idle to WOT or the voltage was
less than 0.5 V at low idle. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination
of fault.
5. Measure the throttle signal from the sensor to the Instrument Cluster.
Remove the breakout harness and reconnect the sensor to the Instrument Cluster harness.
ground). Move the throttle from low idle to WOT (wide open throttle). The voltage should change from approxi-
mately 0.55 V volts at low idle to 4.2 V at WOT.
A. The voltage changed from approximately 0.5 V to 4.2 V. Temporarily replace the instrument cluster and retest.
47540694 28/04/2014
55.16 [55.DTC] / 42
B. The voltage did not change from 0.55 V to 4.2 V as the throttle moved from low idle to WOT or the voltage
was less than 0.5 V at low idle. There is a problem in the throttle signal wire from the sensor to the instrument
cluster. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault.
Turn the ignition switch OFF. Remove the wires X-C23 pin 17 and X-C23 25 from instrument cluster connector.
A. The voltage is correct. There is a problem in the wiring harness from the Instrument Cluster to the Throttle
Position Sensor. Repair or replace the harness as required. Return to step 1.
B. The voltage is greater than 5.2 V or less than 4.8 V. Temporarily replace the Instrument Cluster and retest.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 43
1040-Engine overspeed warning, Engine speed greater than 2750

RPM for 5 seconds
Cause:
The instrument cluster has detected an engine speed greater than 2750 RPM for a period greater than 5 s. The
Warning Lamp will illuminate Amber. The fault will stay active until engine speed drops below 2700 RPM.
Solution:
1. Fault Code 1040 is displayed on the instrument cluster to warn the operator that the engine speed has exceeded
2750 RPM for a period greater than 5 s.
47540694 28/04/2014
55.16 [55.DTC] / 44
1041-RPM Monitoring - Over Speed

Cause:
The instrument cluster has detected an engine speed greater than 3000 RPM for a period greater than 5 s. The
Warning Lamp will illuminate Amber. The fault will stay active until engine speed drops below 2950 RPM.
Solution:
1. Fault Code 1041 is displayed on the instrument cluster to warn the operator that the engine speed has exceeded
3000 RPM for a period greater than 5 s.
47540694 28/04/2014
55.16 [55.DTC] / 45
1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Context:
The instrument cluster has detected the fuel sender resistance is below 2 Ω for a period greater than 2 s.
Cause:
The instrument cluster has detected the fuel sender resistance is below 2 Ω for a period greater than 2 s.
1. Wiring or circuits shorted to minus battery or chassis ground.

2. Faulty fuel level sensor.
Solution:

Inspect the instrument cluster and the fuel level sender connections. All connections should be secure, tight, free
of corrosion, abrasion and damage.
Inspect the harness from the instrument cluster to the fuel level sender. Verify that the harness is free of damage,
A. The connectors are secure and the harness is free of damage. Go to step 3.
to step 1 to confirm elimination of fault.
3. Measure the resistance at the fuel level sensor.
Tilt the cab and remove the fuel level sender from the tank.
Disconnect the harness from the sender.
Move the fuel level float from the low to high position while measuring the resistance of the sender. The resistance
should change linearly from approximately 4.5 Ω at the full tank position to approximately 340 Ω at the empty tank
position. The resistance should change linearly without any fluctuations to a higher or lower resistance.
A. The resistance measurements from the sensor are within specifications. Go to step 4.
B. The resistance readings from the sensor are not steady or the values are not accurate. Temporarily replace
sensor and retest. Return to step 1 to confirm elimination of fault.
4. Check fuel level wiring.
Measure the resistance between X-14 pin A and chassis ground. The resistance should be less than 10 Ω. Wiggle
47540694 28/04/2014
55.16 [55.DTC] / 46
Measure the resistance between X-14 pin B and instrument cluster connector X-C23, pin 24. The resistance
should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance measurements from the sensor are within specifications. Temporarily replace the instrument
cluster and retest. Return to step 1 to confirm elimination of the fault.
B. The resistance readings are not within the limits defined in the step. Repair or replace the harness as required.
Return to step 1 to confirm elimination of fault.
EH Units F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 47
1045-Fuel Level Sensor Open Circuit

Context:
The instrument cluster has detected an open circuit in the fuel sender signal.
Cause:
The instrument cluster has determined that the fuel level sensor resistance has failed high.

2. Faulty fuel level sensor.
3. Instrument cluster has internal failure.
Solution:

Inspect the instrument cluster and the fuel level sender connections. All connections should be secure, tight, free
Inspect the harness from the instrument cluster to the fuel level sender. Verify that the harness is free of damage,
corrosion, abrasion or incorrect attachment.
3. Measure the resistance at the fuel level sensor.
Disconnect the harness from the sender.
Tilt the cab and remove the fuel level sender from the tank.
Move the fuel level float from the low position to the high position while measuring the resistance across the sender.
The resistance should change linearly from approximately 4.5 Ω at the full tank position to approximately 340 Ω
at the empty tank position. The resistance should change linearly without any fluctuations to a higher or lower
resistance.
A. The resistance measurements from the sensor were within specifications. Go to step 4.
B. The resistance readings from the sensor were not steady or the values were not accurate. Temporarily replace
the sensor and retest. Return to step 1 to confirm elimination of fault.
4. Check fuel level wiring.
Measure the resistance between X-14 pin A and chassis ground. The resistance should be less than 10 Ω. Wiggle
Measure the resistance from X-14 pin B to instrument cluster connector X-C23, pin 24. The resistance should be
less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
47540694 28/04/2014
55.16 [55.DTC] / 48
Measure the resistance between X-14 pin B and ground (engine block). The resistance should be greater than
20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance measurements are within specifications. Temporarily replace the instrument cluster and retest.
Go to step 1 to confirm elimination of the fault.
B. The resistance readings are not with the limits defined in the step. Repair or replace the harness as required.
EH Units F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 49
1051-Timeout of CAN message EEC1, 5 seconds without message

Context:
CAN bus communications between the instrument cluster and the ECU have been lost. The instrument cluster did not
receive the EEC1 message from the ECU. This fault code may be displayed with other CAN bus fault code messages.
Cause:
The instrument cluster has stopped receiving CAN messages from the ECU. CAN bus communications between the
instrument cluster and the ECU have been lost.
1. CAN data link wiring or circuits open.

2. CAN data link wiring or circuits shorted.
3. Faulty CAN Data Link device.
5. Faulty ECU.
Solution:
Use the Electronic Service Tool to verify that the CAN data link faults are ACTIVE.
To check for fault codes: Start and operate the machine. Wiggle the harness to reveal an intermittent condition.
If three or more fault codes are active, such as 1051 through 1059 or 3096, 3334, 3339 or 3358, this is an indication
of a problem in the CAN bus circuit, continue with this procedure. If one or two CAN bus fault codes are active,
this is an indication of an intermittent connection in the CAN circuit. Check the wiring and connectors to verify they
are secure and free of damage, corrosion, abrasion or incorrect attachment.
A. CAN bus fault codes are not recorded again and are no longer ACTIVE. OK to return the machine to service.
B. CAN bus fault codes are present and ACTIVE. Go to step 2.

Verify the connections to the ECU, instrument cluster, diagnostic connector, UCM (if installed) and the optional
Telematics unit are tight and secure.
Verify the harness is free of damage, abrasion, corrosion and incorrect attachment from the ECU to the instrument
cluster. Verify all data link drops are free of damage, abrasion, corrosion and incorrect attachment.
A. The CAN bus harness is not damaged and all connections are secure. Go to step 3.
B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required.
Go to step 1 to confirm elimination of fault.
3. Measure the resistance through the CAN Data Link harness.
Measure the resistance between the diagnostic port connector, CAN High pin C and CAN Low pin D. The resis-
tance should be approximately 60 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance is between 54 Ω and 66 Ω. Go to step 4.
B. The resistance is less than 50 Ω. Go to step 5.
C. The resistance is greater than 70 Ω. Go to step 6.
47540694 28/04/2014
55.16 [55.DTC] / 50
4. Measure harness resistance to chassis ground and positive battery.
Disconnect the instrument cluster connector, X-C23. Disconnect all devices connected to the CAN Data Link.
Measure the resistance between X-C23 pin 5 and chassis ground. The chassis ground connection must be clean
and free of paint, oil, and dirt. The resistance should be greater than 20,000 Ω. Wiggle the harness during mea-
Measure the resistance between X-C23 pin 6 and chassis ground. The chassis ground connection must be clean
and free of paint, oil, and dirt. The resistance should be greater than 20,000 Ω. Wiggle the harness during mea-
Measure the resistance between X-C23 pin 5 and positive battery, X-C23 pin 7. The resistance should be greater
than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
Measure the resistance between X-C23 pin 6 and positive battery, XST2 pin 7.The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
Circuit description Instrument Cluster connection Alternate Diagnostic Port connection

Switched Battery X-C23 pin 7 X-DIAG pin B
Minus Battery X-C23 pin 34 X-DIAG pin A
CAN High X-C23 pin 6 X-DIAG pin C
CAN Low X-C23 pin 5 X-DIAG pin D
A. All resistance measurements are greater than 20,000 Ω. Verify the ECU is powered and operational. Verify
that all minus battery and chassis ground connections to the CAN Bus modules are clean and secure. Return
to step 1 to confirm elimination of the fault.
B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the CAN bus. Tem-
porarily replace the CAN bus wires and retest. Repair or replace the harness as required. Return to step 1 to
confirm elimination of the fault code.
5. Measure the resistance between the CAN high and CAN low.
Turn the ignition switch OFF. Disconnect all modules on the CAN bus.
Measure the resistance between CAN high (diagnostic connector X-DIAG pin C) and CAN low (diagnostic con-
nector X-DIAG pin D). The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement
A. The resistance is greater than 20,000 Ω. Connect each component to the CAN Bus one at a time. The resis-
tance should be greater than 60 Ω. Replace the module that drops the CAN Bus line resistance below 54 Ω.
B. The resistance is less than 54 Ω there is a short circuit between the CAN high and CAN low wires. Repair or
replace the harness as required. Return to test step 1 to confirm elimination of the fault.
6. Measure the resistance through the CAN Data Link circuit.
Turn the ignition switch OFF. Disconnect all components connected to the CAN Bus.
Fabricate a jumper 20 cm (8 in) that will connect between the CAN High and CAN Low pins on the ECU harness
connector.
Connect the jumper wire between the CAN High and CAN Low pins on the ECU harness connector.
Measure the resistance across Diagnostic Port connector X-DIAG pin C and pin D. The resistance should be less
than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
Measure the resistance across the Telematics connector pins 3 and 4. The resistance should be less than 10 Ω.
Wiggle the harness during measurement to reveal an intermittent condition.
47540694 28/04/2014
55.16 [55.DTC] / 51
Measure the resistance across the UCM connector (if installed) X-CN2B pin 1 and X-CN2B pin 10. The resistance
Measure the resistance across Instrument Cluster connector X-C23 pin 5 and X-C23 pin 6. The resistance should
be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. All resistance measurements are less than 10 Ω. Go to step 7.
B. One or more resistance measurement are greater than 20,000 Ω. There is an open circuit in the CAN bus
wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault.
7. Measure the resistance of the CAN circuit in the ECU and the instrument cluster.
Disconnect the ECU and the instrument cluster from the harness.
Measure the resistance directly on the ECU CAN bus pin. The resistance should be between 108 Ω and 132 Ω.
RAIL12DOZ0152FA 1
Measure the resistance directly on the instrument cluster CAN bus pins. Measure the resistance between XST2
pin 4 and pin 3. The resistance should be between 108 Ω and 132 Ω.
A. Both resistance measurements are approximately 120 Ω. Return to step 6.
B. One or more resistance measurements are greater than 140 Ω. There is an open circuit in the CAN bus within
the control. Replace the control module. Return to step 1 to confirm elimination of the fault.
EH Units F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 52

47540694 28/04/2014
55.16 [55.DTC] / 53
1053-Timeout of CAN message CM1BC

Context:
CAN bus communications between modules on the data link have been lost. This fault code may be displayed with
other CAN bus fault code messages.
Cause:
CAN bus communications between modules on the data link have been lost.

5. Faulty ECU.
Solution:
B. CAN bus fault codes are present and ACTIVE. Refer to 1051-Timeout of CAN message EEC1, 5 seconds
without message (55.408)
47540694 28/04/2014
55.16 [55.DTC] / 54
1054-Timeout of CAN message engine temperature, 5 seconds

without message
Context:
Cause:

5. Faulty ECU.
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 55
1056-Timeout of CAN message DPFC1, 5 seconds without message

Context:
Cause:

5. Faulty ECU.
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 56
1058-Timeout of CAN message EDC2BC, 5 seconds without

message
Context:
Cause:

5. Faulty ECU.
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 57
1059-Timeout of CAN message DM1, 5 seconds without message

Context:
Cause:

5. Faulty ECU.
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 58
1201-Hydraulic oil filter switch open circuit

Context:
Instrument Cluster has sensed that there is an open circuit in the hydraulic filter restriction circuit. Diagnostic trouble
code 1201 has an error priority of white. White errors are not displayed on the instrument cluster and are not known
to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes.
Cause:
The instrument cluster has sensed that there is an open circuit in the hydraulic filter restriction circuit. The fault is
active when the ignition switch is ON and the start input is low and there is an open circuit in the hydraulic filter circuit.
1. Open circuit in the wiring.

2. Failure of the hydraulic filter restriction switch.
3. Failure in the instrument cluster.
Solution:

Inspect the instrument cluster and the hydraulic oil filter switch connections. All connections should be secure,
tight, free of corrosion, abrasion and damage.
Inspect the harness from the instrument cluster to the hydraulic oil filter switch . Verify that the harness is free of
damage, corrosion, abrasion and incorrect attachment.
3. Measure the resistance across the switch.
Disconnect the hydraulic oil filter switch connector.
Measure the resistance between hydraulic oil filter switch pin and chassis ground. The chassis ground connection
must be clean and free of paint, oil and dirt. The resistance should be less than 10 Ω.
A. The resistance is less than 10 Ω. Go to step 4.
B. The resistance is greater than 10 Ω. There is an open circuit in the switch. Replace the switch and retest.
Leave the hydraulic oil filter switch disconnected.
Disconnect instrument cluster connector X-C23.
47540694 28/04/2014
55.16 [55.DTC] / 59
Fabricate a jumper wire that will connect between the hydraulic oil filter switch pin 1 and chassis ground.
Connect the jumper wire between the hydraulic oil filter switch pin 1 and chassis ground. The chassis ground
connection must be clean and free of paint, oil and dirt.
Measure the resistance between instrument cluster connector X-C23 pin 1 and chassis ground. The resistance
should be less than 10 Ω.
A. The resistance is less than 10 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to
B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Replace the wiring harness as
required. Return to step 1 to confirm elimination of fault.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 60
1202-RPM Monitoring - Over Speed (Max)

Context:
Diagnostic Trouble Code 1202 has an error priority of Red.
The vehicle is disabled with Diagnostic Trouble Code 1202.
Cause:
Instrument Cluster has sensed very high Engine RPM. The fault is active when Engine is Running, (EH machines
code 9406 is not active) and Engine RPM is greater than 2900 RPM.
1. Failure of Alternator.
2. Failure of Instrument Cluster.
Solution:
1. Verify correct mechanical operation of the Engine before troubleshooting this fault electrically. Use the machine to
recreate conditions for error. Use the EST to verify fault code 1202 RPM Monitoring - Over Speed (Max) is active.
A. If the fault is active, continue with step 2.
B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.
2. Check if Diagnostic Trouble Code 1041 or 1203 is active.
A. If Diagnostic Trouble Code 1041 or 1203 is not active, continue with step 3.
B. If Diagnostic Trouble Code 1041 or 1203 is active, follow procedure for

1203-RPM Monitoring - Open Circuit/ Short to Ground/ Short to Power Mechanical Units (55.301) or
1203-RPM Monitoring - Open Circuit/ Short to Ground/ Short to Power EH Units (55.301) .
3. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals
or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent
breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate
nearby wiring.
This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a fail-
ure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for
replacement.
A. If damage is found or other than normal display readings are indicated, repair the damage discovered during
the inspection or locate and repair the other than normal display condition and verify that the error has been
resolved.
B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 61
1203-RPM Monitoring - Open Circuit/ Short to Ground/ Short to

Power Mechanical Units
Context:
Cause:
Instrument Cluster has sensed that the Alternator Tach signal has failed. The fault is active while the Engine is running
and Instrument Cluster senses low RPM.

Solution:
1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1203 RPM Monitoring - Open
Circuit/ Short to Ground/ Short to Power is active.
2. Check for open circuit. Disconnect connector X-5 from the Alternator. Disconnect connector X-C23 from the
Instrument Cluster. Using a multi-meter, check continuity between connector X-5 pin 3 and connector X-C23 pin
19.
A. If there is continuity, continue with step 6.
B. If there is no continuity, there is an open wire condition on wire 124 (Yellow) between connector X-5 pin 3 and
connector X-C23 pin 19. Continue with step 3.
3. Locate the open circuit. Disconnect connector X-CC1A from connector X-CC1B. Disconnect connector X-52B
from connector X-52A. Using a multi-meter, check continuity between connector X-CC1A pin 6 and connector
X-C23 pin 19.
A. If there is no continuity, there is an open wire condition on wire 124 (Yellow) between connector X-CC1A pin
6 and connector X-C23 pin 19. Repair or replace the wire.
B. If there is continuity, continue with step 4.

4. Locate the open circuit. Using a multi-meter, check continuity between connector X-CC1B pin 6 and connector
X-52B pin 4.
A. If there is no continuity, there is an open wire condition on wire 124 (Yellow) between connector X-CC1B pin
6 and connector X-52B pin 4. Repair or replace the wire.

5. Locate the open circuit. Using a multi-meter, check continuity between connector X-5 pin 3 and X-52A pin 4.
A. If there is no continuity, there is an open wire condition on wire 124 (Yellow) between connector X-52A pin 4
and connector X-5 pin 3. Repair or replace the wire.
47540694 28/04/2014
55.16 [55.DTC] / 62
B. If there is continuity, connectors X-CC1A and X-CC1B are not making a good connection at pin 6, or connec-
tors X-52A and X-52B are not making a good connection at pin 4. Repair the connector.
6. Check for a short to ground. Using a multi-meter, check for continuity between connector X-C23 pin 19 and
ground.
A. If there is no continuity, continue with step 9.
B. If there is continuity, there is a short to ground condition on wire 124 (Yellow) between connector X-5 pin 3
and connector X-C23 pin 19. Continue with step 7.
7. Locate the short to ground. Disconnect connector X-CC1A from connector X-CC1B. Disconnect connector X-52A
from connector X-52B. Using a multi-meter, check for continuity between connector X-C23 pin 19 and ground.
B. If there is continuity, there is a short to ground condition on wire 124 (Yellow) between connector X-CC1A pin
6 and connector X-C23 pin 19. Repair or replace the shorted wire.
8. Locate the short to ground. Using a multi-meter, check for continuity between connector X-CC1B pin 6 and
ground.
A. If there is no continuity, there is a short to ground on wire 124 (Yellow) between connector X-5 pin 3 and X-52A
pin 4. Repair or replace the shorted wire.
B. If there is continuity, there is a short to ground condition on wire 124 (Yellow) between connector X-CC1B pin
6 and connector X-52B pin 4. Repair or replace the shorted wire.
9. Check for short to high. Using a multi-meter, check for voltage between connector X-C23 pin 19 and ground.
A. If there is no voltage, continue with step 12.
B. If there is voltage, there is a short to high source on wire 124 (Yellow) between connector X-5 pin 3 and
connector X-C23 pin 19. Continue with step 10.
10. Locate the short to high. Disconnect connector X-CC1A from connector X-CC1B. Disconnect connector X-52A
from connector X-52B. Using a multi-meter, check for voltage between connector X-5 pin 3 and ground.
connector X-CC1B pin 6. Repair or replace the wire.
11. Locate the short to high. Using a multi-meter, check for voltage between connector X-52B pin 4 and ground.
A. If there is no voltage, there is a short to high source on wire 124 (Yellow) between connector X-CC1A pin 6
and connector X-C23 pin 19. Repair or replace the wire.
B. If there is voltage, there is a short to high source on wire 124 (Yellow) between connector X-52B pin 4 and
connector X-CC1B pin 6. Repair or replace the wire.
12. Check for proper resistance of the Instrument Cluster.
Disconnect connector X-C23 to the Instrument Cluster. Using a multi-meter, check for resistance between Instru-
ment Cluster pins 19 and 20.
A. If resistance is about 1.1 M Ω, continue with step 13.
B. If resistance is 0 Ω, the Instrument Cluster has shorted internally. Replace the Instrument Cluster.
C. If resistance is greater than 1.5 M Ω, the Instrument Cluster has opened internally. Replace the Instrument
Cluster.
nearby wiring.
This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a
failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered
for replacement.
47540694 28/04/2014
55.16 [55.DTC] / 63
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 64
1203-RPM Monitoring - Open Circuit/ Short to Ground/ Short to

Power EH Units
Context:
Cause:
Instrument Cluster has sensed that the Alternator Tach signal has failed. The fault is active when Engine is running,
code 9406 is not active and Instrument Cluster senses low RPM.

3. Failure of UCM.
Solution:
1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1203 RPM Monitoring - Open
Circuit/ Short to Ground/ Short to Power is active.
A. If the fault is active, continue with step 2 for EH machines.
2. Check for open circuit. Disconnect connector X-5 from the Alternator. Disconnect connector X-CN1A from the
UCM. Using a multi-meter, check continuity between connector X-5 pin 3 and connector X-CN1A pin 16.
B. If there is no continuity, there is an open wire condition on wire 124 (Yellow) between connector X-5 pin 3 and
connector X-CN1A pin 16. Continue with step 3.
3. Locate the open circuit. Disconnect connector X-52B from connector X-52A. Using a multi-meter, check continuity
between connector X-52B pin 4 and connector X-CN1A pin 16.
A. If there is no continuity, there is an open wire condition on wire 124 (Yellow) between connector X-CC1A pin
6 and connector X-CN1A pin 16. Repair or replace the wire.

4. Locate the open circuit. Using a multi-meter, check continuity between connector X-5 pin 3 and X-52A pin 4.
A. If there is no continuity, there is an open wire condition on wire 124 (Yellow) between connector X-52A pin 4
and connector X-5 pin 3. Repair or replace the wire.
B. If there is continuity, connectors X-52A and X-52B are not making a good connection at pin 4. Repair the
connector.
5. Check for a short to ground. Using a multi-meter, check for continuity between connector X-CN1A pin 16 and
ground.
B. If there is continuity, there is a short to ground condition on wire 124 (Yellow) between connector X-5 pin 3
and connector X-CN1A pin 16. Continue with step 6.
47540694 28/04/2014
55.16 [55.DTC] / 65
6. Locate the short to ground. Disconnect connector X-52A from connector X-52B. Using a multi-meter, check for
continuity between connector X-CN1A pin 16 and ground.
A. If there is no continuity, there is a short to ground on wire 124 (Yellow) between connector X-5 pin 3 and X-52A
pin 4. Repair or replace the shorted wire.
B. If there is continuity, there is a short to ground condition on wire 124 (Yellow) between connector X-52B pin 4
and connector X-CN1A pin 16. Repair or replace the shorted wire.
7. Check for short to high. Using a multi-meter, check for voltage between connector X-CN1A pin 16 and ground.
connector X-CN1A pin 16. Continue with step 8.
8. Locate the short to high. Disconnect connector X-52A from connector X-52B. Using a multi-meter, check for
voltage between connector X-5 pin 3 and ground.
A. If there is no voltage, there is a short to high source on wire 124 (Yellow) between connector X-CN1A pin 16
and connector X-52B pin 4. Repair or replace the wire.
connector X-52A pin 4. Repair or replace the wire.
9. Check for proper operation of the UCM. Reconnect connector X-CN1A to the UCM. Using a multi-meter, check
for voltage between connector X-52B pin 4 and ground.
A. If there is voltage, the UCM has failed. Replace the UCM.
B. If voltage is 0 V, continue with step 10.

10. Check for proper resistance of the UCM.
Completely power down the UCM by removing all connectors.
Using a multi-meter, check for resistance between UCM pins CN1A-16 and CN1A-1.
A. If resistance is normal, continue with step 11.
B. If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.
C. If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.
nearby wiring.
This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a
failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered
for replacement.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 66
1205-Hydraulic Enable (EH Machines) - Hydraulic Enable Output,

Short to Power
Context:
Fault code 1205 has an error priority of Amber.
There are no restrictions with Fault code 1205.
Cause:
The Instrument Cluster has determined that the Hydraulic Enable output from the Instrument Cluster does not match
the request from the Instrument Cluster. The fault is active while Ignition is on and Hydraulic Enable Commanded
State is Low and Hydraulic Enable Solenoid is energized.
1. Faulty wiring or connectors.

2. Faulty Instrument Cluster.
Solution:

Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
B. Fault code is recorded again. Go to Step 2.

(1) Inspect Instrument Cluster connector X-C23 and the UCM connections. All connections should be secure,
tight, free of corrosion, abrasion and/or damage.
(2) Inspect the harness from the Instrument Cluster to the UCM. Verify that the harness is free of damage, corro-
sion, abrasion and incorrect attachment.
RAPH12SSL0269FA 1
47540694 28/04/2014
55.16 [55.DTC] / 67
Schematic Legend
(1) Instrument Cluster Connector (2) UCM Connector
X-C23 pin 30 X-CN3A pin 23
B. The connectors or harness has damage. Repair or replace the harness or connectors as required. Return to
Step 1 to confirm elimination of fault.
3. Measure the voltage on the power wire.
(1) Turn the key switch OFF.
(4) Measure the voltage from Instrument Cluster connector X-C23, pin 30 to chassis ground. The voltage should
be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition.
A. The voltage is less than 0.5 V, temporarily replace the Instrument Cluster and retest. Return to Step 1 to
confirm the elimination of the fault.
B. The voltage is greater than 0.5 V. The Hydraulic Loader Interlock power wire is shorted to another voltage
source. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault.
EH Units F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 68
1206-CAN Connection: Configuration Response Timeout

Context:
Cause:

5. Faulty ECU.
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 69
1207-Memory Parameters - Invalid Configuration Between IC and

UCM
Context:
On EH controled machines, error code 9403 and/or 1207 displays after updating the earlier instrument cluster software
to version 1.3.0.0
Cause:
The Instrument Cluster expects the Enhanced High Flow (EHF) option is on the machine and displays the error codes
when the machine model configuration does not match the expectation of the Instrument Cluster.
Solution:
1. Use EST to reset the machine model configurations and clear the fault code(s).
(1) Connect the EST to the machine diagnostics connector per the Cable and Adapter Help icon.
(2) Sit in the seat to power the controllers.
(3) Click on the Controller Status icon. Verify that the Instrument Cluster (IC) and the Vehicle Control Module
(VCM) are both online.
(4) Click on the configuration icon.
(5) Double click on the Machine Configurations selection.
(6) Click on Set up Controller for Configuring. .
(7) Change the drop down box selections to match the machine.
a) In Panel identifier, Select Electro-hydraulic.
b) Select Door Status.
c) Select Model
d) Select Region
e) If the machine is EHF, Select available and if the machine is not EHF, select not available.
(8) Click on Send Modified Values to Controller.
(9) Wait 5 seconds and then Power Cycle the machine by exiting the seat.
(10) Verify error code 9403 and/or 1207 is no longer displayed.
A. Error code 9403 and/or 1207 is no longer displayed. OK to return the machine to service.
B. Error code 9403 and/or 1207 are active,

For non-EHF machines continue with step 2
C. Error code 9403 and/or 1207 are active,

For EHF machines continue with step 3
2. Configure the machine to a model that offers EHF as an option and reconfigure to the original model.
Example: The SR150 or L215 are models that do not offer the EHF option and is displaying fault code 9403 after
configuring correctly and performing the power cycle.
47540694 28/04/2014
55.16 [55.DTC] / 70
c) Select a known EHF model such as SV300 or L230.

d) Select Region
e) Select available.
(5) Configure the machine to the correct settings of SR150 or L215 and EHF Not Available.
3. Ensure Enhanced High Flow is available and select a different model that offers EHF option.
Example: SV300 and L230 are models that offer EHF option and display 9403 after configuring correctly.
c) Select a different known model that is not the same model as the actual machine.
d) Select Region
(5) When fault code 9403 and/or 1207 are no longer displayed, follow steps 1 - 4 again to reconfigure the machine
back to the correct model.
47540694 28/04/2014
55.16 [55.DTC] / 71
1208-Seat Switch - Plausibility Fault

Context:
Cause:
The Instrument Cluster X-C23 pin 12 and UCM X-CN3B pin 30 do not agree on the presence of an operator.
1. Faulty wiring.
3. Failure of the UCM.
Solution:
(1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes, write down all fault codes,
(2) To check for active fault codes: Start and operate machine.

RAPH12SSL0404FA 1
47540694 28/04/2014
55.16 [55.DTC] / 72
Schematic legend
(1) Battery supply to switch (4) Cab to chassis interface harness
Fuse F-011 4 A Connector X-ECC2A/2B pin 3
(2) Seat Switch (5) Seat switch signal to the UCM
Connector X-58 Connector X-CN3B pin 30
Fault code 1208
(3) Seat switch signal to instrument cluster (6) To seat switch diode
Connector X-C23 pin 12 To UCM connector X-CN1A pin 14
Fault code 1208
(1) Inspect the UCM, instrument cluster, and the seat switch connections. All connections should be secure, tight,
free of corrosion, abrasion and damage.
(2) Inspect the harness from the UCM to the instrument cluster and the seat switch. Verify that the harness is free
of damage, corrosion, abrasion and incorrect attachment.
3. Use EST to test the circuit.
(2) Sit in the operator’s seat.
(3) Use the EST to access the status of the park brake pressure switch. The switch status should be ON.
EST park brake parameters

Reference Data Description Source
Seat switch status UCM
A. The UCM park brake switch status is OFF. Go to step 4.
B. The UCM park brake switch status is ON. Go to step 5.

4. Test the UCM input.
(2) Fabricate a jumper that can connect between the positive battery terminal and UCM connector X-CN3B pin 30.
(5) Use the EST to access the status of the park brake pressure switch. The switch status should be ON.
A. The UCM park brake switch status is OFF. Temporarily replace the UCM and retest. Return to step 1 to confirm
B. The UCM park brake switch status is ON. There is a problem in the wiring between the seat switch and UCM
connector X-CN3B. Check splice SP-101. Repair or replace the harness as required. Return to step 1 to
5. Test the instrument cluster input.
(2) Fabricate a jumper that can connect between the positive battery terminal and instrument cluster connector
X-C23 pin 12.
47540694 28/04/2014
55.16 [55.DTC] / 73
(5) Use the EST to access the active fault codes. Fault code 1208 should no longer be active.
A. Fault code 1208 is no longer active. There is a problem in the wiring between the seat switch and instrument
cluster connector X-C23. Check splice SP-086. Return to step 1 to confirm elimination of the fault.
B. Fault code 1208 is still active. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm
EH machine F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 74
1211-Calibration Functions - Joystick Calibration Not Complete

Context:
Cause:
UCM has sensed that the Joystick Calibration is not complete.
1. Calibration not complete

2. Failure of UCM
Solution:
1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1211 Calibration Functions -
Joystick Calibration Not Complete is active.
2. Use the EST to perform calibration on the Joystick.
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Joystick (55.000)
A. If the fault code clears, continue normal operation.
B. If the fault code does not clear, replace the Joystick and reperform calibration. If the code persists, replace the
UCM.
nearby wiring.
This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. There-
fore, all other possibilities should be investigated before the UCM is considered for replacement.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 75
1212-Calibration Functions - Ground Drive Calibration Not Complete

Context:
Cause:
UCM has sensed that the Ground Drive Calibration is not complete.

2. Failure of UCM
Solution:
Ground Drive Calibration Not Complete is active.
2. Use the EST to perform calibration on the Ground Drive.
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Ground Drive (55.000)
B. If the fault code does not clear, replace the Ground Drive and reperform calibration. If the code persists, replace
UCM.
nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 76
1213-Calibration Functions - Loader Valve Calibration Not Complete

Context:
Cause:
UCM has sensed that the Loader Valve Calibration is not complete.

2. Failure of UCM
Solution:
Loader Valve Calibration Not Complete is active.
2. Use the EST to perform calibration on the Loader Valve.
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Loader valve (55.000)
B. If the fault code does not clear, replace the Loader Valve and reperform calibration. If the code persists, replace
UCM.
nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 77
1214-Calibration Functions - Throttle Calibration Not Complete

Context:
Cause:
UCM has sensed that the Throttle Calibration is not complete.

2. Failure of UCM
Solution:
Throttle Calibration Not Complete is active.
2. Use the EST to perform calibration on the Throttle.
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures – Throttle (55.000)
B. If the fault code does not clear, replace the Throttle and reperform calibration. If the code persists, replace
UCM.
nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 78
1221-Health Monitor Functions - UCM - UCM Temperature / Current

Draw Over Limit
Context:
Limp Home Hydraulics are enabled with Diagnostic Trouble Code 1221.
Cause:
UCM has sensed high current or high temperature in the UCM.
1. Failure of UCM.
Solution:
1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify fault code 1221
Health Monitor Functions - UCM - UCM Temperature / Current Draw Over Limit is active.
A. If the fault is active, the UMC has failed. Replace the UCM.
nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 79
1222-Health Monitor Functions - UCM - UCM Sustained Over

Temperature Limit
Context:
Disable Hydraulics is enabled with Diagnostic Trouble Code 1222.
Cause:
UCM has sensed high temperature in the UCM.
1. Failure of UCM.
Solution:
Health Monitor Functions - UCM - UCM Sustained Over Temperature Limit is active.
A. If the fault is active, the UCM has failed. Replace the UCM.
nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 80
1223-Health Monitor Functions - UCM - UCM Sustained Over

Current Limit
Context:
Cause:
UCM has sensed high current in the UCM.
1. Failure of UCM.
Solution:
Health Monitor Functions - UCM - UCM Sustained Over Current Limit is active.
nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 81
1224-Health Monitor Functions - UCM - Internal Memory or Core

Monitoring Fault
Context:
Cause:
UCM has sensed an internal fault in the UCM.
1. Failure of UCM.
Solution:
Health Monitor Functions - UCM - Internal Memory or Core Monitoring Fault is active.
nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 82
1225-Health Monitor Functions - UCM - EEPROM Memory

Checksum Fault
Context:
Cause:
UCM has sensed a checksum failure in the UCM memory.
1. Failure of UCM.
Solution:
Health Monitor Functions - UCM - EEPROM Memory Checksum Fault is active.
A. If the fault persists for three machine restarts, the UCM has failed. Replace the UCM.
nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 83
1350-Hyd Enable Switch - Implausible State (Hardwire vs CAN)

L223 TIER 4 [NDM474381 - ] NA
Context:
Diagnostic Trouble Code 1350 has an error priority of amber.
Loader limp home and ground drive limp home operating modes are enabled while Diagnostic Trouble Code 1350 is
active.
Cause:
UCM is receiving conflicting information about the hydraulic enable button. The fault is active when the ignition is on
and hydraulic enable pin voltage is opposite of value transmitted from instrument cluster.

Solution:
B. Fault code 1350 is recorded again. Fault code 9156 may also be active. Go to step 2.
Verify the connections to the UCM and instrument cluster are tight and secure.
Verify the harness is free of damage, abrasion, corrosion and incorrect attachment from the UCU to the instrument
cluster.
A. The harness is not damaged and all connections are secure. Go to step 3.
3. Measure the resistance of the signal line to chassis ground.
Disconnect UCM connector X-CN3A.
Measure the resistance between X-CN3A pin 23 and chassis ground. The resistance should be greater than
A. The resistance is greater than 20,000 Ω. Go to step 4.
47540694 28/04/2014
55.16 [55.DTC] / 84
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness
as required. Return to step 4.
4. Measure the voltage on the signal wire.
Measure the voltage between X-CN3A pin 23 and chassis ground. The voltage should be less than 0.5 V. Wiggle
A. The voltage is less than 0.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination
of the fault.
B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the
harness as required. Return to step 1 to confirm elimination of the fault.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 85
1511-Right Brake Lights Open Circuit

L223 TIER 4 [NDM474381 - ] NA
Context:
Diagnostic Trouble Code 1511 has an error priority of White. White errors are not displayed on the Instrument Cluster
and are not known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble
codes.
Brake Lights are disabled while Diagnostic Trouble Code 1511 is active.
Cause:
The UCM has sensed an open circuit condition on the brake light actuation line X-CN1B pin 29. The fault is active
when engine is ON and the brake light voltage is less than 1 V or greater than 8 V.

2. Short circuit in the wiring.
3. Failure of the brake light.
Solution:


(1) Inspect the UCM and brake lamp connections. All connections should be secure, tight, free of corrosion, abra-
sion and damage.
(2) Inspect the harness from the UCM to the brake lamps. Verify that the harness is free of damage, corrosion,
abrasion or incorrect attachment.
A. The wiring is free of corrosion, damage, abrasion and incorrect attachment. Go to Step 3.
as required. Go to Step 1 to confirm elimination of the fault.
3. Measure the resistance of the signal wire.
(1) Disconnect UCM connector X-CN1B.
(2) Measure the resistance between X-CN1B pin 29 and CX-CN1B pin 30. The resistance should be less than
10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Check splice SP-150. Repair or
replace the harness as required. Go to Step 1 to confirm elimination of the fault.
4. step 4
47540694 28/04/2014
55.16 [55.DTC] / 86
1512-Right Brake Lights Short to Ground

L223 TIER 4 [NDM474381 - ] NA
Context:
and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for
active trouble codes while troubleshooting another fault.
Brake Lights are disabled with Diagnostic Trouble Code 1512.
Cause:
UCM has sensed a short circuit condition on the Brake Light actuation line. (The fault is only activated when Brake
Lights are commanded On and Brake Light current greater than 3 A.)

2. Failure of brake light.
Solution:
1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1512 Right Brake Light Short to
Ground is active.
2. Check for proper resistance in the RH Rear Road Lamp Brake Lamp. Remove the Brake Lamp bulb from the RH
Rear Road Lamp. Using a multi-meter, check for resistance across the Brake Lamp bulb.
A. If resistance is normal, replace bulb and continue with step 3.
B. If resistance is infinite, the bulb has blown. Replace the Brake Lamp bulb.
C. If resistance is 0 Ω, the Brake Lamp bulb has shorted internally. Replace the Brake Lamp bulb.
3. Check for a short to ground. Disconnect connector X-44 from the RH Rear Road Lamp. Disconnect connector
X-CN1B from the UCM. Disconnect connector X-37 from the LH Rear Road Lamp. Disconnect connector X-39.
Using a multi-meter, check for continuity between connector X-44 pin C, or connector X-CN1B pin 29 and ground.
B. If there is continuity, there is a short to ground condition on wire 580/721/737/734 (Violet) between connector
X-44 pin C and connector X-CN1B pin 29, or adjacent wiring. Continue with step 4.
4. Locate the short to ground. Disconnect connector X-200 from connector X-203. Using a multi-meter, check for
continuity between connector X-200 pin 5, or connector X-CN1B pin 29, and ground.
A. If there is no continuity, there is a short to ground on wire 737/734 (Violet) between connector X-44 pin C and
X-203 pin 5, or adjacent wiring. Repair or replace the shorted wire.
B. If there is continuity, there is a short to ground condition on wire 580/721 (Violet) between connector X-200 pin
5 and connector X-CN1B pin 29, or adjacent wiring. Repair or replace the shorted wire.
Completely power down the UCM by removing all eight connectors.
Using a multi-meter, check for resistance between UCM pins CN1B-29 and CN1A-1.
47540694 28/04/2014
55.16 [55.DTC] / 87
nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 88
1513-Right Brake Lights Short to Power

L223 TIER 4 [NDM474381 - ] NA
Context:
Cause:
UCM has sensed an short to high condition on the Brake Light actuation line. (The fault is only activated when Brake
Lights are commanded Off and Brake Light voltage is greater than 8 V.)
Solution:
1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1513 Right Brake Light Short
to Power is active.
2. Check for short to high. Disconnect connector X-44 from the RH Rear Road Lamp. Disconnect connector X-CN1B
from the UCM. Disconnect connector X-37 from the LH Rear Road Lamp. Disconnect connector X-39. Using a
multi-meter, check for voltage between connector X-44 pin C, or connector X-CN1B pin 29 and ground.
B. If voltage greater than 8 V, there is a short to high source on wire 580/721/737/734 (Violet) between connector
3. Locate the short to high. Disconnect connector X-200 from connector X-203. Using a multi-meter, check for
voltage between connector X-44 pin C, or connector X-203 pin 5 and ground.
A. If there is no voltage, there is a short to high source on wire 580/721 (Violet) between connector X-200 pin 5
and connector X-CN1B pin 29, or adjacent wiring. Repair or replace the wire.
B. If voltage greater than 8 V, there is a short to high source on wire 737/734 (Violet) between connector X-44 pin
C and connector X-203 pin 5, or adjacent wiring. Repair or replace the wire.
4. Check for proper operation of the UCM. Reconnect connector X-CN1B to the UCM. Using a multi-meter, check for
voltage between connector X-44 pin C and ground.
A. If voltage is greater than 8 V, the UCM has failed. Replace the UCM.
B. If voltage is less than 8 V, continue with step 5.

nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 89
1521-Left Brake Lights Open Circuit

L223 TIER 4 [NDM474381 - ] NA
Context:
Cause:
UCM has sensed an open circuit condition on the Brake Light actuation line. (The fault is only activated when Engine
is On and Brake Light voltage falls out of the range of 1 - 8 V.)

Solution:
1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1521 Left Brake Lights Open
Circuit is active.
2. Check for proper resistance in the LH Rear Road Lamp Brake Lamp. Remove the Brake Lamp bulb from the LH
3. Check for open circuit. Disconnect connector X-37 from the LH Rear Road Lamp. Disconnect connector X-CN1B
from the UCM. Using a multi-meter, check continuity between connector X-37 pin C and connector X-CN1B pin
30.
B. If there is no continuity, there is an open wire condition on wire 579/721/737/732 (Violet) between connector
X-37 pin C and connector X-CN1B pin 30. Continue with step 4.
4. Locate the open circuit. Disconnect connector X-200 from connector X-203. Using a multi-meter, check continuity
between connector X-200 pin 5 and connector X-CN1B pin 30.
A. If there is no continuity, there is an open wire condition on wire 579/721 (Violet) between connector X-200 pin
5 and connector X-CN1B pin 30. Repair or replace the wire.

5. Locate the open circuit. Using a multi-meter, check continuity between connector X-203 pin 5 and connector X-37
pin C.
A. If there is no continuity, there is an open wire condition on wire 737/732 (Violet) between connector X-203 pin
5 and connector X-37 pin C. Repair or replace the wire.
B. If there is continuity, connectors X-200 and X-203 are not making a good connection at pin 5. Repair the
connector.
6. Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector
X-44 pin B and ground.
47540694 28/04/2014
55.16 [55.DTC] / 90
B. If there is no continuity, there is an open in the ground circuit on wire 998/1000/950/965/967 (Black). Use
Frames 16, 8, and 1 to troubleshoot and isolate the faulty wire.
nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 91
1522-Left Brake Lights Short to Ground

L223 TIER 4 [NDM474381 - ] NA
Context:
Cause:
UCM has sensed a short circuit condition on the Brake Light actuation line. (The fault is only activated when Brake
Lights are commanded On and Brake Light current greater than 3 A.)

Solution:
1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1522 Left Brake Lights Short to
Ground is active.
2. Check for proper resistance in the LH Rear Road Lamp Brake Lamp. Remove the Brake Lamp bulb from the LH
3. Check for a short to ground. Disconnect connector X-37 from the LH Rear Road Lamp. Disconnect connector
X-CN1B from the UCM. Disconnect connector X-44 from the RH Rear Road Lamp. Disconnect connector X-39.
Using a multi-meter, check for continuity between connector X-37 pin C, or connector X-CN1B pin 30 and ground.
B. If there is continuity, there is a short to ground condition on wire 579/721/737/732 (Violet) between connector
4. Locate the short to ground. Disconnect connector X-200 from connector X-203. Using a multi-meter, check for
continuity between connector X-200 pin 5, or connector X-CN1B pin 30, and ground.
A. If there is no continuity, there is a short to ground on wire 737/732 (Violet) between connector X-37 pin C and
X-203 pin 5, or adjacent wiring. Repair or replace the shorted wire.
B. If there is continuity, there is a short to ground condition on wire 579/721 (Violet) between connector X-200 pin
5 and connector X-CN1B pin 30, or adjacent wiring. Repair or replace the shorted wire.
47540694 28/04/2014
55.16 [55.DTC] / 92
nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 93
1523-Left Brake Lights Short to Power

L223 TIER 4 [NDM474381 - ] NA
Context:
Cause:
UCM has sensed an short to high condition on the Brake Light actuation line. (The fault is only activated when Brake
Lights are commanded Off and Brake Light voltage is greater than 8 V.)
Solution:
1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1523 Left Brake Lights Short to
Power is active.
2. Check for short to high. Disconnect connector X-37 from the LH Rear Road Lamp. Disconnect connector X-CN1B
from the UCM. Disconnect connector X-44 from the RH Rear Road Lamp. Disconnect connector X-39. Using a
multi-meter, check for voltage between connector X-37 pin C, or connector X-CN1B pin 30 and ground.
B. If voltage greater than 8 V, there is a short to high source on wire 579/721/737/732 (Violet) between connector
3. Locate the short to high. Disconnect connector X-200 from connector X-203. Using a multi-meter, check for
voltage between connector X-37 pin C, or connector X-203 pin 5 and ground.
A. If there is no voltage, there is a short to high source on wire 579/721 (Violet) between connector X-200 pin 5
and connector X-CN1B pin 30, or adjacent wiring. Repair or replace the wire.
B. If voltage greater than 8 V, there is a short to high source on wire 737/732 (Violet) between connector X-37 pin
C and connector X-203 pin 5, or adjacent wiring. Repair or replace the wire.
4. Check for proper operation of the UCM. Reconnect connector X-CN1B to the UCM. Using a multi-meter, check for
voltage between connector X-37 pin C and ground.

nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 94
1532-Backup Alarm - Short to Ground

Context:
and are not known to the Owner/Operator. They will appear in EST when the technician checks for active trouble
codes.
Backup Alarm is disabled with Diagnostic Trouble Code 1532.
Cause:
UCM has sensed improper current from the Backup Alarm. The fault is only when both pumps are in reverse and
backup alarm solenoid output current is high.

2. Faulty backup alarm.
3. UCM has internal failure.
Solution:
1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1532 is active.
2. Check for a short circuit to ground. Disconnect connector X-BKUP-PWR from the backup alarm. Disconnect UCM
connector X-CN3B. Using a multi-meter, check for continuity between X-CN3B pin 18 and chassis ground.
B. If there is continuity, there is a short to ground condition on wire 895 (White) between connector X-BKUP-PWR
pin 1 and UCM connector X-CN3B pin 18. Repair or replace the wire.
3. Check for proper resistance in the Backup Alarm. Disconnect connector X-BKUP-GND from the Backup Alarm.
Using a multi-meter to check for resistance between pins on the Backup Alarm.
A. If resistance is normal, replace the UCM.
B. If resistance is infinite, the Backup Alarm has developed an open. Replace the Backup Alarm .
C. If resistance is 0 Ω, the Backup Alarm has shorted internally. Replace the Backup Alarm.
nearby wiring.
resolved.
continue operation.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 95
1533-Backup Alarm - Short to Power

Context:
codes.
Backup Alarm is disabled with Diagnostic Trouble Code 1533.
Cause:
UCM has sensed that the Backup Alarm solenoid output does not agree with the desired Backup Alarm status. The
fault is activate when the pumps not in reverse and the backup alarm solenoid output voltage is greater than 8 V.

Solution:
1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1533 is active.
2. Check for short to high. Disconnect connector X-BKUP-PWR from the Backup Alarm. Disconnect UCM connector
X-CN3B. Using a multi-meter, check for voltage between UCM connector X-CN3B pin 18 and chassis ground.
B. If there is voltage, there is a short to high source on wire 895 (White) between connector X-BKUP-PWR pin 1
and connector X-CN3B pin 18. Repair or replace the wire.
3. Check for proper operation of the UCM. Reconnect UCM connector X-CN3B. Using a multi-meter, check for volt-
age between connector X-BKUP-PWR pin 1 and chassis ground.

nearby wiring.
resolved.
continue operation.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 96
1900-UCM - UCM Ground Fault

Context:
All hydraulics are disabled while Diagnostic Trouble Code 1900 is active.
Cause:
The UCM has sensed low current in the UCM ground line. The fault is active while the ignition is on and there is a
high resistance in the UCM ground line.
1. Bad chassis ground connections.

2. Open wire in the UCM ground circuit.
Solution:
C. If fault code 1900 is recorded along with other UCM fault codes, verify that the chassis ground connection is
clean and secure to the frame. Verify that the frame connection is free of paint, grease, oil, dirt, and debris.
Verify the connections from the UCM to chassis ground are tight and secure.
Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the UCM to the chassis
ground connection.
Verify that the chassis ground connection is clean and secure to the frame. Verify that the connection is free of
paint, grease, oil, dirt, and debris.
A. The harness is not damaged and all connections are secure. Go to step 3.
3. Measure the resistance of the UCM ground connection.
Disconnect the UCM connector X-CN1A.
Measure the resistance between X-CN1A pin 7 and chassis ground. The chassis ground connection must be clean
and free of paint, oil and dirt. The resistance should be less than 10 Ω. Wiggle the harness during measurement
47540694 28/04/2014
55.16 [55.DTC] / 97
Measure the resistance between X-CN1A pin 1 and chassis ground. The chassis ground connection must be clean
and free of paint, oil and dirt. The resistance should be less than 10 Ω. Wiggle the harness during measurement
A. Both resistance measurements are less than 10 Ω. The UCM ground connection is free of grease, oil, paint,
dirt and debris. Temporarily replace the UCM and retest. Return to 1 to confirm elimination of the fault.
B. One or both resistance measurements are greater than 10 Ω. There is a high resistance or open circuit in the
UCM chassis ground connection. Verify that the UCM ground connection is free of paint, oil, grease, dirt, and
debris. Repair or replace the UCM ground wire as required. Return to 1 to confirm elimination of the fault.
EH machines F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 98
1901-UCM - UCM Supply Voltage High

Context:
codes.
Cause:
UCM has sensed that the supply voltage is high. The fault is active while Ignition is On, and the input voltage is
greater than 16 V.

2. Failure of UCM.
Solution:
C. If fault code 1901 is recorded along with other diagnostic codes such 1014 and 3051, there is a problem in the
electrical charging system on the machine. Troubleshoot the alternator charging system.
Verify the connections to the UCM connector X-CN1A pin 20 and the alternator are tight and secure.
Verify the chassis ground connections to the UCM are tight and secure. The chassis ground connections must be
free of paint, rust oil dirt and debris.
Verify the harness is free of damage, abrasion, corrosion and incorrect attachment.
A. The wiring harness is not damaged and all connections are secure. Go to step 3.
3. Measure the alternator output.
Start the engine. Set engine speed to low idle and measure the voltage at the alternator. The voltage should be
approximately 14.8 V.
A. The voltage is approximately 14.8 V. Go to step 4.
B. The voltage is greater than 16 V. Replace the alternator. Return to step 1 to confirm elimination of fault.
4. Measure the voltage at the UCM.
47540694 28/04/2014
55.16 [55.DTC] / 99
Measure the voltage between UCM connector X-CN1A pin 20 and chassis ground. The voltage should be between
11 V and 14.8 V.
A. The voltage is approximately 14.8 V. Temporarily replace the UCM and retest. Return to step 1 to confirm
B. The voltage is greater than 16 V. Replace the alternator. Return to step 1 to confirm elimination of fault.
Small EH machines F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 100
1902-UCM - UCM Supply Voltage Low

Context:
Cause:
UCM has sensed that a 12 V UCM input is low. The fault becomes active when UCM input voltage, X-CN1A pin 20
is less than 11.5 V but greater than 9 Vfor a period greater than 30 s.
1. Faulty alternator output.

2. Shorted wire in the charging circuit.
Solution:
Verify the chassis ground connections to the UCM are tight and secure. The chassis ground connections should
be free of paint, rust oil dirt and debris.
B. The voltage is less than 9 V. Replace the alternator. Return to step 1 to confirm elimination of fault.
47540694 28/04/2014
55.16 [55.DTC] / 101
11 V and 14.8 V.
47540694 28/04/2014
55.16 [55.DTC] / 102
1903-UCM - UCM Supply Voltage Below Operational Limit

Context:
All Hydraulics are disabled while Diagnostic Trouble Code 1903 is active.
Cause:
UCM has sensed that a 12 V UCM input is low. The fault becomes active when UCM input voltage, X-CN1A pin 20
is less than 11.5 V but greater than 9 V for a period greater than 30 s.
1. Alternator output.
3. Failure of UCM.
Solution:
Verify the chassis grounds connections to the UCM are tight and secure. The chassis ground connections should
be free of paint, rust oil dirt and debris.
47540694 28/04/2014
55.16 [55.DTC] / 103
11 V and 14.8 V.
B. The voltage is less than 9 V. Replace the alternator and retest. Return to step 1 to confirm elimination of fault.
47540694 28/04/2014
55.16 [55.DTC] / 104
1904-UCM - Rail 12VB: 5V Regulators Supply Input Power Off

Context:
UCM has sensed that a 12 V UCM input has failed low. Diagnostic Trouble Code 1904 has an error priority of Red.
Cause:
UCM has sensed that a 12 V UCM input has failed low. The fault is active while the ignition is ON, crank input pin is
low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.

Solution:
C. Fault code 1904 is recorded along with other diagnostic codes such as 1907 to 1917 and/or Right or Left
Swatch Plate Sensor fault codes. Test the fuses and relays. Repair as required. Return to step 1 to confirm
Verify the connections to the UCM connector X-CN1A pin 26 are tight and secure.
3. Test the UCM connection
Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN1A pin 26.
Connect the jumper from the positive battery post to UCM connector X-CN1A pin 26.
Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer
be active.
A. The fault code is not longer active. There is a problem in the wiring from between Splice SP-119 and the UCM
connector. Repair as required. Return to step 1 to confirm elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 105
B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to
step 1 to confirm elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 106
1905-UCM - 5VREF1 Sensor Supply Voltage Out of Range

Context:
UCM has sensed that the sensor supply voltage X-CN1A pin 8 is out of range. Diagnostic Trouble Code 1905 has
an error priority of Red.
All hydraulics are disabled while Diagnostic Trouble Code 1905 is active.
Cause:
UCM has sensed that the sensor supply voltage X-CN1A pin 8 is out of range. The fault is active while the ignition
switch is ON and the voltage at pin 8 is less than 4.8 V or greater than 5.2 V.
1. Faulty wiring.
2. Faulty sensor.
3. Faulty UCM.
Solution:
B. Fault code 1905 is active and recorded again. Go to step 2.

Inspect the UCM, EHF pressure transducer, right hand control handle, throttle position sensor, chassis loader
interface and Universal Joystick Module. All connections should be secure, tight, free of corrosion, abrasion and
damage.
Inspect the harness from the UCM to the EHF pressure transducer, right hand control handle, throttle position sen-
sor, chassis loader interface and Universal Joystick Module. Verify that the harness is free of damage, corrosion,
abrasion and incorrect attachment.
3. Measure the voltage at the UCM
Turn the ignition switch ON and measure the voltage between UCM connector X-CN1A pin 8 and chassis ground.
B. The voltage is greater than 5.2 V. Go to step 6.
C. The voltage is greater than 4.8 V but less than 5.2 V. There does not seem to be a problem at this time. Re-
program the UCM with the latest software. If the fault code persists, temporarily replace the UCM and retest.
4. Check for a short to chassis ground.
47540694 28/04/2014
55.16 [55.DTC] / 107
Disconnect the UCM connector, X-CN1A.
Disconnect the EHF pressure transducer, right hand control handle, throttle position sensor, chassis loader inter-
face and Universal Joystick Module.
Use a digital voltmeter to measure the resistance between X-CN1A pin 8 and chassis ground. The resistance
should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
5. Reconnect the components to the harness while monitoring the resistance
Use a digital voltmeter to measure the resistance between X-CN1A pin 8 and chassis ground.
Reconnect the components one at a time (EHF pressure transducer, right hand control handle, throttle position
sensor, chassis loader interface and Universal Joystick Module), while monitoring the resistance reading. The
resistance should be greater than 20,000 Ω while the components are reconnected into the circuit.
A. The resistance is greater than 20,000 Ω but dropped below 20,000 Ω when a component was reconnected
into the circuit. Temporarily replace the component that dropped the resistance and retest. Return to step 1 to
B. The resistance is greater than 20,000 Ω while each component was reconnected into the circuit. Temporarily
replace the UCM and retest. Return to step 1 to confirm the elimination of the fault.
6. Check for a short to battery
Disconnect the EHF pressure transducer, right hand control handle, throttle position sensor, chassis loader inter-
face and Universal Joystick Module.
Turn the ignition switch ON and measure the voltage between X-CN1A pin 8 and chassis ground. The voltage
should be less than 0.5 V. Wiggle the harness during measurement to reveal and intermittent condition.
harness as required. Return to step 1 to confirm the elimination of the fault.
7. Reconnect the components to the harness while monitoring the voltage
Use a digital voltmeter to measure the voltage between X-CN1A pin 8 and chassis ground.
Reconnect the components one at a time (EHF pressure transducer, right hand control handle, throttle position
sensor, chassis loader interface and Universal Joystick Module), while monitoring the volatge reading. The voltage
should be less than 0.5 V while the components are reconnected into the circuit.
A. The voltage is less than 0.5 V but changed to a voltage greater than 1 V when a component was reconnected
into the circuit. Temporarily replace the component that changed the voltage. Return to step 1 to confirm
B. The voltage is less than 0.5 V while each component was reconnected into the circuit. Temporarily replace the
UCM and retest. Return to step 1 to confirm the elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 108

47540694 28/04/2014
55.16 [55.DTC] / 109
1906-UCM - 5VREF3 Sensor Supply Voltage Out of Range

Context:
Cause:
UCM has sensed that the sensor supply voltage X-CN1A pin 9 is out of range. The fault is active while the ignition
switch is ON and voltage at pin 9 is less than 4.8 V or greater than 5.2 V.
1. Faulty wiring.
2. Faulty sensor.
3. Faulty UCM.
Solution:

Inspect the UCM, right hand control handle and Universal Joystick Module. All connections should be secure,
Inspect the harness from the UCM to the right hand control handle and Universal Joystick Module. Verify that the
harness is free of damage, corrosion, abrasion and incorrect attachment.
Turn the ignition switch ON and measure the voltage between UCM connector X-CN1A pin 9 and chassis ground.
B. The voltage is greater than 5.2 V. Go to step 6.
C. The voltage is greater than 4.8 V but less than 5.2 V. There does not seem to be a problem at this time. Re-
program the UCM with the latest software. If the fault code persists, temporarily replace the UCM and retest.
4. Check for a short to chassis ground.
47540694 28/04/2014
55.16 [55.DTC] / 110
Disconnect the right hand control handle and Universal Joystick Module.
Use a digital voltmeter to measure the resistance between X-CN1A pin 9 and chassis ground. The resistance
5. Reconnect the components to the harness one at a time while monitoring the resistance.
Use a digital voltmeter to measure the resistance between X-CN1A pin 9 and chassis ground.
Reconnect the components one at a time (right hand control handle and Universal Joystick Module), while monitor-
ing the resistance reading. The resistance should be greater than 20,000 Ω while the components are reconnected
into the circuit.
A. The resistance is greater than 20,000 Ω but dropped below 20,000 Ω when a component was reconnected
into the circuit. Temporarily replace the component that dropped the resistance. Return to step 1 to confirm
B. The resistance is greater than 20,000 Ω while each component was reconnected into the circuit. Temporarily
replace the UCM and retest. Return to step 1 to confirm the elimination of the fault.
6. Check for a short to battery.
Disconnect the right hand control handle and Universal Joystick Module.
Turn the ignition switch ON and measure the voltage between X-CN1A pin 9 and chassis ground. The voltage
should be less than 0.5 V. Wiggle the harness during measurement to reveal and intermittent condition.
harness as required. Return to step 1 to confirm the elimination of the fault.
7. Reconnect the components to the harness while monitoring the voltage.
Use a digital voltmeter to measure the voltage between X-CN1A pin 9 and chassis ground.
Reconnect the components one at a time (right hand control handle and Universal Joystick Module), while moni-
toring the voltage reading. The voltage should be less than 0.5 V while the components are reconnected into the
circuit.
A. The voltage is less than 0.5 V but changed to a voltage greater than 1 V when a component was reconnected
into the circuit. Temporarily replace the component that changed the voltage. Return to step 1 to confirm
B. The voltage is less than 0.5 V while each component was reconnected into the circuit. Temporarily replace the
UCM and retest. Return to step 1 to confirm the elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 111

47540694 28/04/2014
55.16 [55.DTC] / 112
1907-UCM - Rail 12VF1: Aux Retract Input Power Off

Context:
Disable Aux operating mode is enabled with Diagnostic Trouble Code 1907.
Cause:
UCM has sensed that a 12 V UCM input has failed low. The fault is active while Ignition is On, crank pin is low,
Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.
1. Blown fuse.
4. Failure of UCM.
Solution:
C. Fault code 1907 is recorded along with other diagnostic codes such as 1904, 1908 to 1917 and/or Right or Left
Verify the connections to the UCM connector X-CN1B pin 26 and X-CN1B pin 27 are tight and secure.
3. Measure the voltage at the fuse
Measure voltage from the UCM Prop Aux Fuse F-018 terminal B2 to chassis ground. The voltage should be
approximately 12 V.
A. The voltage is approximately 12 V. Go to step 4.
B. The voltage is less than 9 V. Go to step 5.

47540694 28/04/2014
55.16 [55.DTC] / 113
Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN1B pin 26 and
X-CN1B pin 27.
be displayed.
A. The fault code is not longer active. There is a problem in the wiring from between Fuse F-018 and the UCM
5. Measure the voltage at the Fuse
Measure voltage from the UCM Prop Aux Fuse F-018 terminal B1 to chassis ground. The voltage should be
approximately 12 V.
A. The voltage is approximately 12 V. Replace the fuse. Return to step 1 to confirm elimination of the fault.
B. The voltage is less than 9 V. There is a problem in the wiring from the UCM Power Relay to the fuse. Check
Splice 119 and Splice 118 and associated wiring. Repair as required. Return to step 1 to confirm elimination
of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 114
1908-UCM - Rail 12VF2: Bucket Extend Input Power Off

Context:
Disable Bucket operating mode is enabled while Diagnostic Trouble Code 1908 is active.
Cause:
UCM has sensed that a 12 V UCM input has failed low. The fault is active while the ignition is ON, crank pin is low,

3. Failure of UCM.
Solution:
C. Fault code 1908 is recorded along with fault code 1913. Check Fuse F-019 and the wiring to splice SP-111.
Repair as required. Return to step 1 to confirm elimination of the fault.
D. Fault code 1908 is recorded along with other diagnostic codes such as 1904, 1907, 1909 to 1917 and/or Right
or Left Swatch Plate Sensor fault codes. Test the fuses and relays. Repair as required. Return to step 1 to
Verify the connections to the UCM connector X-CN4A pin 1 and X-CN4A pin 8 are tight and secure.
3. Test the UCM connection.
Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN4A pin 1 and
X-CN4A pin 8.
Connect the jumper from the positive battery post to UCM connector X-CN4A pin 1 and X-CN4A pin 8.
47540694 28/04/2014
55.16 [55.DTC] / 115
be displayed.
47540694 28/04/2014
55.16 [55.DTC] / 116
1909-UCM - Rail 12VF3: Boom Raise/Lower Input Power Off

Context:
Boom operation is disabled while Diagnostic Trouble Code 1909 is active.
Cause:
UCM has sensed that a 12 V UCM input has failed low. The fault is only activated when the ignition is ON, crank pin
is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.
1. Blown fuse.
Solution:
C. Fault code 1909 is recorded along with other diagnostic codes such as 1904, 1907, 1908, 1910 to 1917 and/or
Right or Left Swatch Plate Sensor fault codes. Test the fuses and relays. Repair as required. Return to step 1
to confirm elimination of the fault.
3. Measure the voltage at the fuse.
Measure voltage from the UCM Boom Fuse F-022 terminal B6 to chassis ground. The voltage should be approx-
imately 12 V.

47540694 28/04/2014
55.16 [55.DTC] / 117
X-CN2B pin 17.
Connect the jumper from the positive battery post to UCM connector X-CN2B pin 9 and X-CN2B pin 17.
be displayed.
A. The fault code is not longer active. There is a problem in the wiring between Fuse F-022 and the UCM connec-
tor. Check Splice SP-110 and associated wiring. Repair as required. Return to step 1 to confirm elimination
of the fault.
Measure voltage from the UCM Boom Fuse F-022 terminal B5 to chassis ground. The voltage should be approx-
imately 12 V.
of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 118
1910-UCM - Rail 12VH: Ldr Plt Interlk & Port Lock Input Power Off
Context:
Loader Hydraulics are disabled while Diagnostic Trouble Code 1910 is active.
Cause:
1. Blown fuse.
4. Failure of UCM.
Solution:
C. Fault code 1910 is recorded along with other diagnostic codes such as 1904, 1907 to 1909, 1911 to 1917
and/or Right or Left Swatch Plate Sensor fault codes. Test the fuses and relays. Repair as required. Return
Measure voltage from the UCM Interlocks Fuse F-025 terminal C4 to chassis ground. The voltage should be
approximately 12 V.

47540694 28/04/2014
55.16 [55.DTC] / 119
X-CN2A pin 13.
be displayed.
of the fault.
Measure voltage from the UCM Prop Aux Fuse F-025 terminal C3 to chassis ground. The voltage should be
approximately 12 V.
of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 120
1911-UCM - Rail 12VH1: Left & Right Pump Reverse Input Power Off
Context:
UCM has sensed that a 12 V UCM input has failed low. Diagnostic Trouble Code 1911 has an error priority of red.
Reverse Ground Drive is disabled while Diagnostic Trouble Code 1911 is active.
Cause:

Solution:
C. Fault code 1911 is recorded along with Swash Plate Sensor Faults such as 4734 and 4744. Check Fuse F-017
and the wiring to splice SP-152. Repair as required. Return to step 1 to confirm elimination of the fault.
D. Fault code 1911 is recorded along with other diagnostic codes such as 1904, 1907 to 1910, 1912 to 1917
X-CN2A pin 3.
47540694 28/04/2014
55.16 [55.DTC] / 121
be displayed.
47540694 28/04/2014
55.16 [55.DTC] / 122
1912-UCM - Rail 12VM: Left & Right Brake Lights & Aux Extend
Input Power Off
Context:
UCM has sensed that a 12 V UCM input has failed low. Diagnostic Trouble Code 1912 has an error priority of Amber.
Aux operating mode is disabled while Diagnostic Trouble Code 1912 is active.
Cause:
1. Blown fuse.
4. Failure of UCM.
Solution:
Measure voltage from the UCM Brake Lamps Fuse F-015 terminal A2 to chassis ground. The voltage should be
approximately 12 V.
47540694 28/04/2014
55.16 [55.DTC] / 123
X-CN1B pin 32.
be displayed.
A. The fault code is not longer active. There is a problem in the wiring to the UCM. Check Splice SP-113 and
associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault.
Measure voltage from the UCM Brake Lamps Fuse F-015 terminal A1 to chassis ground. The voltage should be
approximately 12 V.
A. The voltage is approximately 12 V. Replace the fuse and retest. Return to step 1 to confirm elimination of the
fault.
Splice 119 and associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 124
1913-UCM - Rail 12VS1: Bucket Curl Input Power Off

Context:
Bucket operating mode is disabled while Diagnostic Trouble Code 1913 is active.
Cause:
UCM has sensed that a 12 V UCM input has failed low. The fault is active while the ignition is On, crank pin is low,

3. Failure of UCM.
Solution:
C. Fault code 1913 is recorded along with fault code 1908. Check Fuse F-019 and the wiring to splice SP-111.
Repair as required. Return to step 1 to confirm elimination of the fault.
D. Fault code 1913 is recorded along with other diagnostic codes such as 1904, 1907 to 1912, 1914 to 1917
X-CN3B pin 9.
47540694 28/04/2014
55.16 [55.DTC] / 125
be displayed.
47540694 28/04/2014
55.16 [55.DTC] / 126
1914-UCM - Rail 12VS2: Backup Alarm Input Power Off

Context:
Cause:
1. Blown fuse.
4. Failure of UCM.
Solution:
Verify the connections to the UCM connector X-CN3B pin 3 are tight and secure.
3. Measure the voltage at the fuse
Measure voltage from the UCM Backup Alarm Fuse F-007 terminal B2 to chassis ground. The voltage should be
approximately 12 V.

47540694 28/04/2014
55.16 [55.DTC] / 127
Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN3B pin 3.
Connect the jumper from the positive battery post to UCM connector X-CN3B pin 3.
be displayed.
Measure voltage from the UCM Backup Alarm Fuse F-007 terminal B1 to chassis ground. The voltage should be
approximately 12 V.
Splice 119 and Splice 117. Repair as required. Return to step 1 to confirm elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 128
1915-UCM - Rail 12VT1: Two Speed Input Power Off

Context:
Cause:
1. Blown fuse.
4. Failure of UCM.
Solution:
C. Fault code 1915 is recorded along with other diagnostic codes such as 1904, 1907 to 1914, 1916 and 1917
Measure voltage from the UCM 2SPD Fuse F-027 terminal E4 to chassis ground. The voltage should be approx-
imately 12 V.

47540694 28/04/2014
55.16 [55.DTC] / 129
X-CN3A pin 13.
be displayed.
Measure voltage from the UCM 2SPD Fuse F-027 terminal E3 to chassis ground. The voltage should be approx-
imately 12 V.
Splice 119 and associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 130
1916-UCM - Rail 12VU1: Right & Left Pumps Forward Input Power
Off
Context:
Forward Ground Drive is disabled while Diagnostic Trouble Code 1916 is active.
Cause:
UCM has sensed that a 12 V UCM input has failed low. The fault is active while Ignition is On, crank pin is low,
1. Blown fuse.
4. Failure of UCM.
Solution:
C. Fault code 1916 is recorded along with other diagnostic codes such as 1904, 1907 to 1915, 1917 and/or Right
or Left Swatch Plate Sensor fault codes. Test the fuses and relays. Repair as required. Return to step 1 to
Verify the connections to the UCM connector X-CN3A pin 21 are tight and secure.
Measure voltage from the UCM Pump FWD Fuse F-021 terminal B4 to chassis ground. The voltage should be
approximately 12 V.
47540694 28/04/2014
55.16 [55.DTC] / 131
Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN3A pin 21.
Connect the jumper from the positive battery post to UCM connector X-CN3A pin 21.
be displayed.
Measure voltage from the UCM Pump FWD Fuse F-021 terminal B3 to chassis ground. The voltage should be
approximately 12 V.
Splice 119 and Splice 117. Repair as required. Return to step 1 to confirm elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 132
1917-UCM - Rail 12VU2: Park Brake Solenoid Input Power Off

Context:
Ground Drive is disabled while Diagnostic Trouble Code 1917 is active.
Cause:
1. Blown fuse.
4. Failure of UCM.
Solution:
C. If fault code 1917 is recorded along with other diagnostic codes such as 1904, 1907 to 1916 and/or Right or Left
Measure voltage from the UCM GRND DRV Interlocks Fuse F-016 terminal A4 to chassis ground. The voltage
should be approximately 12 V.

47540694 28/04/2014
55.16 [55.DTC] / 133
X-CN3A pin 3.
be displayed.
of the fault.
Measure voltage from the UCM GRND DRV Interlocks Fuse F-016 terminal A3 to chassis ground. The voltage
should be approximately 12 V.
of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 134
3007-Engine Coolant Temperature Sender - Short to Ground

Context:
Instrument Cluster has received a message from the ECM that the Engine Coolant Temperature Sender signal is
above the maximum limit.
Cause:
above the maximum limit. The ECM monitors coolant temperature on X-016 pin 57 and sends a message via the
CAN Bus to the Instrument Cluster. The signal voltage is less than 4.8 volts.
1. Coolant temperature signal wire shorted to positive battery or has an open circuit.
2. Failure of Engine Coolant Temperature Sender.
3. Failure of ECU.
Solution:

RAPH12SSL0302FA 1
Schematic Legend
(2) Connector X-017
47540694 28/04/2014
55.16 [55.DTC] / 135
3. Measure the voltage of the signal wire to chassis ground
(3) Measure the voltage from X-016 pin 57 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
A. The voltage is less than 0.5 volts. Go to Step 4.
B. The voltage is greater than 0.5 volts. There is a short circuit to another voltage source. Repair or repalce the
(2) Measure the resistance across X-016 pin 58 and X-016 pin 57. The resistance should be greater than 10 ohms
but less than 20,000. Wiggle the harness during measurement to reveal an intermittent condition.

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
A. The resistance measurement is greater than 10 ohms but less than 20,000 ohms. Temporarily replace the
ECU and retest. Return to Step 1 to confirm elimination of the fault.
B. The resistance is greater than 20,000 ohms. Go to Step 5.


-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
47540694 28/04/2014
55.16 [55.DTC] / 136
47540694 28/04/2014
55.16 [55.DTC] / 137
3008-Engine Coolant Temperature Sender - Open Circuit

Context:
below the minimum range.
Cause:
below the minimum range. The ECM monitors coolant temperature on X-016 pin 57 and sends a message via the
CAN Bus to the Instrument Cluster. The signal voltage is less than 0.2 volts.
1. Coolant temperature signal wire shorted to ground or has an open circuit.

2. Failure of Engine Coolant Temperature Sender.
3. Failure of ECU.
Solution:

RAPH12SSL0302FA 1
Schematic Legend
(2) Connector X-017
47540694 28/04/2014
55.16 [55.DTC] / 138
(2) Measure the resistance across X-016 pin 58 and X-016 pin 57. The resistance should be greater than 10 ohms.

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
A. The resistance measurement is greater than 10 ohms but less than 20,000 ohms. Go to Step 4.
B. The resistance is less than 10 ohms. Go to Step 5.
C. The resistance is greater than 20,000 ohms. Go to Step 6.

4. Measure the resistance to chassis ground
(1) Measure the resistance from ECM connector X-016 pin 58 to chassis ground. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance measurement is greater than 20,000 ohms. Temporarily replace the ECU and retest. Return
B. The resistance is less than 10 ohms. The coolant temperature signal wire has a short circuit to chassis ground.
Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault.
5. Measure the resistance through the harness without the sensor connected
(1) Turn the key switch OFF. Disconnect ECU connector X-016. Disconnect the coolant temperature sensor.
(2) Measure the resistance across X-016 pin 58 and X-016 pin 57. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance measurement is greater than 20,00 ohms. Temporarily replace the coolant temperature sensor
and retest. Return to Step 1 to confirm elimination of the fault.
B. The resistance is less than 10 ohms. There is a short circuit between the coolant temperature signal wire and
the coolant temperature ground wire. Repair or replace the harness as required. Return to Step 1 to confirm

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
47540694 28/04/2014
55.16 [55.DTC] / 139

60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
47540694 28/04/2014
55.16 [55.DTC] / 140
3010-Air intake temperature sensor signal above maximum range

Context:
The Engine Control Unit (ECU) generated an error from a fault associated with the air intake temperature sensor. The
boost pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is
related to the temperature sensing function of the device. This error could result from a signal out of range or a signal
that is either erratic or intermittent.
Cause:
The air intake temperature sensor signal to the ECU is greater than the upper threshold limit.
1. Faulty electrical wiring or connection.

2. Faulty sensor.
3. Faulty ECU.
Solution:

Inspect the ECU and the air intake temperature sensor connections. All connections should be secure, tight, free
Inspect the harness from the ECU to the air intake temperature sensor. Verify that the harness is free of damage,
3. Measure the sensor supply voltage.
Disconnect the boost pressure/ air temperature sensor from the engine harness.
Measure the voltage between the boost pressure sensor connector pin 3 and pin 1. The voltage should be ap-
proximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
B. The voltage is less than 4.5 V. There is a problem in the voltage supply to the sensor. Repair as required.
4. Measure the voltage of the signal wires to chassis ground.
47540694 28/04/2014
55.16 [55.DTC] / 141
Disconnect the ECU connector X-016.
Measure the voltage between ECU connector X-016 pin 55 and chassis ground. The voltage should be less than
0.5 V. Wiggle the harness during measurement to reveal an intermittent condition.
as required. Return to step 1 to confirm the elimination of the fault. .
5. Test the ECU.
Reconnect the UCM connector X-016.
Fabricate a jumper wire that will connect between the air temperature sensor pin 2 and the air temperature sensor
pin 1.
Connect the jumper wire between the air temperature sensor pin 2 and the air temperature sensor pin 1.
Access the fault code screen on the Electronic Service Tool. Fault code 3010 should no longer be active. Fault
code 3011 should be active. Fault code 3019 may also be active, ignore this code.
A. Fault code 3011 is active. Fault code 3010 is no longer active. Temporarily replace the air intake temperature
sensor and retest. Return to step 1.
B. Fault code 3010 is still active. Fault code 3011 did not become active. Temporarily replace the ECU and retest.
Return to step 1.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 142
3011-Air intake temperature sensor signal below minimum range

Context:
The Engine Control Unit (ECU) generated an error from a fault associated with the air intake temperature sensor. The
boost pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is
related to the temperature sensing function of the device. This error could result from a signal out of range or a signal
that is either erratic or intermittent.
Cause:
The air intake temperature sensor signal to the ECU is out of range of the lower threshold limit.

2. Faulty sensor.
3. Faulty ECU.
Solution:

Inspect the ECU and the air intake temperature sensor connections. All connections should be secure, tight, free
Inspect the harness from the ECU to the air intake temperature sensor. Verify that the harness is free of damage,
Measure the voltage between the boost pressure sensor connector pin 3 and pin 1. The voltage should be ap-
proximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
B. The voltage is less than 4.5 V. There is a problem in the voltage supply to the sensor. Repair as required.
4. Measure the resistance of the signal wires to chassis ground.
47540694 28/04/2014
55.16 [55.DTC] / 143
Measure the resistance between ECU connector X-016 pin 55 and chassis ground. The resistance should be
greater than 20,000 Ω.
as required. Return to step 1 to confirm the elimination of the fault. .
5. Test the ECU.
Reconnect the UCM connector X-016.
Fabricate a jumper wire that will connect between the air temperature sensor pin 2 and the air temperature sensor
pin 3.
Connect the jumper wire between the air temperature sensor pin 2 and the air temperature sensor pin 3.
Access the fault code screen on the Electronic Service Tool. Fault code 3011 should no longer be active. Fault
code 3010 should be active. Fault code 3019 may also be active, ignore this code.
A. Fault code 3010 is active. Fault code 3011 is no longer active. Temporarily replace the air intake temperature
sensor and retest. Return to step 1.
B. Fault code 3011 is still active. Fault code 3010 did not become active. Temporarily replace the ECU and retest.
Return to step 1.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 144
3027-Oil pressure signal not plausible

Context:
The ECU has detected oil pressure while the engine is not running.
Cause:
Engine speed is less than 500 RPM and the oil pressure switch is in the closed position. The oil pressure switch will
close to indicate to the ECU that the engine is running and the engine has the proper oil pressure.
1. Faulty electrical wiring, short circuit to ground in the signal wire to the ECU
2. Faulty oil press switch
3. Faulty ECU
Solution:
(2) To check for Active fault codes: Start and operate machine.

RAPH12SSL0304FA 1
Schematic legend
(1) Oil pressure switch (3) ECU Connector
X-016 pin 6
(2) Engine Harness Connector (4) Chassis Ground
X-017 pin 3
(1) Inspect the ECU and the Oil Pressure Switch connections. All connections should be secure, tight, free of
corrosion, abrasion and damage.
(2) Inspect the harness from the ECU to the Oil Pressure Switch. Verify that the harness is free of damage,
A. OK – The connectors are secure and the harness is free of damage. Go to Step 3.
47540694 28/04/2014
55.16 [55.DTC] / 145
B. NOT OK – The connectors or the harness has damage. Repair or replace the harness or connectors as re-
quired. Return to Step 1 to confirm elimination of fault.
3. Measure the resistance through the signal wire to chassis ground
(2) Disconnect ECU connector X-016 and the Oil Pressure Switch connector.
(3) Measure the resistance between ECU X-016 pin 6 and chassis ground. The resistance should be greater than
A. The resistance is greater than 20,000 Ω. Go to Step 4.
B. The resistance is less than 20,000 Ω. There is a short circuit in the signal wire to chassis ground. Repair as
required. Go to Step 1 to confirm elimination of fault.
4. Measure the resistance through the oil pressure switch
(2) Disconnect the oil pressure switch connector.
(3) Measure the resistance through the switch to chassis ground. The chassis ground connection should be clean
and free of oil, paint and dirt. The resistance should be greater than 20,000 Ω.
A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU and retest. Return to Step 1 to confirm
B. The resistance is less than 10 Ω. There is a problem with the oil pressure switch. Temporarily replace the oil
pressure switch and retest. Return to Step 1 to confirm elimination of fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 146
3051-Battery Voltage To Engine Controller - Voltage Too High

Context:
The ECU detects a battery voltage greater than 18 V.
Cause:
The battery voltage to the ECU is above 18 V.
1. Faulty alternator.
2. Faulty ECU.
Solution:

Inspect the ECU, battery and the alternator connections. All connections should be secure, tight, free of corrosion,
abrasion and damage.
Inspect the harness from the battery to the ECU. Verify that the harness is free of damage, corrosion, abrasion
and incorrect attachment.
3. Measure the voltage to the ECU.
Turn ignition OFF.
Disconnect ECU connector X-012 from the engine controller.
Turn the ignition ON.
Measure the voltage between X-012 pin 1 and X-012 pin 2. The voltage should be approximately 14.5 V.
Measure the voltage between X-012 pin 54 and chassis ground. The chassis ground connection must be clean
and free of paint, oil and dirt. The voltage should be approximately 14.5 V.
A. The voltage is between 10 V and 14.8 V. Temporarily replace the ECU and retest. Return to step 1 to confirm
B. The voltage is greater than 14.8 V. There is a problem in the charging system. Temporarily replace the alter-
nator and retest. Return to step 1 to confirm elimination of fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 147
3052-Battery Voltage To Engine Controller - Voltage Too Low

Context:
The ECU detects a battery voltage less than 10 V.
Cause:
The battery voltage to the ECU is below 10 V.
1. Faulty wiring or fuses.

3. Faulty ECU.
Solution:

Turn ignition OFF.
B. The voltage is less than 10 V. There is a problem in the charging system. Temporarily replace the alternator
and retest. Return to step 1 to confirm elimination of fault.
Mechanical Units
47540694 28/04/2014
55.16 [55.DTC] / 148
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 149
3059-ECM afterrun was interrupted

NOTICE: Fault Code 3059 is stored in historical information. For multiple occurrences of this fault proceed with the
following tests.
Cause:
1. Faulty wiring.
2. Faulty alternator or charging system.
3. Faulty ECU.
Solution:

Turn ignition OFF.
B. The voltage is less than 10 V or the voltage is greater than 14.8 V. There is a problem in the charging system.
Temporarily replace the alternator and retest. Repair as required. Return to step 1 to confirm elimination of
fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 150
3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground)

NOTE: This diagnostic procedure requires a good quality multi-meter to be able to take accurate resistance measure-
ments. The meter should be able to measure to a resolution of 0.1 ohms. Some of the measurements required to
be taken, could be as low as 0.4 ohms (typical injector solenoid coil resistance is 0.4 - 0.5 Ω) and any inaccuracies
in the DMM could cause a technician to take the wrong diagnostic path.
Context:
The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 1. A
power stage component energizes the unit injection system transistors and simultaneously observes the current flow
in the high-side and low-side switching branch by sensing resistors. If there is a deviation from the expected current
flow the component detects specific errors and reports them to the ECU . This error message is then rearranged so
it holds information on performed injections, errors of cylinders on the same bank, bank specific errors and cylinder
specific errors. The rearranged error message is then compared to applicable error patterns and if there is a match
the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect
is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result
of a short circuit of the high side to the low side or ground over 3 camshaft revolutions. As a result of this error an
individual cylinder or bank is shut off, based on parameters established in the ECU . Certain parameters, as currently
applied, are permanent (without a healing possibility, once tested by switching on the component to see if the defect
is still present). and others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of the
injector output power driver stage.
1. Faulty cylinder 1 solenoid windings.

2. Faulty electrical wiring, short high side to low side or ground (damaged wiring harness).
3. Faulty ECU, ECU hardware or software.
Solution:
1. Verify this error code is still present and in an active state.
A. If the error is still present and active, continue with step 2.
B. If the error is no longer present or is in an inactive state, continue with step 8.

2. Carefully disconnect the engine cylinder harness from the ECU at ECU cylinder harness connector 3. Use a
multi-meter to check the resistance, on the cylinder harness side of connector 3, between pins 4 and 13. There
should be 0.4 - 0.5 Ω.
A. If the resistance was within range, leave ECU cylinder connector 3 disconnected and continue with step 3
B. If the resistance was lower than range minimum, continue with step 6.
3. Use a multi-meter to check for continuity, on the ECU cylinder harness side of connector 3, from pin 4 to chassis
ground and pin 13 to chassis ground. There should not be continuity.
A. If there was continuity on either or both pins to chassis ground, continue with step 4
B. If there was no continuity on either pin to chassis ground, the ECU may have failed. Try reloading the ECU
software and if the fault reoccurs, replace the ECU .
4. Disconnect the engine cylinder harness from the injector (valve) cover at connector VC1. Use a multi-meter to
check for continuity, on the injector (valve) cover side of connector VC1 from pin A to chassis ground and pin B to
chassis ground. There should not be continuity.
A. If there was continuity on either or both pins to chassis ground, leave connector VC1 disconnected and continue
with step 5.
47540694 28/04/2014
55.16 [55.DTC] / 151
B. If there was no continuity on either pin to chassis ground, there is a short to ground condition in the engine
cylinder harness between Valve cover connector VC1 and ECU to cylinder harness connector 3. Locate and
repair the grounded conductor.
5. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 1 injector at connector INJ1
terminal 1 (high side ring terminal). Use a multi-meter to check for continuity, on the injector, from terminal 1 to
A. If there is continuity, Cylinder 1 injector's solenoid coil has failed, replace the injector.
B. If there is no continuity, there is a short to ground condition in Cylinder 1 injector circuit, between connector
INJ1 and connector VC1. Locate and repair the grounded conductor.
6. Disconnect the engine injector harness from the injector cover at Cylinder 1 /2 valve cover connector VC1 and
use a multi-meter to check the resistance on the injector cover side of Cylinder 1 /2 valve cover connector VC1
between pins A and B. There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, there is a short circuit condition in the engine injector harness between the
Cylinder 1 / 2 valve cover connector VC1 and ECU cylinder harness connector 3, locate and repair the short
circuit.
B. If the resistance was lower than range minimum, continue with step7.
7. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 1 injector at connector
INJ1 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder 1 injector, from
terminal 1 to terminal 2. There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, there is a short circuit condition in the injector harness, between Cylinder 1
injector connector INJ1 and connector VC1. Locate and repair the shorted conductors.
B. If the resistance was lower than minimum range, the Cylinder 1 injector solenoid coil has failed. Replace the
injector.
breaks or shorts in the wiring concerned. Operate the machine while monitoring the Display.
resolved.
B. If no damage or other than normal display readings are indicated, erase the fault code and continue operation.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 152

NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to be able to take accurate resis-
tance measurements. The meter should be able to measure to a resolution of 0.1 ohms. Some of the measurements
required to be taken, could be as low as 0.4 ohms (typical injector solenoid coil resistance is 0.4 - 0.5 Ω) and any
inaccuracies in the DMM could cause a technician to take the wrong diagnostic path.
Context:
The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 3.
A power stage component energizes the injection system transistors and simultaneously observes the current flow
flow the component detects specific errors and reports them to the ECU. This error message is then rearranged so
the failure corresponding to the matched pattern is output. If an error message does not match any pattern the defect
individual cylinder or bank is shut off, based on parameters established in the ECU. Certain parameters, as currently
is still present) and others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
1. Faulty injection valve or shorted solenoid windings.

3. Faulty ECU, hardware or software.
Solution:
1. Carefully disconnect the engine injector harness from the ECU at connector 3. Use a multi-meter to check the
resistance, on the ECU engine injector harness side of connector 3, between pins 12 and 5. There should be 0.4
- 0.5 Ω.
A. If the resistance was within range, leave ECU harness connector 3 disconnected, and continue with step 2.
2. Use a multi-meter to check for continuity, on the ECU engine injector harness side of connector 3, from pin 12 to
chassis ground and pin 5 to chassis ground. There should not be continuity.
A. If there was continuity on either or both pins to chassis ground, continue with step 3.
software and if the fault reoccurs, replace the ECU.
3. Disconnect the engine injector harness from the injector (valve) cover at connector VC2. Use a multi-meter to
check for continuity, on the injector (valve) cover side of connector VC2 from pin 3 to chassis ground and pin 4 to
with step 4.
injector harness between connector VC2 and ECU harness connector 3. Locate and repair the grounded con-
ductor.
4. Remove the injector (valve) cover and disconnect the injector harness from Cylinder #3 injector at connector INJ3
terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder #3 injector, from
terminal 1 to chassis ground. There should not be continuity.
47540694 28/04/2014
55.16 [55.DTC] / 153
A. If there is continuity, the Cylinder #3 injector solenoid coil has failed, replace the injector.
B. If there is no continuity, there is a short to ground condition in the Cylinder #3 injector circuit, between connector
5. Disconnect the engine injector harness from the injector cover at connector VC2 and use a multi-meter to check
the resistance on the injector cover side of connector VC2 between pins 3 and 4. There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, there is a short circuit condition in the engine injector harness between
connector VC2 and ECU harness connector 3, locate and repair the short circuit.
6. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder #3 injector at connector
INJ3 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder #3 injector, from
A. If the resistance was within range, there is a short circuit condition in the injector harness, between connector
INJ3 and connector VC2. Locate and repair the shorted conductors.
B. If the resistance was lower than minimum range, the Cylinder #3 injector solenoid coil has failed. Replace the
injector.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 154

Context:
Cause:

Solution:
- 0.5 Ω.
with step 4.
injector harness between connector VC1 and ECU harness connector 3. Locate and repair the grounded con-
ductor.
47540694 28/04/2014
55.16 [55.DTC] / 155
VC1 and connector VC1. Locate and repair the grounded conductor.
injector.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 156

Context:
Cause:

Solution:
- 0.5 Ω.
with step 4.
injector harness between connector VC2 and ECU harness connector 3.Locate and repair the grounded con-
ductor.
47540694 28/04/2014
55.16 [55.DTC] / 157
injector.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 158
3088-Crankshaft Sensor - No Signal

Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Increment speed (Crankshaft speed)
sensor. If the engine has a defective Crankshaft speed sensor it can run off the Segment speed (Camshaft speed)
sensor. This is referred to as BACKUP mode. Diagnostics of the SIG failure is only active if voltage is present at
terminal 15 (Ignition ON) and no errors are active for the sensor supply voltage.
Cause:
The ECU has determined that there is no signal from the Crankshaft speed sensor. The engine is now operating in
BACKUP mode.
1. Faulty Crankshaft speed sensor.

2. Faulty electrical wiring and/or connections.
3. Faulty ECU, or ECU supply voltages or grounds.
Solution:

2. Remove Crankshaft speed sensor connector DG6 Incr and inspect housing body/latch, pins and wiring harness
for damage or corrosion. Also, inspect connector portion of the Crankshaft speed sensor.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good
and sound electrical connection. Replace Crankshaft speed sensor if damaged.
B. If no damage is determined, leave connector disconnected and proceed to step 3.

3. Operation: Resistance Check for Faulty CKP, Engine flywheel RPM, sensor.
Vehicle Status: Key Off Engine Off
Measure the resistance between the crankshaft speed sensor pins 1 and 2.
Test Type From To Results (Min) Results (Max)

1. Resistance Crankshaft speed Crankshaft speed 750 ohms 1000 ohms
sensor connector sensor connector
DG6 Incr, (Pin 1) DG6 Incr, (Pin 2)
A. If the resistance test does not fall in the specified range, replace Crankshaft speed sensor.
B. If the resistance test does fall in the specified range, leave connector disconnected and proceed to step 4.
4. Operation: Check Output of Crankshaft speed sensor.
Vehicle Status: Key Off Engine Off (test setup)
Vehicle Status: Key On Engine On (during test)
Single Ended Test Lead Connection Test (Standalone Crankshaft speed sensor Test)
Remove Crankshaft speed sensor connector and connect the above mentioned special test lead to the Crankshaft
speed sensor. Start the engine and measure the (AC) voltage using a multi-meter across the breakout alligator
clips from the test leads. Use the test table below to determine the measurement results.
In-Line Test Lead Connection Test:

Remove Crankshaft speed sensor connector and connect the above mentioned special test lead in-line with the
sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection
process. Start the engine and measure the (AC) voltage using a multi-meter across the breakout alligator clips
from the test leads. Use the test table below to determine the measurement results.
47540694 28/04/2014
55.16 [55.DTC] / 159
Note:
The engine will be running off the Camshaft speed sensor during the single ended test, if it isn't already (based on
the fault code type). The engine can also be very hard to start when running exclusively off the Camshaft speed
sensor. The ECU needs to see a few revolutions of the camshaft to be able to use this information to start the
engine.
The Crankshaft speed sensor and the Camshaft speed sensor are exactly the same. These sensors may be
swapped in this diagnostic procedure to determine the functionality of the Crankshaft speed sensor. A new set of
error codes may be generated by the ECU if the sensors are swapped.
Test Type From To Expected Results

1. Voltage (AC) - Single Crankshaft speed sensor Crankshaft speed sensor Approx. 16 - 18 volts (AC)
ended connection at low connector DG6 Incr, (Pin 1) connector DG6 Incr, (Pin 2)
RPM ( 1000 - 1100 RPM)
2. Voltage (AC) - Single Crankshaft speed sensor Crankshaft speed sensor Approx. 32 - 34 volts (AC)
ended connection at high connector DG6 Incr, (Pin 1) connector DG6 Incr, (Pin 2)
RPM ( 2000 - 2200 RPM)
3. Voltage (AC) - In-line Crankshaft speed sensor Crankshaft speed sensor Approx. 10 - 12 volts (AC)
connection at low RPM ( connector DG6 Incr, (Pin 1) connector DG6 Incr, (Pin 2)
1000 - 1100 RPM)
connection at high RPM ( connector DG6 Incr, (Pin 1) connector DG6 Incr, (Pin 2)
2000 - 2200 RPM)
A. If the voltage test was successful, proceed to step 6.
B. If the voltage test was not successful for any of the single ended connections, replace the sensor.
C. If the voltages encountered during testing are low and the sensor was replaced on a prior diagnostic procedure
of this type, ensure the Crankshaft speed sensor is installed properly.
D. If the voltage test was successful for the single ended connections and not for any of the in-line connections,
leave the connector disconnected and proceed to step 5.
5. Operation: Check for Faulty Wiring.
Vehicle status: Key Off Engine Off.
Perform continuity tests between connector DG6 Incr and connector 2 on ECU engine harness. Flex harness
during test to check for any intermittent operation. See test table below.
Important Note: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when
removing main ECU connectors if this is not followed.

1. Continuity Crankshaft speed sensor ECU engine harness con- Approx. 0 - 0.10 ohms
connector DG6 Incr, (Pin: nector 2, (Pin: 23)
1)
2)
3. Short Circuit ECU engine harness con- ECU engine harness con- Open Circuit
nector 2, (Pin: 23) nector 2, (Pin: 19)
A. If continuity/shorts test is successful, go to step 6.
B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
6. Operation: Check for ECU Voltages and Ground Continuity.
Vehicle Status (when removing connector 1): Key Off Engine Off.
Vehicle Status (when performing test) Key On Engine Off.
Vehicle Status (when replacing connector 1): Key Off Engine Off.
Using the product schematics for a reference, remove connector 1 from the ECU and check for voltage and con-
tinuity at the appropriate pins defined in the test table below.
47540694 28/04/2014
55.16 [55.DTC] / 160
Important Note: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage
could result when removing and replacing main ECU connectors if this is not followed.

1. Voltage ECU vehicle harness con- Ground (engine block) Approx. 12 volts (DC)
nector 1, (Pin: 2, 3, 8, 9, 40)
2. Continuity ECU vehicle harness con- Ground (engine block) Approx. 0 - 0.10 ohms
nector 1, (Pin: 5, 6, 10, 11)
A. If the voltages and ground paths are correct and the Crankshaft speed sensor was not replaced on a prior
diagnostic procedure of this type, replace the sensor.
B. If the voltages and ground paths are correct and the Crankshaft speed sensor was replaced on a prior diag-
nostic procedure of this type and the sensor mechanical alignment and spacing was verified, re-initialize the
ECU as if it was blank (new) and load the appropriate data-set.
C. If the voltages and ground paths are correct and the ECU was re-initialized on a prior diagnostic of this type,
replace the ECU .
D. If the voltages and ground paths are not correct, refer to product schematics and determine root cause of power
and/or continuity problem(s).
resolved.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 161
3089-Crankshaft Sensor - Invalid Signal

Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Crankshaft speed sensor. If the engine
has a defective Crankshaft speed sensor it can run off the Camshaft speed sensor.
Cause:
The ECU has determined that there are errors in the signal from the Crankshaft speed sensor.
1. Faulty crankshaft speed sensor.

3. Faulty ECU, supply voltages or ground paths.
Solution:
1. Verify the fault code is present and active.
A. If fault code is present and active, continue with step 2.
B. If fault code is no longer present, continue with step 7.

2. Inspect the Crankshaft speed sensor. Remove the Crankshaft speed sensor connector DG6 Incr, and inspect
housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect the connector portion of the
Crankshaft speed sensor.
and sound electrical connection. Replace Crankshaft speed sensor if damaged.
B. If no damage is determined, proceed to step 3.

3. Measure the internal resistance of Crankshaft speed sensor. Remove Crankshaft speed sensor connector. Use
a multi-meter to measure the resistance between pins 1 (yellow) and 2 (yellow) of the Crankshaft speed sensor.
There should be between 825 - 975 Ω at 20 °C (68 °F).
A. If the resistance is not within the specified range, replace the Crankshaft speed sensor.
B. If the resistance is within the specified range, proceed to step 4.

4. Measure the AC voltage from Crankshaft speed sensor output. Use a multi-meter to check for voltage while
starting the engine. Measure the voltage between pins 1 (yellow) and 2 (yellow) of the Crankshaft speed sensor
connector, DG6 Incr. here should be a minimum of .50 V while cranking and a higher reading once the engine
starts.
A. If the voltage is less than .50 V (AC), replace the sensor.
B. If the voltage is above .50 V (AC), proceed to step 5.

5. Check for faulty wiring between the Crankshaft speed sensor and the ECU.
Measure resistance between the Crankshaft speed sensor, DG6 Incr, pin 1, and the ECU engine connector X-016,
pin 59.
Measure resistance between the Crankshaft speed sensor, DG6 Incr, pin 2, and the ECU engine connector X-016,
pin 44.
A. If there is continuity, go to step 6.
B. If there is no continuity, find and repair the damaged wiring between connector DG6 Incr, and ECU connector
X-016.
6. Check voltage and ground supply to ECU. Disconnect ECU vehicle connector 1 and use a multi-meter to verify
the ECU has sufficient supply voltage and ground paths. Use the table below as a reference.
47540694 28/04/2014
55.16 [55.DTC] / 162

1. Voltage ECU vehicle connector Ground (engine block) Approx. 12 volts (DC)
X-012, (Pin: 1, 3, 5, 54)
2. Continuity ECU vehicle connector 1, Ground (engine block) Approx. 0 - 0.10 ohms
(Pin: 2, 4, 6)
A. If the voltage supply and ground paths are sufficient, continue with step 7.
B. If the voltage supply and ground paths are not present, use the vehicle schematics to find and repair the cause.
7. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals
breaks or shorts in the wiring concerned. Operate the machine while monitoring the display.
resolved.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 163
3090-Camshaft Sensor - No Signal

Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Segment speed sensor (Camshaft
speed sensor). If the engine has a defective Camshaft speed sensor it can run off the Increment speed sensor (Crank-
shaft speed sensor). Diagnostics is active if voltage is present at terminal 15 (Ignition On), the current engine speed
is above 50 RPM, no error in the Crankshaft speed sensor is present and the sensor supply voltage ( 5 volts ) is not
defective.
Cause:
The ECU has determined that there is no signal from the Camshaft speed sensor.
1. Faulty Camshaft speed sensor.

2. Camshaft speed sensor is not mechanically installed correctly.
Solution:

2. Remove Camshaft speed sensor connector DG6 Segm and inspect housing body/latch, pins and wiring harness
for damage or corrosion. Also, inspect connector portion of the Camshaft speed sensor.
and sound electrical connection. Replace Camshaft speed sensor if damaged.

3. Operation: Resistance Check for Faulty Camshaft speed sensor.
Measure the resistance between Camshaft sensor pins 1 and 2. See test table below.

1. Resistance Camshaft speed sen- Camshaft speed sen- 750 ohms 1000 ohms
sor connector DG6 sor connector DG6
Segm (Pin 1) Segm (Pin 2)
A. If the resistance test does not fall in the specified range, replace Camshaft speed sensor.
4. Operation: Check Output of Camshaft speed sensor.
Make the following electrical tests in the table below.

Single Ended Test Lead Connection Test (Standalone Camshaft speed sensor Test).
Remove Camshaft speed sensor connector DG6 Segm and connect the above mentioned special test lead to the
Camshaft speed sensor. Start the engine and measure the (AC) voltage using a multi-meter across the breakout
alligator clips from the test leads. Use the test table below to determine the measurement results.

Remove Camshaft speed sensor connector DG6 Segm and connect the special test lead in-line with the sensor
and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection process.
47540694 28/04/2014
55.16 [55.DTC] / 164
Start the engine and measure the (AC) voltage using a multi-meter across the breakout alligator clips from the test
leads. Use the test table below to determine the measurement results.
Note:
The engine will be running off the Crankshaft speed sensor during this test. The Camshaft speed sensor and the
Crankshaft speed sensor are exactly the same. These sensors may be swapped in this diagnostic procedure to
determine the functionality of the Camshaft speed sensor. A new set of error codes may be generated by the ECU
if sensors are swapped.

1. Voltage (AC) - Single Camshaft speed, sensor Camshaft speed, sensor Approx. 2 - 3 volts (AC)
ended connection at low connector DG6 Segm (Pin connector DG6 Segm (Pin
RPM ( 1000 - 1100 RPM) 1) 2)
ended connection at high connector DG6 Segm (Pin connector DG6 Segm (Pin
RPM ( 2000 - 2200 RPM) 1) 2)
3. Voltage (AC) - In-line Camshaft speed, sensor Camshaft speed, sensor Approx. 1.5 - 2.8 volts (AC)
connection at low RPM ( connector DG6 Segm (Pin connector DG6 Segm (Pin
1000 - 1100 RPM) 1) 2)
4. Voltage (AC) - In-line Camshaft speed, sensor Camshaft speed, sensor Approx. 3 - 4.5 volts (AC)
connection at high RPM ( connector DG6 Segm (Pin connector DG6 Segm (Pin
2000 - 2200 RPM) 1) 2)
C. If the voltages encountered during testing are low and the sensor was replaced on a prior diagnostic of this
type, ensure the Camshaft speed sensor was properly installed.
proceed to step 5.
Perform continuity tests between connector DG6 Segm and connector 2 on engine wiring harness. Flex harness

1. Continuity Camshaft speed sensor ECU engine harness con- Approx. 0 - 0.10 ohms
connector DG6 Segm (Pin: nector 2 (Pin: 10)
1)
2)
nector 2 (Pin: 10) nector 2 (Pin: 9)
Vehicle Status (when removing connector 1). Key Off Engine Off.
Vehicle Status (when performing test). Key On Engine Off.
Vehicle Status (when replacing connector 1). Key Off Engine Off.
47540694 28/04/2014
55.16 [55.DTC] / 165

1. Voltage ECU vehicle harness 1, Ground (engine block) Approx. 12 volts (DC)
(Pin: 2, 3, 8, 9, 40)
2. Continuity ECU vehicle harness 1, Ground (engine block) Approx. 0 - 0.10 ohms
(Pin: 5, 6, 10, 11)
A. If the voltages and ground paths are correct and the Camshaft speed sensor was not replaced on a prior
B. If the voltages and ground paths are correct and the Camshaft speed sensor was replaced on a prior diagnostic
procedure of this type and the sensor mechanical alignment and spacing was verified, re-initialize the ECU as
if it was blank (new) and load the appropriate data-set.
replace the ECU .
resolved.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 166
3091-Camshaft sensor - Invalid signal

Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Segment speed sensor (Camshaft
speed sensor). If the engine has a defective Camshaft speed sensor it can run off the Increment speed sensor (Crank-
shaft speed sensor). Diagnostics is active if voltage is present at terminal 15 (Ignition On), the current engine speed
is above 50 RPM, no error in the Crankshaft speed sensor is present and the sensor supply voltage ( 5 volts) is not
defective.
Cause:
The ECU has determined that there is no signal from the Camshaft speed sensor.
1. Faulty Camshaft speed sensor.

2. Camshaft speed sensor is not mechanically installed correctly.
Solution:

2. Remove Camshaft speed sensor connector DG6 Segm and inspect housing body/latch, pins and wiring harness
for damage or corrosion. Also, inspect connector portion of the Camshaft speed sensor.
and sound electrical connection. Replace Camshaft speed sensor if damaged.

3. Operation: Resistance Check for Faulty Camshaft speed sensor.
Measure the resistance between the camshaft sensor connector pins 1 and 2. See test table below.

Segm (Pin 1) Segm (Pin 2)
4. Operation: Check Output of Camshaft speed sensor.
Make the following electrical tests in the table below. Reference the descriptions below to make the proper elec-
trical connections for each test type.
Single Ended Test Lead Connection Test (Standalone Camshaft speed sensor Test).
Remove Camshaft speed sensor connector DG6 Segm and connect the above mentioned special test lead to the
Camshaft speed sensor. Start the engine and measure the (AC) voltage using a multi-meter across the breakout
alligator clips from the test leads. Use the test table below to determine the measurement results.
47540694 28/04/2014
55.16 [55.DTC] / 167
Remove Camshaft speed sensor connector DG6 Segm and connect the special test lead in-line with the sensor
and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection process.
Start the engine and measure the (AC) voltage using a multi-meter across the breakout alligator clips from the test
leads. Use the test table below to determine the measurement results.
Note:
The engine will be running off the Crankshaft speed sensor during this test. The Camshaft speed sensor and the
Crankshaft speed sensor are exactly the same. These sensors may be swapped in this diagnostic procedure to
determine the functionality of the Camshaft speed sensor. A new set of error codes may be generated by the ECU
if sensors are swapped.

ended connection at low connector DG6 Segm (Pin connector DG6 Segm (Pin
RPM ( 1000 - 1100 RPM) 1) 2)
ended connection at high connector DG6 Segm (Pin connector DG6 Segm (Pin
RPM ( 2000 - 2200 RPM) 1) 2)
3. Voltage (AC) - In-line Camshaft speed, sensor Camshaft speed, sensor Approx. 1.5 - 2.8 volts (AC)
connection at low RPM ( connector DG6 Segm (Pin connector DG6 Segm (Pin
1000 - 1100 RPM) 1) 2)
4. Voltage (AC) - In-line Camshaft speed, sensor Camshaft speed, sensor Approx. 3 - 4.5 volts (AC)
connection at high RPM ( connector DG6 Segm (Pin connector DG6 Segm (Pin
2000 - 2200 RPM) 1) 2)
C. If the voltages encountered during testing are low and the sensor was replaced on a prior diagnostic of this
type, ensure the Camshaft speed sensor was properly installed.
proceed to step 5.
Perform continuity tests between connector DG6 Segm and connector 2 on engine wiring harness. Flex harness

1)
2)
nector 2 (Pin: 10) nector 2 (Pin: 9)
Vehicle Status (when removing connector 1). Key Off Engine Off.
Vehicle Status (when performing test). Key On Engine Off.
Vehicle Status (when replacing connector 1). Key Off Engine Off.
47540694 28/04/2014
55.16 [55.DTC] / 168

1. Voltage ECU vehicle harness 1, Ground (engine block) Approx. 12 volts (DC)
(Pin: 2, 3, 8, 9, 40)
2. Continuity ECU vehicle harness 1, Ground (engine block) Approx. 0 - 0.10 ohms
(Pin: 5, 6, 10, 11)
A. If the voltages and ground paths are correct and the Camshaft speed sensor was not replaced on a prior
B. If the voltages and ground paths are correct and the Camshaft speed sensor was replaced on a prior diagnostic
procedure of this type and the sensor mechanical alignment and spacing was verified, re-initialize the ECU as
if it was blank (new) and load the appropriate data-set.
replace the ECU .
resolved.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 169
3093-Offset Between Camshaft And Crankshaft - Outside

Boundaries
Context:
The Engine Control Unit (ECU) has reported an error with the phase relationship between the Increment speed sensor
(Crankshaft speed sensor) and the Segment speed sensor (Camshaft speed sensor). The engine will alternatively
use a redundant angular system which is based on the Crankshaft speed sensor. Diagnostics is active under these
conditions:
1) terminal 40 (Key On) is active,
2) current engine speed is above 50 RPM,
3) no error is reported for the Crankshaft speed sensor and
4) sensor supply voltage ( 5 volts DC) is not defective
Cause:
The ECU has determined that there is a phase relationship error between the Crankshaft speed sensor and the
Camshaft speed sensor.
1. Faulty Camshaft speed sensor or Crankshaft speed sensor.

2. Camshaft speed sensor or Crankshaft speed sensor are not mechanically installed correctly.
4. Faulty ECU, or ECU supply voltages or ground.
Solution:
2. Operation: Electrical and Sensor Mounting Inspection.
Vehicle Status: Key Off Engine Off.
Remove Camshaft speed sensor connector DG6 Incr and Crankshaft speed sensor connector DG6 Incr and
inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect the connector portion
and mechanical mounting (seating) of the Camshaft speed sensor and Crankshaft speed sensor.
and sound electrical connection. Replace Camshaft speed sensor or Crankshaft speed sensor if damaged.
B. If any of the sensors are not mounted correctly (loose, not seated properly, etc.), remount the sensors taking
special care to make sure it is properly seated (flush with sealing surface) and fastened.
C. If no damage is determined, proceed to step 3.

3. Operation: Resistance Test for Camshaft speed sensor.
Remove Camshaft speed sensor connector. Measure the resistance between the camshaft sensor pins 1 and 2.
See test table below.

Incr (Pin 1) Incr (Pin 2)
B. If the resistance test does fall in the specified range, proceed to step 4.
47540694 28/04/2014
55.16 [55.DTC] / 170
4. Operation: Resistance Test for Crankshaft speed sensor.

Measure the resistance between the crankshaft speed sensor pins 1 and 2. See test table below.

1. Resistance Crankshaft speed Crankshaft speed 750 ohms 1000 ohms
sensor connector sensor connector
DG6 Incr (Pin 1) DG6 Incr (Pin 2)
A. If the resistance test does not fall in the specified range, replace Crankshaft speed sensor.
B. If the resistance test does fall in the specified range, proceed to step 5.
5. Operation: Check Crankshaft speed sensor Output Voltage and Harness Wiring.
Perform both (2) electrical tests defined below:
1) AC output voltage test for Crankshaft speed sensor

Remove Crankshaft speed sensor connector DG6 Incr and connect the Coolant/Fuel Temp Sensor test lead
in-line with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during
the connection process. Start the engine and measure the (AC) voltage using a multi-meter across the breakout
alligator clips from the Coolant/Fuel Temp Sensor test lead. Use the table below to determine test parameters
and the measurement results.

connection at low RPM ( connector DG6 Incr (Pin 1) connector DG6 Incr (Pin 2)
1000 - 1100 RPM)
connection at high RPM ( connector DG6 Incr (Pin 1) connector DG6 Incr (Pin 2)
2000 - 2200 RPM)
2) Harness wiring continuity/shorts electrical test (Crankshaft speed sensor).

Remove and perform continuity tests between Crankshaft speed sensor connector DG6 Incr and ECU engine
harness connector 2 on engine wiring harness. Flex harness during test to check for any intermittent operation.
See test table below.

1)
2)
3. Shorts ECU engine harness con- ECU engine harness con- Open Circuit
nector 2, (Pin: 23) nector 2, (Pin: 19)
A. If both electrical tests are successful, proceed to step 7.
B. If harness wiring continuity/shorts test was not successful, find and repair the damaged section(s) of the wiring
harness.
C. If the voltage test was not successful and the continuity/shorts test was successful, proceed to step 6.
47540694 28/04/2014
55.16 [55.DTC] / 171
6. Operation: Crankshaft speed sensor alignment.

Check proper mechanical alignment and tooth spacing of the Crankshaft speed sensor. The spacing between
the trigger teeth and the sensor is critical for proper voltage output. Make sure that the sensor is seated properly
(flush with mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared.
A. If this fault code is still present and has not cleared, Replace Crankshaft speed sensor, being careful to ensure
the sensor's mechanical alignment and tooth spacing is correct and the sensor is seated properly.
B. If this fault code is still present and has not cleared, proceed to step 13.
7. Operation: Check Camshaft speed sensor Output Voltage and Harness Wiring.
Perform both (2) electrical tests defined below:
1) AC output voltage test for Camshaft speed sensor:

Remove Camshaft speed sensor connector DG6 Segm and connect the Coolant/Fuel Temp Sensor test lead
in-line with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during
the connection process. Start the engine and measure the (AC) voltage using a multi-meter across the breakout
alligator clips from the Coolant/Fuel Temp Sensor test lead. Use the table below to determine test parameters
and the measurement results.

1. Voltage (AC) - In-line Camshaft speed sensor Camshaft speed sensor Approx. - 1.5 - 2.8 volts
connection at low RPM ( connector DG6 Segm, (Pin connector DG6 Segm, (Pin (AC)
1000 - 1100 RPM) 1) 2)
2. Voltage (AC) - In-line Camshaft speed sensor Camshaft speed sensor Approx. - 3 - 4.5 volts (AC)
connection at high RPM ( connector DG6 Segm, (Pin connector DG6 Segm, (Pin
2000 - 2200 RPM) 1) 2)
2) Harness wiring continuity/shorts electrical test (Camshaft speed sensor).

Remove and perform continuity tests between Camshaft speed sensor connector DG6 Segm and ECU engine
harness connector. Flex harness during test to check for any intermittent operation. See test table below.

connector DG6 Segm (Pin: nector 2, (Pin: 10)
1)
connector DG6 Segm (Pin: nector 2, (Pin: 9)
2)
nector 2 (Pin: 10) nector 2, (Pin: 9)
A. If both electrical tests are successful, proceed to step 10.
B. If harness wiring continuity/shorts test was not unsuccessful, find and repair the damaged section(s) of the
wiring harness.
C. If the voltage test was not successful and the continuity/shorts test was successful, proceed to step 8.
8. Operation: Camshaft Position (CMP), Engine camshaft RPM B-07, sensor Alignment.
47540694 28/04/2014
55.16 [55.DTC] / 172
Check proper mechanical alignment and tooth spacing of the Camshaft speed sensor. The spacing between the
trigger teeth and the sensor is critical for proper voltage output. Make sure that the sensor is seated properly
(flush with mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared.
A. If this fault code is still present and has not cleared, proceed to step 9.
9. Operation: Replace Camshaft speed sensor.
Replace the Camshaft speed sensor. Make sure that the proper mechanical alignment and tooth spacing is
correct. The spacing between the trigger teeth and the sensor is critical for proper voltage output. Make sure
that the sensor is seated properly (flush with mounting flange). After the sensor alignment is complete, check to
see if this fault code has cleared.
10. Operation: Replace Crankshaft speed sensor.
Replace the Crankshaft speed sensor. Make sure that the proper mechanical alignment and tooth spacing is
11. Operation: Swap the New Crankshaft speed sensor with the Old Camshaft speed sensor.
Replace the new Crankshaft speed sensor with the old Camshaft speed sensor. Make sure that the proper me-
chanical alignment and tooth spacing is correct for both sensors. The spacing between the trigger teeth and the
sensor is critical for proper voltage output. Make sure that the sensors are seated properly (flush with mounting
flange). After the sensor alignment is complete, check to see if this fault code has cleared.
A. If this fault code still exists, proceed to step 12.

12. Operation: Replace Old Camshaft speed sensor.
Replace the old Camshaft speed sensor. When this is complete, both Crankshaft speed sensor and Camshaft
speed sensor will have been replaced. Make sure that the proper mechanical alignment and tooth spacing is
A. If this fault code still exists, proceed to step 13.

Vehicle Status (when removing the ECU vehicle harness connector 1): Key Off Engine Off.
Vehicle Status (when performing test): Key On Engine Off.
Vehicle Status (when replacing ECU vehicle harness connector 1): Key Off Engine Off.
Using the product schematics for a reference, remove the ECU vehicle connector from the ECU and check for
voltage and continuity at the appropriate pins defined in the test table below.
47540694 28/04/2014
55.16 [55.DTC] / 173

1. Voltage ECU vehicle harness con- Ground (engine block) Approx. 12 volts (DC)
nector 1, (Pin: 2, 3, 8, 9, 40)
2. Continuity ECU vehicle harness con- Ground (engine block) Approx. 0 - 0.1 ohms
nector 1, (Pin: 5, 6, 10, 11)
A. If the voltages and ground paths are correct, proceed to step 14.
B. If the voltages and ground paths are not correct, refer to schematics and determine root cause of power and/or
continuity problem(s).
14. Operation: Re-Initialize the ECU .
Vehicle Status: Key On Engine Off.
Using the EST service tool, re-initialize the ECU and load the appropriate data-set for this engine type. A call will
have to be made to CNH TSS to get an authorization code for the ECU initialization download. Check to see if
the fault code has cleared.
A. If the fault code did not clear, replace the ECU.

resolved.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 174
3096-ECM Busoff on vehicle CAN

Context:
The ECU is not receiving messages on the vehicle CAN bus.
Cause:
1. Open or shorted wire in system.

3. Failure of ECM.
Solution:
Continue with this procedure if three or more fault codes are active, such as 9151 - 9154, 9405, 9406, 9410, or
1051 through 1059. This is an indication of a problem in the CAN Data Link circuit.
If one or two CAN bus fault codes are active, check all CAN bus wires and connectors to verify they are secure
and free of damage, corrosion, abrasion and incorrect attachment. This may be an indication of an intermittent
connection in the CAN bus.
Verify all modules on the CAN bus have the latest software versions.
A. CAN Data Link fault codes are not recorded again and are no longer ACTIVE. OK to return the machine service.
B. CAN Data Link fault codes are present and ACTIVE.

Please see 9151-CAN Connection: CAN Communication Timed Out After 5 Seconds (55.640), step 2.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 175
3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum

Context:
The engine control unit (ECU) has sensed that the rail pressure sensor signal is too low. The test frequency of the
sensor is every 10 ms and if the signal is below 0.25 V for over 200 ms, the error is set. Once set the ECU will output
a substitute value from a curve (MAP) in the ECU depending on engine speed and injection quantity.
Cause:
The Rail Pressure sensor signal is too low.
1. Faulty circuit wiring, shorted to low source.

2. Faulty rail pressure sensor.
Solution:

Inspect the ECU and the rail pressure sensor connections. All connections should be secure, tight, free of corro-
Inspect the harness from the ECU to the rail pressure sensor. Verify that the harness is free of damage, corrosion,
Disconnect the rail pressure sensor.
Measure the voltage between the rail pressure sensor supply, 284, PK and rail pressure sensor ground 282, BL.
The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent con-
dition.
B. The voltage is less than 4.5 V. There is a problem with the sensor supply to the sensor. Repair or replace the
harness as required. Return to step 1 to confirm elimination of fault.
4. Check for a short circuit to ground.
Disconnect ECU connector X-016.
Disconnect the rail pressure sensor from the engine harness.
47540694 28/04/2014
55.16 [55.DTC] / 176
Measure the voltage between X-016 pin 41 and chassis ground. The chassis ground connection should be clean
and free of paint, oil, and dirt. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent
condition.
5. Check for a short circuit to ground.
Disconnect the rail pressure sensor from the engine harness.
Measure the voltage between X-016 pin 41 and chassis ground. The chassis ground connection should be clean
and free of paint, oil, and dirt. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent
condition.
6. Test the ECU
Disconnect the rail pressure sensor.
Connect the ECU connector, X-016.
Fabricate a jumper wire that will connect between the rail pressure sensor supply, 284, PK and rail pressure sensor
signal 283.
Connect the jumper between rail pressure sensor supply, 284, PK and rail pressure sensor signal 283.
Access the Electronic Service Tool fault code screen. Fault code 3102 should change to 3103.
A. The fault code changed to 3103. Fault code 3102 is no longer active. Temporarily replace the rail pressure
sensor and retest. Return to step 1 to confirm elimination of the fault.
B. The fault code 3102 is still active. Fault code 3103 did not become active. Temporarily replace the ECU and
retest. Return to step 1 to confirm elimination of fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 177
3104-Rail Pressure Relief Valve - Open Circuit

Context:
The engine control unit (ECU) has determined that the pressure relief valve (PRV) is open. Normally the fuel pressure
in the rail is regulated by the metering unit of the high pressure pump. However, if this component is malfunctioning
the rail pressure can rise to critical levels. For this reason the common rail has a pressure relief valve (PRV) which is
a mechanical safety valve (no electrical connectors) that opens at a certain pressure level. An opening of the PRV is
detected by evaluating the gradient of the rail pressure (calculated by the ECU). If the PRV does not open on its own
after exceeding the pressure threshold it can also be forced open by a so-called 'kickoff' or pressure shock when the
metering valve of the high pressure fuel pump is set to maximum possible quantity. Once the PRV has been opened
it will remain open as long as the engine is running. A defective common rail pressure sensor, as judged by the ECU,
which evokes a kickoff (pressure shock) or a defect in an injection relevant component (small leak) can cause this
error to occur. This fault will only be cleared after an ECU reset.
1. Faulty rail pressure sensor, signal not plausible.

2. Faulty common rail fuel system, small leak.
Solution:
1. Use EST to check for other Rail Pressure sensor and injector (cylinder or bank) errors.
A. If Rail Pressure sensor or injector errors exist, follow troubleshooting procedure for existing Rail Pressure sen-
sor or injector error.
B. If no Rail Pressure sensor or injector errors exist, continue with step 2.

2. Check common rail fuel system for leaks.
A. If common rail fuel system leak is found, repair as required.
B. If no common rail fuel system leak is found, continue with step 3.

3. Visually inspect the rail pressure sensor connector and ECU connector X-016 for electrical integrity.
A. If damage or connectivity issues are discovered, repair, clean or replace as required.
B. If no damage or connectivity issues are discovered, replace Rail Pressure sensor and restart engine. If error
reoccurs continue with step 4
4. Visually inspect ECU connector X-016 for electrical integrity.
B. If no damage or connectivity issues are discovered, continue with step 5

5. Visually inspect injector connectors INJ1, INJ2, INJ3, and INJ4 for electrical integrity.
B. If no damage or connectivity issues are discovered, continue with step 6

6. Reload ECU software.
A. If error reoccurs after trying to reload software, replace ECU.
B. If error has been resolved, continue with normal operation of machine.

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 178
3105-Rail Pressure Relief Valve - Pressure Shock Requested

Context:
The engine control unit (ECU) has determined that the fuel rail/system pressure is too high and the pressure relief
valve (PRV) did not open. Normally the fuel pressure in the rail is regulated by the metering unit of the high pressure
pump. However, if this component is malfunctioning the rail pressure can rise to critical levels. For this reason the
common rail has a PRV which is a mechanical safety valve (no electrical connectors) that opens at a certain pressure
level. An opening of the PRV is detected by evaluating the gradient of the rail pressure (calculated by the ECU). If the
PRV does not open on its own after exceeding the pressure threshold it can also be forced open by a so-called 'kickoff'
or pressure shock when the metering valve of the high pressure fuel pump is set to maximum possible quantity. Rail
pressure in excess of 148500 kPa (21538.1 psi) for 1 s evokes a kickoff (pressure shock) request by the ECU. If the
pressure shock (kickoff) does not immediately open the PRV, this error will occur. This fault will only be cleared after
an ECU reset.
1. Faulty ECU, improper data set.

2. Faulty PRV, mechanical valve does not function.
Solution:
1. Use the EST to flash the ECU with the appropriate data set.
A. If the error reoccurs, replace the PRV.
B. If the error does not reoccur, return the combine to service.

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 179
3106-Rail Pressure Relief Valve - Did Not Open After Pressure

Shock
Context:
The engine control unit (ECU) has determined that the Pressure Relief Valve (PRV) did not open after a pressure
shock (kickoff). Normally the fuel pressure in the rail is regulated by the metering unit of the high pressure pump.
However, if this component is malfunctioning the rail pressure can rise to critical levels. For this reason the common
rail has a Pressure Relief Valve (PRV) which is a mechanical safety valve (no electrical connectors) that opens at a
certain pressure level. An opening of the PRV is detected by evaluating the gradient of the rail pressure (calculated
by the ECU). If the PRV does not open on its own after exceeding the pressure threshold it can also be forced open
by a so-called 'kickoff' or pressure shock when the metering valve of the high pressure fuel pump is set to maximum
possible quantity. Rail pressure in excess of 148500 kPa (21538.1 psi) for 1 s evokes a kickoff (pressure shock)
request by the ECU. If the pressure shock (kickoff) request is present longer than 2 s and did not immediately open
the PRV, this error will occur. This fault will only be cleared after an ECU reset.
1. Faulty ECU, improper data set.

2. Faulty PRV, mechanical valve does not function.
Solution:
1. Use the EST to flash the ECU with the appropriate data set.
A. If the error reoccurs, replace the PRV.
B. If the error does not reoccur, return the combine to service.

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 180
3107-Fuel Metering Unit - Short Circuit To Battery

Context:
The engine control unit (ECU) has determined that a short to high source circuit condition exists in the fuel high pres-
sure pump low side circuit. The metering unit of the fuel high pressure pump regulates the pressure in the common
rail. The metering unit is closed-loop controlled by both main relay 1 (high side) and a low side power stage (main
relay 1 is an electronic control circuit within the ECU, providing source voltage to devices external to the ECU. The
low side power stage works in conjunction with the main relay 1 source, providing sensing and current limiting for the
circuit). The monitoring at low side is stopped if a short circuit to ground at the high side (main relay 1) is detected or it
is switched off for some reason. Failure detection of is only possible if the low side power stage is switched on. With
the current settings, the monitoring is shut off during after-run. This error is the result of the power stage hardware
report of 'short circuit to battery' (on the low side of the metering unit) longer than 0.0 (zero) milliseconds and once
the permanent error is detected the power stage is switched off.
Cause:
Fuel high pressure pump circuit is shorted to a high source.
1. Faulty fuel high pressure pump control circuit, shorted to a high source.
Solution:

2. Disconnect the Engine Injector harness from the ECU connector X-016 and place the ignition switch in the ON
position. Use a multi-meter to test for voltage from the Engine Injector harness side of connector X-016, pin 60 to
chassis ground. There should be no voltage.
A. If there is voltage, locate and repair the short to the voltage source.
B. If there is no voltage, continue with step 3

3. Disconnect the Engine Injector harness from the fuel high pressure pump at connector ZME and use a multi-meter
to check the resistance of the fuel high pressure pump solenoid coil. There should be a small amount of resistance.
A. If there is a small amount of resistance, try reloading the ECU software and if the error reoccurs, replace the
ECU.
B. If there is no resistance, the fuel high pressure pump solenoid coil has failed, replace the solenoid.
resolved.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 181
3108-Fuel Metering Unit - Short Circuit to Ground

Context:
The engine control unit (ECU) has determined that a short to low source circuit condition exists in the fuel high pres-
sure pump low side circuit. The metering unit of the fuel high pressure pump regulates the pressure in the common
rail. The metering unit is closed-loop controlled by both main relay 1 (high side) and a low side power stage (main
relay 1 is an electronic control circuit within the ECU, providing source voltage to devices external to the ECU. The
low side power stage works in conjunction with the Main Relay 1 source, providing sensing and current limiting for the
circuit). The monitoring at low side is stopped if a short circuit to ground at the high side (main relay 1) is detected or it
is switched off for some reason. Failure detection of is only possible if the low side power stage is switched off. With
report of 'short circuit to ground' (on the low side of the metering unit) longer than 0.28 seconds and the power stage
has most likely switched off.
Cause:
Fuel high pressure pump circuit is shorted to a low source.
1. Faulty fuel high pressure pump control circuit, shorted to a low source.
Solution:

2. Disconnect the Engine Injector harness from the ECU at connector X-016. Use a multi-meter to test for continuity
from the Engine Injector harness side of connector X-016, pin 60 to ground. There should be no continuity.
B. If there is no continuity, try reloading the ECU software and if the error reoccurs, replace the ECU.
3. Disconnect the Engine Injector harness from the Fuel high pressure pump at connector ZME and use a multi-meter
to check for continuity on the fuel high pressure pump side of connector ZME, pins 1 and 2 to chassis ground.
There should be no continuity on either pin to ground.
A. If there is continuity on either pin, the fuel high pressure pump solenoid coil has failed, replace the solenoid.
B. If there is no continuity on either pin, there is a short to low source in the Engine Injector harness, locate and
repair the short to ground.
resolved.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 182
3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range

Context:
The engine control unit (ECU) has sensed that the Fuel Pressure sensor signal is too high. The test frequency of the
sensor is every 10 ms and if the signal is in excess of 4.86 V for over 200 ms, the error is set. Once set the ECU will,
instead of using the peak rail pressure value of the last 10 ms and the current rail pressure, output a substitute value
from a curve (MAP) in the ECU depending on engine speed and injection quantity.
Cause:
The Fuel Pressure sensor signal is too high.
1. Faulty Fuel Pressure sensor.

2. Faulty circuit wiring, shorted to high source.
Solution:
1. Disconnect the engine sensor harness from the ECU at ECU engine connector X-016 and place the ignition switch
in the ON position. Using a multi-meter check the voltage on the ECU engine connector from pin 11 to pin 26.
There should be 5 V.
A. If there is 5 V reconnect ECU engine connector and continue with step 2.
B. If there is greater than 5 V, there is a failure inside the ECU, replace the ECU.
2. Disconnect the engine sensor harness from the Rail Pressure sensor and place the ignition switch in the ON
position. Use a multi-meter check the voltage on the engine harness side of Rail pressure sensor connector RDS4
from pin 3 to pin 1. There should be 5 V.
A. If there is 5 V leave the Rail pressure sensor connector disconnected and continue with step 3.
B. If there is greater than 5 V, there is a short to high source in the sensor circuit wiring, leave the Rail pressure
sensor connector RDS4 disconnected and continue with step 4.
3. Disconnect the engine sensor harness from the ECU at ECU engine connector X-016. Use a multi-meter test for
voltage between the engine sensor harness side of ECU engine connector X-016, pin 41 and chassis ground and
also between Rail pressure sensor connector RDS4, pin 2 and chassis ground. There should be no voltage.
A. If there is voltage on either or both tests, there is a short to high source in the sensor signal wire, locate and
repair the short to high source.
B. If there is no voltage, either the sensor has failed or the ECU is faulty. Replace the Rail Pressure sensor and
if the fault reoccurs reload the ECU software. If the fault reoccurs after replacing the sensor and reloading
software, replace the ECU.
4. Disconnect the engine sensor harness from the ECU at ECU engine connector X-016. Use a multi-meter test for
voltage between the engine sensor harness side of ECU engine connector X-016, pin 11 and ground and also
between Rail pressure sensor connector RDS4, pin 3 and ground. There should be no voltage.
A. If there is voltage, on either or both tests, there is a short to high source in the sensor source wire. Locate and
repair the short to high source.
B. If there is no voltage, on both tests, there is a short to high source in the sensor ground reference wire. Locate
and repair the short to high source.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 183
3137-Metering Unit - Open Load

Context:
The engine control unit (ECU) has determined that an open circuit condition exists in the Pump control valve (Metering
Unit - High Pressure Pump Regulator solenoid/valve) circuit. The metering unit of the fuel high pressure pump regu-
lates the pressure in the common rail. The metering unit is controlled by both main relay 1 high side and a low side
power stages (main relay 1 is an electronic control circuit within the ECU used to provide fixed and variable control
signals to devices external to the ECU). The monitoring at low side is stopped if a short circuit to ground at the high
side (main relay 1) is detected or it is switched off for some reason. Failure detection of an over current condition is
only possible if the low side power stage is switched on and the open circuit condition only if it is switched off. With
report of an 'open load' in the metering unit longer than 200 milliseconds.
Cause:
Pump control valve circuit is open.
1. Faulty Pump control valve, open solenoid coil.

2. Faulty circuit, open conductor.
Solution:
1. Disconnect the ECU cylinder connector from the ECU at connector X-016. Use a multi-meter to check the resis-
tance on the Engine Injector harness side of connector X-016, from pin 60 to pin 15. There should be approximately
3.2 Ω.
A. If there is approximately 3.2 Ω, check for other ECU errors and follow those troubleshooting procedures.
B. If there is a high resistance reading, leave connector X-016 disconnected and continue with step 2.
2. Disconnect the Engine Injector harness from the pump control valve at connector ZME. Use a multi-meter to check
the resistance of the pump control valve solenoid coil. There should be approximately 3.2 Ω.
A. If there is approximately 3.2 Ω, leave connector ZME disconnected and continue with step 3.
B. If there is a high resistance reading, replace the Pump control valve solenoid.
3. Use a multi-meter to check for continuity from the Engine Injector harness side of connector ZME, pin 1 to the
Engine Injector harness side of connector X-016, pin 15. There should be continuity.
A. If there is continuity, leave the connectors disconnected and continue with step 4
B. If there is no continuity, locate and repair the break in the wire.

4. Use a multi-meter to check for continuity from the Engine Injector harness side of connector ZME, pin 2 to the
Engine Injector harness side of connector X-016, pin 60. There should be continuity.
A. If there is continuity, try reloading the ECU software and if the error reoccurs, replace the ECU.
B. If there is no continuity, locate and repair the break in the wire.

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 184
3139-Metering Unit Signal Range Check - Signal Too High

Context:
The engine control unit (ECU) has determined that it is sensing a voltage greater than 5.2 V. The metering unit of the
fuel high pressure pump regulates the pressure in the common rail.
Cause:
Fuel high pressure pump circuit is shorted to a high source.
1. Faulty fuel high pressure pump control circuit, shorted to a high source.
2. Faulty fuel high pressure pump.
Solution:
B. If the error is no longer present or is in an inactive state, return machine to proper operation.
2. Disconnect the wiring harness from the ECU. Place the ignition switch in the ON position. Use a multi-meter to
test for voltage from the wiring harness side connector pin 15 to chassis ground. There should be no voltage.
A. If there is voltage, locate and repair the short to the voltage source.
B. If there is no voltage, continue with step 3

3. Disconnect the wiring harness from the fuel high pressure pump. Use a multi-meter to check the resistance of the
fuel high pressure pump solenoid coil. There should be a small amount of resistance.
A. If there is a small amount of resistance, try reloading the ECU software and if the error reoccurs, replace the
ECU.
B. If there is no resistance, the fuel high pressure pump solenoid coil has failed, replace the solenoid.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 185
3140-Metering Unit Signal Range Check - Signal Too Low

Context:
The engine control unit (ECU) has determined that the sensing voltage is less than 0.0 V. The metering unit of the
fuel high pressure pump regulates the pressure in the common rail.
Cause:
Fuel high pressure pump circuit is shorted to a low source.
1. Fuel high pressure pump control circuit, shorted to a low source.

2. Faulty Fuel high pressure pump.
3. Faulty control module.
Solution:
2. Disconnect the wiring harness from the ECU module. Use a multi-meter to check for continuity from the wiring
harness side of ECU connector pin 15 to chassis ground. There should be no continuity.
A. If there is continuity, continue with step 3
B. If there is no continuity, try reloading the ECU software and if the error reoccurs, replace the ECU.
3. Disconnect the wiring harness from the Fuel high pressure pump. Use a multi-meter to check for continuity on the
fuel high pressure pump connector pins 1 and 2 to chassis ground. There should be no continuity on either pin to
ground.
A. If there is continuity on either pin, the fuel high pressure pump solenoid coil has failed, replace the solenoid.
B. If there is no continuity on either pin, there is a short to low source in the wiring harness, locate and repair the
short to ground.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 186
3141-Set point of fuel volume flow through metering unit is lower

than calculated limit
Context:
The engine control unit (ECU) has determined that there is either Fuel System Leakage or the Metering Unit (High
Pressure Pump Regulator solenoid/valve) is jammed in closed position. The rail pressure is monitored by various fault
paths during active pressure control by the metering unit. The fault path at hand detects a leakage of fuel by monitoring
the set-point current used to control the metering unit. The monitoring is only active if the high pressure governor (High
Pressure Pump Regulator solenoid/valve) is operating in closed loop control, the rail pressure governor deviation is
within the range +/- 5000 kPa (725.2 psi) and the monitoring has not been inhibited by other faults. If the metering
unit current control set-point current is below a calculated minimum limit over 2.5 seconds this error will occur. [This
limit is calculated from various curves, maps and correction factors established by the ECU]. This error is the result
of an inaccurate Rail pressure sensor or defective high pressure pump in the high pressure system or Metering unit
reflux too low, fuel system leakage, or metering unit jammed in the closed position in the low pressure system.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 187
3146-Water detected in fuel

Context:
The Engine Control Unit (ECU) has sensed that the fuel filter water tank is full. The fuel filter separates any water
from the fuel, and collects it in a special tank. This fault path is set if the tank is full and not emptied over a certain
time. After preliminary debouncing of the signal. if the fuel filter water level sensor is active over 5 s, this fault is set.
This fault will reset, if after preliminary debouncing, the level sensor is not active for over 0.5 s.
Cause:
The water in fuel sensor detects there is water in fuel filter.
1. The fuel filter water tank is full.

2. Faulty wiring harness.
3. Faulty sensor.
Solution:
1. Check the fault is still present and in an active state.
A. If fault is still present and active, continue with Step 2.
B. If fault is no longer present or inactive, check for intermittent fault.

2. Check the filter water tank.
Place the key switch in the OFF position.
Check the fuel filter water tank for contents.
A. If the fuel filter water tank is not full, do not reinstall. Continue with Step 3.
B. If the fuel filter water tank is full, properly dispose the tank contents and reinstall.
3. Verify the wiring harness and connectors are not damaged.
Inspect the wiring harness from the ECU to the water in fuel sensor.
Check that the wiring harness is free of damage, corrosion, abrasion and incorrect attachment.
A. If the connectors are secure and the wiring harness is free of damage, continue with Step 4.
B. If damage is found to the wiring harness or connectors, repair or replace as required.

4. Check the water in fuel signal wire.
Place the key switch OFF.
Disconnect the wiring harness from the water in fuel sensor.
Place the key switch ON.
Use a multimeter to check for voltage from the sensor wiring harness side of connector pin 1 to chassis ground.
There should be less than 0.5 V.
A. If the voltage reading is correct, the sensor has failed. Replace the sensor.
B. If the voltage reading is greater than 0.5 V, there is a short to high source. Locate and repair faulty wiring.
47540694 28/04/2014
55.16 [55.DTC] / 188
3157-CAN Engine Timeout SCH Code

Cause:
Engine configuration does not match the instrument cluster configuration stored.
1. Configuration error
2. Problem in the CAN bus wiring.
Solution:
(1) Connect the Electronic Service Tool to the service tool connector.
A. Fault code 3157 and/or 3158 are active. No other fault codes are active. The engine configuration does not
match the instrument cluster configuration stored. Correct configuration error.
B. Fault code 3157 and other CAN Data Link fault codes such as 9151 - 9154, 9405, 9406, 9410, or 1051 through
1059 are present and ACTIVE. This is an indication of a problem in the CAN Data Link circuit.
47540694 28/04/2014
55.16 [55.DTC] / 189
3158-Engine controller configuration error anti-tamper

Cause:
Engine configuration does not match the instrument cluster configuration stored.
1. Configuration error
Solution:
1. Engine configuration does not match the instrument cluster configuration stored. Correct configuration error.
47540694 28/04/2014
55.16 [55.DTC] / 190
3166-Fuel filter heater relay - short circuit to battery

Context:
The Engine Control Unit (ECU) provides a signal to actuate the fuel filter heating relay control circuit.
Cause:
The power stage of the fuel filter heating relay control circuit is shorted to a high source.

2. Faulty relay.
3. Faulty ECU.
Solution:
1. Verify the fault is still active and present.
A. If the fault is still active, continue with Step 2.
B. If the fault is not present, the fault may be intermittent. Check for an intermittent fault. If no faults are found,
clear the fault code. Return the machine to service.
Inspect the wiring harness from the ECU to the fuel filter heating relay.

3. Check the relay.
Disconnect the fuel filter heating relay.
Use a multimeter to measure the resistance of the relay from pin 85 to pin 86.
A. If the relay has a nominal resistance value, leave the relay removed. Continue with Step 4.
B. If there is infinite or 0 Ω the relay has failed. Replace the relay.

4. Check the relay control signal.
Use a multimeter to check for voltage from the relay cavity pin 1 to chassis ground.
There should be less than 0.5 V.
A. If the voltage reading is greater than 0.5 V, continue with Step 5.
B. If the voltage reading is correct, try to update the ECU software. If the fault is still present, replace the ECU.
5. Locate the short to high source.
Disconnect the wiring harness from the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 191
Use a multimeter to check for voltage from the ECU wiring harness connector X-012 pin 70 to chassis ground.
There should be no voltage.
A. If there is voltage, there is a short to high source in the wiring harness. Locate and repair faulty wiring.
B. If there is no voltage, try to update the ECU software. If the fault is still present, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 192
3167-Fuel Filter Heater Relay - Short Circuit To Ground

Context:
Cause:
The power stage of the fuel filter heating relay control circuit is shorted to a low source.

2. Faulty relay.
3. Faulty ECU.
Solution:

3. Check the relay.

Use a multimeter to check for continuity from the relay cavity pin 1 to chassis ground.
There should be no continuity.
A. If there is continuity, continue with Step 5.
B. If there is no continuity, try to update the ECU software. If the fault is still present, replace the ECU.
5. Locate the short to low source.
Use a multimeter to check for continuity from the ECU wiring harness connector X-012 pin 70 to chassis ground.
47540694 28/04/2014
55.16 [55.DTC] / 193
A. If there is continuity, there is a short to low source in the wiring harness. Locate and repair faulty wiring.
B. If there is no continuity, try to update the ECU software. If the fault is still present, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 194
3168-Fuel filter heater relay - open load

Context:
Cause:
The power stage of the fuel filter heating relay control circuit is open.

2. Faulty relay.
3. Faulty ECU.
Solution:

3. Check the relay.

Use a multimeter to check for continuity from the relay wiring harness pin 1 to ECU wiring harness connector X-012
pin 70.
There should be continuity.
A. If there is no continuity, there is an open circuit in the wiring harness. Locate and repair the faulty wiring.
B. If there is continuity, try to update the ECU software. If the fault is still present, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 195
3169-Fuel filter heater relay - signal not plausible

Context:
Cause:
The power stage of the fuel filter heating relay control circuit has developed a fault.

2. Faulty relay.
3. Faulty ECU.
Solution:

3. Check the relay.

4. Check the relay control signal for a short circuit.
Use a multimeter to check for continuity from the relay cavity connector pin 1 to pin 2.
A. If there is no continuity, try to update the ECU software. If the fault is still present, replace the ECU.
B. If there is continuity, there is a short circuit in the wiring harness. Locate and repair faulty wiring.
47540694 28/04/2014
55.16 [55.DTC] / 196
3176-Setpoint of metering unit not plausible in overrun

Context:
The engine control unit (ECU) has determined that the Metering Unit (High Pressure Pump Regulator solenoid/valve)
has excessively opened to reach the desired Rail pressure. The rail pressure is monitored by various fault paths
during active pressure control by the metering unit. The fault path at hand detects an excessive leakage of fuel by
monitoring the set-point value of the fuel volume flow through the metering unit during overrun. The monitoring is
only active if the high pressure governor (High Pressure Pump Regulator solenoid/valve) is operating in closed loop
control, the engine is in overrun condition, the fuel injection quantity is zero and the monitoring has not been inhibited
by other faults. If the set-point value of the rail pressure governor for the fuel volume flow through the metering unit
exceeds an upper limit over 2.5 seconds this error will occur. [This limit is interpolated from the rail pressure dependent
curve, established by the ECU]. This error is the result of leakage in the high pressure section; injection nozzle stuck
in open position, worn or defective high pressure pump, worn injector, leaking pressure relief valve. or leakage in the
low pressure system; 'Zero delivery' is not active in metering unit (excessive leakage in metering unit).
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 197
3177-Engine overspeed detected

Context:
• An unacceptably high engine speed may arise in the event of a fault in the Engine Control Unit (ECU) or under
certain operating states like downhill travel. In this case the failure should not indicate a fault but simply informs
about a "misuse" of the engine.
• No action is necessary, unless this fault occurs repeatedly. Check for ECU fault codes. If there are fault codes
present, proceed to that troubleshooting procedure.
47540694 28/04/2014
55.16 [55.DTC] / 198
3179-Timeout of CAN Message BC2EDC2

NOTE: It is normal to log Controller Area Network (CAN) fault codes while the control module is being programmed.
In this case, clear the fault codes from the modules and retest the system.
NOTE: Check for multiple CAN fault codes. If there are CAN Bus fault codes, check the entire CAN bus circuit.
Context:
The Engine Control Unit (ECU) did not receive a Controller Area Network (CAN) message from the main communi-
cation system within the allotted time limit. The Controller Area Network (CAN) is made up of a twisted pair of wires,
identified as CAN HI (yellow) and CAN LO (green). These two wires are used to form a "linear bus" network, in that
the wires run in parallel from one end of the vehicle to the other, and each module is connected to both wires as
a "node". These two wires are connected together at each end of the network using a 120 ohms resistor, which is
known as a "termination" resistor. Because there is a 120 ohms resistor at each end of the network, the resistance
should always be 60 ohms between the CAN HI and CAN LO wires.
Cause:
The primary CAN bus circuit is not communicating between the ECU and vehicle control modules.
1. A failed terminating resistor.

2. A problem in the primary CAN bus wiring.
Solution:
1. Verify the fault is still present and in an active state.
B. If the fault is no longer present or inactive, continue with Step 7.

2. Inspect the wiring and connectors.
Verify all the connectors to the ECU and vehicle control modules are not damaged and are properly connected.
Verify the connector locks are not broken and securely hold the connectors in a connected and locked position.
Replace the connectors if the locks are broken.
A. If damaged wiring is found, repair the damaged wiring. Retest the circuit(s).
B. If there is no damage and the connectors are properly connected, continue to Step 3.
3. Use the Electronic Service Tool (EST) to check the CAN network.
Monitor which CAN networks are “Off line”.
A. If multiple CAN networks are “Off line”, you will need to troubleshoot the entire CAN network. Use schematics
to determine common wiring and terminating resistors to locate starting point.
B. If only CAN networks between the ECU and vehicle control modules are “Off line”, continue with Step 4.
4. Measure the resistance of the CAN bus circuit.
Use a multimeter to measure the resistance of the CAN bus circuit from the diagnostic connector X-DIAG between
pin C to pin D.
There should be approximately 54 - 66 Ω.
A. If the CAN bus reading is incorrect, continue with Step 5.
B. If the CAN bus reading is correct, continue with Step 7.
47540694 28/04/2014
55.16 [55.DTC] / 199
5. Measure the resistance of the CAN bus circuit with one terminating resistor removed.
Disconnect the wiring harness from the ECU where the CAN wires are located.
Use a multimeter to measure the resistance from the ECU wiring harness connector X-012 between pin 24 and
pin 25.
A. If the CAN bus reading is incorrect, check the CAN bus wiring and terminating resistor between the ECU to the
vehicle controllers.

NOTE: The ECU has an internal terminating resistor.
6. Check the internal resistor located in the ECU.
Use a multimeter to measure the resistance from the ECU connector X-012 between pin 24 and pin 25.
A. If the reading is incorrect, the resistor has failed. Replace the ECU.
B. If the reading is correct, continue with Step 7.

7. Check the power and ground supplies to the controllers (nodes).
Verify that the connectors are fully installed.
Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned.
A. If damage is found or other than normal readings are indicated, repair the damage discovered during the in-
spection or locate and repair the other than normal conditions and verify that the fault code has been resolved.
B. If no damage or other than normal display readings are indicated, clear the fault code and continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 200
3180-Timeout of CAN Message VCM2EDC

Context:
Cause:

Solution:

pin C to pin D.
47540694 28/04/2014
55.16 [55.DTC] / 201
pin 25.


47540694 28/04/2014
55.16 [55.DTC] / 202
3182-Timeout Of CAN Message RxCCVS

Context:
Cause:

3. Failure of ECM.
Solution:

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 203
3188-Cylinder 1 Warning - Open Load

Context:
The Engine control unit (ECU) has determined that an open circuit condition exists in the Cylinder 1 injector circuit. A
the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect is
treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of an
open circuit failure being present for over 3 camshaft revolutions. As a result of this error an individual cylinder or bank
is shut off, based on parameters established in the ECU. Certain parameters, as currently applied, are permanent
(without a healing possibility, once tested by switching on the component to see if the defect is still present) and others
evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
The Engine control unit (ECU) has determined that there is a fault associated with the current monitoring of the Cylin-
der 1 injector output power driver stage.
1. Faulty Cylinder 1 injector solenoid windings.

2. Faulty electrical wiring, open circuit (damaged wiring).
Solution:

2. Carefully disconnect the engine harness from the ECU at the cylinder connector 3. Use a multi-meter to check
the resistance, on the engine harness side of the cylinder connector 3, between pins 4 and 13. There should be
0.4 - 0.5 Ω.
A. If the resistance is within range, the ECU may have failed. Try reloading the ECU software and if the fault
reoccurs, replace the ECU .
B. If the resistance was significantly greater than maximum range, continue with step 3
3. Disconnect the engine cylinder harness from the injector (valve) cover at connector VC1. Use a multi-meter to
check resistance on the injector (valve) cover side of connector from pin 3 to pin 4. There should be 0.4 - 0.5 Ω.
A. If a small amount of resistance exists, there is open circuit condition in the engine cylinder harness between
the ECU cylinder harness connector 3 and the Cylinder 1 /2 valve cover connector VC1. Locate and repair the
broken conductor.
INJ1. Use a multi-meter to check resistance, on the Cylinder 1 injector, from terminal 1 to terminal 2. There should
be 0.4 - 0.5 Ω.
A. If the resistance is within range, there is an open circuit condition in the injector harness, between injector
connector and ECU cylinder connector. Locate and repair the broken conductor.
B. If the resistance was significantly greater than maximum range, the Cylinder 1 injector solenoid coil has failed.
Replace the injector.
47540694 28/04/2014
55.16 [55.DTC] / 204
resolved.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 205

Context:
The engine control unit (ECU) has determined that an open circuit condition exists in the Cylinder 2 injector circuit. A
(without a healing possibility, once tested by switching on the component to see if the defect is still present). and
others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
Cylinder 2 injector output power driver stage.
1. Faulty injection valve or open solenoid windings.

Solution:

resistance, on the engine injector harness side of connector 3, between pins 6 and 11. There should be 0.4 -
0.5 Ω.
reoccurs, replace the ECU.
check resistance on the injector (valve) cover side of connector VC1 from pin 1 to pin 2. There should be 0.4 -
0.5 Ω.
A. If a small amount of resistance exists, there is open circuit condition in the engine injector harness between
connector 3 and connector VC1. Locate and repair the broken conductor.
terminal 1 (high side ring terminal) Use a multi-meter to check resistance, on the Cylinder 2 injector, from terminal
1 to terminal 2. There should be 0.4 - 0.5 Ω.
A. If the resistance is within range, there is an open circuit condition in the injector harness, between connector
VC1 and connector INJ2. Locate and repair the broken conductor.
47540694 28/04/2014
55.16 [55.DTC] / 206
resolved.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 207

Context:
Cause:

Solution:

0.5 Ω.
0.5 Ω.
A. If the resistance is within range, there is an open circuit condition in the injector harness, between connector 3
and connector VC2. Locate and repair the broken conductor.
47540694 28/04/2014
55.16 [55.DTC] / 208
resolved.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 209

Context:
Cause:

Solution:

0.5 Ω.
0.5 Ω.
A. If the resistance is within range, there is an open circuit condition in the injector harness, between connector
VC2 and connector INJ4. Locate and repair the broken conductor.
47540694 28/04/2014
55.16 [55.DTC] / 210
resolved.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 211
3210-Bank 1 - General Short Circuit To Injector Cable

NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to accurately measure resistance
. The DMM must measure to a resolution of 0.1 ohms. The required measurements are as low as 0.4 ohms (typical
injector solenoid coil resistance is 0.4 - 0.5 Ω) and any DMM inaccuracies will cause the technician to inaccurately
troubleshoot.
NOTE: Ensure the DMM's test lead resistance is considered when measuring resistance. Touch the leads together
on the lowest Ohms scale and record the resistance measurement. Subtract this value from all future resistance
measurements.
Context:
The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 1 (Group A, Cylin-
ders 1 & 4). A power stage component energizes the injection system transistors while observing the current flow
in the high-side and low-side switching branch by sensing resistors. Deviations from the expected current flow are
detected as specific errors by the component and reported to the ECU. Error messages are configured to contain
information on performed injections, same bank cylinder errors, bank specific errors and cylinder specific errors. The
configured error message is compared to applicable error patterns, and the failure matching the pattern is output. If
an error message doesn't match a pattern the defect becomes an unclassifiable error. Monitoring is performed once
per camshaft revolution. This error is a result of a general short circuit of the high side to battery or ground over 4
camshaft revolutions. This error shuts off an individual cylinder or bank, based on ECU parameters. Certain param-
eters, as currently applied, are permanent; there is no healing possibility after testing: switching on the component to
ascertain the defect's presence. Others evoke an irreversible or reversible engine shut off.
Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of an injector
output power driver stage in Bank 1.
1. Faulty electrical wiring.

3. Faulty ECU.
Solution:

Inspect the ECU and all four injector connections. All connections should be secure, tight, free of corrosion, abra-
sion and damage.
Inspect the harness from the ECU to all four injectors. Verify that the harness is free of damage, corrosion, abrasion
3. Measure the resistance through the harness.
47540694 28/04/2014
55.16 [55.DTC] / 212
Disconnect injector connectors 1 and 2.
Measure the resistance between X-016 pin 16 and X-016 pin 32. The resistance should be greater than 20,000 Ω.
Measure the resistance between X-016 pin 16 and chassis ground. The chassis ground connection must be clean
and free of paint, dirt, and oil. The resistance should be greater than 20,000 Ω. Wiggle the harness during mea-
A. All resistance measurements are greater than 20,000 Ω. Go to step 4.
B. One or more resistance measurement are less than 20,000 Ω. There is a short circuit in the harness. Repair
or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault.
4. Measure the resistance at the injector.
Leave the ignition switch OFF.
Measure the resistance between the injector pins on the injector 1. The resistance should be approximately 0.4 Ω.
A. Both resistance measurements are between 0.4 - 0.5 Ω. Go to step 5.
B. One or both resistance measurement are less than 0.4 Ω. There is a short circuit in the injector. Temporarily
replace the injector and retest. Return to step 1 to confirm elimination of fault.
5. Measure the resistance of the injector to chassis ground.
Measure the resistance between the injector 1, pin 1 and chassis ground. The chassis ground connection must
be clean and free of paint, dirt, and oil. The resistance should be greater than 20,000 Ω.
A. All resistance measurement are greater than 20,000 Ω. Temporarily replace the ECU and retest. Return to
B. One or more resistance measurement are less than 20,000 Ω. There is a short circuit in the injector to chassis
ground. Temporarily replace the injector and retest. Return to step 1 to confirm elimination of fault.
Mechanical Units
47540694 28/04/2014
55.16 [55.DTC] / 213

EH Units
47540694 28/04/2014
55.16 [55.DTC] / 214
3218-Bank 2 - General Short Circuit On Injector Cable

NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to accurately measure resistance
. The DMM must measure to a resolution of 0.1 ohms. The required measurements are as low as 0.4 ohms (typical
injector solenoid coil resistance is 0.4 - 0.5 Ω) and any DMM inaccuracies will cause the technician to inaccurately
troubleshoot.
NOTE: Ensure the DMM's test lead resistance is considered when measuring resistance. Touch the leads together
on the lowest Ohms scale and record the resistance measurement. Subtract this value from all future resistance
measurements.
Context:
The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 2 (Group B, Cylin-
ders 2 & 3). A power stage component energizes the injection system transistors while observing the current flow
in the high-side and low-side switching branch by sensing resistors. Deviations from the expected current flow are
detected as specific errors by the component and reported to the ECU. Error messages are configured to contain
information on performed injections, same bank cylinder errors, bank specific errors and cylinder specific errors. The
configured error message is compared to applicable error patterns, and the failure matching the pattern is output. If
an error message doesn't match a pattern the defect becomes an unclassifiable error. Monitoring is performed once
per camshaft revolution. This error is a result of a general short circuit of the high side to battery or ground over 4
camshaft revolutions. This error shuts off an individual cylinder or bank, based on ECU parameters. Certain param-
eters, as currently applied, are permanent; there is no healing possibility after testing: switching on the component to
ascertain the defect's presence. Others evoke an irreversible or reversible engine shut off.
Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of an injector
output power driver stage in Bank 2.

3. Faulty ECU.
Solution:

Inspect the ECU and all four injector connections. All connections should be secure, tight, free of corrosion, abra-
sion and damage.
Inspect the harness from the ECU to all four injectors. Verify that the harness is free of damage, corrosion, abrasion
47540694 28/04/2014
55.16 [55.DTC] / 215
Disconnect injector connectors 3 and 4.
B. One or more resistance measurement are less than 20,000 Ω. There is a short circuit in the harness. Repair
4. Measure the resistance at the injector.
A. Both resistance measurement are between 0.4 - 0.5 Ω. Go to step 5.
B. One or both resistance measurement are less than 0.4 Ω. There is a short circuit in the injector. Temporarily
replace the injector and retest. Return to step 1 to confirm elimination of fault.
5. Measure the resistance of the injector to chassis ground.
A. All resistance measurement are greater than 20,000 Ω. Temporarily replace the ECU and retest. Return to
B. One or more resistance measurement are less than 20,000 Ω. There is a short circuit in the injector to chassis
ground. Temporarily replace the injector and retest. Return to step 1 to confirm elimination of fault.
Mechanical Units
47540694 28/04/2014
55.16 [55.DTC] / 216

EH Units
47540694 28/04/2014
55.16 [55.DTC] / 217
3230-Injection processor error - stop engine

Context:
The engine control unit (ECU) has sensed a problem with the internal supply voltage for Fuel Injector Group “A”, the
fault path for errors in the power stage component of the unit injection system. The power stage monitors itself and
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If the power stage compo-
nent On Time-out is present for at least one cylinder for longer than 3 camshaft revolutions , this error will occur. As a
result of this error an individual cylinder or bank is shut off. This shut off is currently applied to be permanent without
a healing possibility by switching on the component to see if the defect is still present. With either an irreversible or
reversible shut off of the engine being executed. The reason for this failure is a defective ECU. If the fault doesn't
reset or reoccurs, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 218
3235-Number of Injections Limited - by Charge Balance

Context:
The number of injections is greater than normal injections released for current engine speed. This fault will correct
when the number of injections are in range with engine speed. To correct this fault, try re-flashing the software. If that
does not correct the fault, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 219
3236-Number of Injections Limited - by Quantity Balance

Context:
The number of injections is greater than normal injections released for current engine speed. This fault will correct
when the number of injections are in range with engine speed. To correct this fault, try re-flashing the software. If that
does not correct the fault, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 220
3237-Number of Injections Limited - by Software

Context:
This fault has occurred because the desired number of injections is greater than maximum number of injections per
cycle, depending on battery voltage and power requirements for energizing. Check battery voltage, and check power
supply of booster banks. If battery voltage is low, charge battery and recheck. If battery does not hold a charge,
replace the battery. If the power supply of the booster banks is insufficient, check for other faults present. Resolve
those faults.
47540694 28/04/2014
55.16 [55.DTC] / 221
3238-Communication error of CJ940 processor

Context:
The engine control unit (ECU) has detected an internal communications error. Internal communications between
the micro-controller and each CJ940 module (peripheral integrated circuit) via the SPI bus is monitored cyclically
every 20 milliseconds by evaluating the corresponding communication error flag which is provided by the hardware
encapsulation. For every test an error counter is increased or decreased in steps of one. If the error counter for
defective SPI buss communications reaches or exceeds a value of 5 this error becomes active and will reset once the
error counter is equal to or below the value of 0 (zero). This error is caused by electrical disturbances or an internal
defect of the ECU. If failure remains present, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 222
3239-Engine Controller EEPROM - Read Operation Error

Context:
The engine control unit (ECU) has detected an error during the last EEPROM read operation. The hardware encap-
sulation of the ECU checks each data block of the EEPROM and sets a status flag depending on if an error is found
or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management (DSM) and
depending on their value a failure or no failure is detected. If a failure is detected this error sets and should reset
immediately if the EEPROM operates correctly. This failure can be the result of wrong programming / flashing of the
ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace the
ECU.
47540694 28/04/2014
55.16 [55.DTC] / 223
3240-Engine controller EEPROM - Write operation failure

Context:
The engine control unit (ECU) has detected an error during the last EEPROM write operation. The hardware encap-
or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management (DSM) and
depending on their value a failure or no failure is detected. If a failure is detected this error sets and should reset
immediately if the EEPROM operates correctly. This failure can be the result of wrong programming / flashing of the
ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace the
ECU.
47540694 28/04/2014
55.16 [55.DTC] / 224
3241-Engine controller EEPROM - Default value used

Context:
The Engine Control Unit (ECU) has detected that substitute values for the Electrically Erasable Programmable Read-
Only Memory (EEPROM) are used. If a failure is detected, this fault sets and should reset immediately if the EEPROM
operates correctly. This failure can be the result of wrong programming / flashing of the ECU or an internal defect.
Cause:
The ECU has detected an internal fault.
1. Faulty software.
2. Faulty ECU.
Solution:
A. If the fault is still active, try to update the ECU software with the proper data set. If the fault still is present,
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 225
3242-Engine Controller (Locked) Recovery Occurred

Context:
The engine control unit (ECU) has detected, during system start up, a hardware or configuration problem. This triggers
an ECU recovery (reset of the CPU - Central Processing Unit) that is stored as protected. During a fresh ECU start
up different hardware tests are performed. If the error remains present even after reset, the software remains in the
boot-block and the driving software is not processed. If three recoveries are triggered within 4 seconds an irreversible
shut off of the system is carried out and the ECU is classified as permanently defective. In this case no error entry is
possible. If, however, the error leading to recovery is not detected repeatedly and the system is allowed to start up,
one of three recovery errors becomes active depending on the visibility of the recovery. This error can be the result
of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error occurs
repeatedly, reprogram the ECU and if the error remains, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 226
3243-Engine Controller Recovery (Suppressed) - Recovery

Occurred
Context:
an ECU recovery (reset of the CPU - Central Processing Unit) that is not stored. During a fresh ECU start up different
hardware tests are performed. If the error remains present even after reset, the software remains in the boot-block
and the driving software is not processed. If three recoveries are triggered within 4 seconds an irreversible shut
off of the system is carried out and the ECU is classified as permanently defective. In this case no error entry is
possible. If, however, the error leading to recovery is not detected repeatedly and the system is allowed to start up,
one of three recovery errors becomes active depending on the visibility of the recovery. This error can be the result
of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error occurs
repeatedly, reprogram the ECU and if the error remains, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 227
3244-Engine Controller Recovery (Visible) - Recovery Occurred

Context:
an ECU recovery (reset of the CPU - Central Processing Unit) that is visible in the error memory. During a fresh ECU
start up different hardware tests are performed. If the error remains present even after reset, the software remains
in the boot-block and the driving software is not processed. If three recoveries are triggered within 4 seconds an
irreversible shut off of the system is carried out and the ECU is classified as permanently defective. In this case no
error entry is possible. If, however, the error leading to recovery is not detected repeatedly and the system is allowed
to start up, one of three recovery errors becomes active depending on the visibility of the recovery. This error can be
the result of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error
occurs repeatedly, reprogram the ECU and if the error remains, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 228
3245-Engine Controller - Watchdog Not Plausible

Context:
The engine control unit (ECU) has detected a fault in the internal monitoring circuitry. The ECU contains a CPU (central
processing unit) and other microprocessor based circuitry one of which serves as a monitoring module (watchdog).
These two components communicate via the internal communications network (SPI-Bus). Both devices mutually
monitor one another for correct functioning. The watchdog initiates a query / response communication with the CPU,
which responds by starting a "command test" (test of the correct functioning of important processor commands) and
"program flow control" (monitors the correct execution of code segments of the monitoring). From the results of these
two procedures the response to the watchdog is composed. If this response does not correspond to the expected
value, an error counter is incremented. The CPU periodically sends incorrect responses (regarding response time
and value, respectively) as result of the watchdog query / response. The CPU then monitors if the above mentioned
counter is incremented or decremented in accordance with the incorrect or correct response. If the behavior of the
counter is implausible, a second counter is incremented. This monitoring process is executed every 80 ms. This error
is the result of one of the counters exceeding a count of 5 and will reset if both counters contain a value less than 5.
If the error exists only temporarily, it can be ignored and deleted in the fault memory. If the error is permanent, engine
injection will not be allowed and the ECU must be replaced.
47540694 28/04/2014
55.16 [55.DTC] / 229
3252-Controller Watchdog - SPI Communication Failure

Context:
The engine control unit (ECU) has detected an internal (SPI Bus) communication failure. The central processing
unit (CPU) and monitoring module (watchdog) contained with in the ECU, communicate with each other via the SPI
bus. Both devices mutually monitor each other for correct functioning. If, however, the SPI communication between
them fails this monitoring is impaired and an error counter is incremented. If the error counter exceeds 2 over two
20 ms (two tests) checks, this fault is activated. Communication status is checked autonomously by the SPI driver
component every 20 ms and reports a detected error to the ECU. This error initiates ECU recovery (reset). If the ECU
functions correctly after recovery, the SPI error is temporary and can be ignored and deleted from fault memory. If
the SPI error is permanent and the ECU does not leave boot-block, the ECU needs to be replaced.
47540694 28/04/2014
55.16 [55.DTC] / 230
3253-ADC Monitoring - Reference Voltage Too High

Context:
The Analog Digital Converter (ADC) of the Engine Control Unit (ECU) is monitored for plausibility using redundantly
read input and test voltage inputs.
Cause:
1. Faulty software.
2. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 231
3255-ADC Monitoring Test Impulse Error

Context:
Cause:
1. Faulty software.
2. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 232
3256-ADC Monitoring Queue Error

Context:
Cause:
1. Faulty software.
2. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 233
3260-Low side power - open load

NOTE: The low side driver power stage is internal to the Engine Control Unit (ECU).
Context:
The crank relay (starter control relay) supplies power to the starter motor to crank the engine. The diagnostic function
of the low side driver monitors for an open load in the circuit.
Cause:
The ECU senses the crank relay (starter control relay) low side driver circuit is open.
1. The crank relay (starter control relay) has failed.

2. The wiring harness is faulty.
3. The ECU has an internal failure.
Solution:
1. Verify fault is present and in an active state.
A. If the fault is active, continue with Step 2.
B. If the fault is inactive or not present, the fault may have been intermittent. Check for an intermittent fault.
2. Verify that the wiring harness and connectors are free of damage.
Inspect the wiring harness from the ECU to the crank relay (starter control relay) K-007.
Verify that the wiring harness is free of damage, corrosion, abrasion and incorrect attachment.
Make sure all connections are secure and locked.
A. The connectors are secure and the wiring harness is free of damage. Continue with Step 3.
B. The connectors or the wiring harness has damage. Repair or replace the wiring harness or connectors as
required.
3. Check the relay control circuit.
Remove the relay K-007.
Use a multimeter to check for continuity on the relay from pin 85 to pin 86.
A. If there is continuity, leave the relay removed. Continue with Step 4.
B. If the relay test fails, replace the relay.

4. Check the wiring harness for an open circuit.
Use a multimeter to check for continuity from the wiring harness side of the K-007 relay cavity pin 85 to the ECU
wiring harness connector X-012 pin 53.
Use a multimeter to check for continuity from the wiring harness side of the K-007 relay cavity pin 86 to the ECU
wiring harness connector X-012 pin 27.
47540694 28/04/2014
55.16 [55.DTC] / 234
A. If there is no continuity, there is an open circuit in the wiring harness. Locate and repair faulty wiring.
B. If there is continuity, try updating the ECU software. If the fault code is still present, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 235
3261-Low side power - short circuit to battery or excess temperature

Context:
The crank relay (starter control relay) supplies power to the starter motor to crank the engine. The low side driver
power stage, internal to the Engine Control Unit (ECU), diagnostic function monitors the circuit for a short to high
source.
Cause:
The ECU senses the crank relay (starter control relay) low side driver circuit is shorted to a high source.

Solution:
required.
Use a multimeter to check the for continuity on the relay from pin 85 to pin 86.
A. If the relay test is good, leave the relay removed. Continue with Step 4.

4. Check the wiring harness for a short circuit.
Use a multimeter to check for continuity from the wiring harness ECU connector X-012 between pin 27 to pin 53.
A. If there is no continuity, leave the ECU connector disconnected. Continue with Step 5.
B. If there is continuity, there is a short circuit in the wiring harness. Locate and repair broken conductor.
5. Check the wiring harness for a short to high source.
47540694 28/04/2014
55.16 [55.DTC] / 236
Use a multimeter to check for voltage from the wiring harness ECU connector X-012 pin 27 to chassis ground.
A. If there is no voltage, leave the ECU connector disconnected. Continue with Step 6.
B. If there is voltage, there is a short to high source in the wiring harness. Locate and repair broken conductor.
6. Check the wiring harness for a short to high source.
Use a multimeter to check for voltage from the wiring harness ECU connector X-012 pin 27 to chassis ground.
A. If there is no voltage, try updating the ECU software. If the fault code is still present, replace the ECU.
B. If there is voltage, there is a short to high source in the wiring harness. Locate and repair broken conductor.
47540694 28/04/2014
55.16 [55.DTC] / 237
3262-Low side power - short circuit to ground

Context:
The crank relay (starter control relay) supplies power to the starter motor to crank the engine. The low side driver
power stage, internal to the Engine Control Unit (ECU), diagnostic function monitors the circuit for a short to low
source.
Cause:
The Engine Control Unit (ECU) senses the crank relay (starter control relay) low side driver circuit is shorted to a low
source.

Solution:
required.
Use a multimeter to check for continuity on the relay from pin 85 to pin 86.
A. If the relay test is good, leave the relay removed. Continue with Step 4.

4. Check the wiring harness for a short to low source.
Use a multimeter to check for continuity from the wiring harness ECU connector X-012 pin 27 to chassis ground.
A. If there is no continuity, try updating the ECU software. If the fault code is still present, replace the ECU.
B. If there is continuity, there is a short to ground source in the wiring harness. Locate and repair broken conductor.
47540694 28/04/2014
55.16 [55.DTC] / 238
47540694 28/04/2014
55.16 [55.DTC] / 239
3265-Overrun Monitoring - Injection Time Too Long

Context:
The engine control unit (ECU) has detected that injection time is too long. The sum of all torque-forming energizing
times of an individual cylinder exceeds the limit, calculated from the map (depending on the engine speed and the
time since the overrun monitoring is active) for more than 100 test events (test frequency every 10 ms). When the
engine is in overrun operation the monitoring becomes active and the current injection energizing time is compared
with a maximum permissible time limit. If the limit is exceeded an ECU recovery (reset ) is triggered and if the error
reoccurs in the same driving cycle, the torque-determining power stages are irreversibly shut off. The basic idea is
that the operator reacts to an unintentional torque increase, caused by a malfunction of the ECU, by releasing the
accelerator pedal (reducing engine speed) which causes the engine to enter the overrun operation mode. Overrun
monitoring is only released if various conditions are met, such as no accelerator pedal activation, no activated cruise
control, no intervention of the vehicle dynamic control or gearbox control is present, etc. This failure could be the
result of electronic disturbances, a requested torque increase via tester, the wrong application of injection relevant
parameters, or a defective ECU. If this failure persists, the ECU may need to be replaced.
47540694 28/04/2014
55.16 [55.DTC] / 240
3266-Error in engine speed check, speed signal not plausible

Context:
The engine control unit (ECU) has determined that the speed signal is not plausible. In order to execute an overrun
monitoring, which checks if the injection energizing time is below a certain limit during overrun, the information of the
current engine speed is required. As the overrun monitoring is executed in layer 2 of the ECU monitoring concept (i.e.
function monitoring) in order to monitor the safety-relevant signal paths of the operational layer (layer 1, application
software) a redundant engine speed is additionally calculated in layer 2, independent of the engine speed information
of layer 1. If the absolute value of the deviation between engine speed (layer 1) and redundant segment speed
(layer 2) exceeds 320 RPM over 800 ms (test frequency is every 40 ms), while the redundant segment speed is
above 1000 RPM this error is activated, which triggers an ECU recovery (reset). If this failure persists after ECU
re-initialization, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 241
3283-Sensor Supply Voltage 2 - High

Context:
The Engine Control Unit (ECU) provides 3 independent 5.0 V voltage supplies for the sensors. These sensor supply
voltages are monitored to ensure they remain within a given range. This check for voltage limits is done autonomously
by the hardware.
Cause:
The sensor supply voltage lies outside of the switching thresholds.
1. Faulty wiring.
2. Faulty battery.
3. Faulty ECU.
Solution:
Inspect the wiring harness from the ECU to the battery.

3. Check the voltage input to the ECU.
Use a multimeter to measure the voltage on the wiring harness side of the ECU connector X-012 pin 1 to pin 2.
Use a multimeter to measure the voltage on the wiring harness side of the ECU connector X-012 pin 28 to chassis
ground.
There should be approximately 10.0 - 18.0 V.
A. If the voltage reading is correct, continue with Step 4.
B. If the voltage reading is greater than 18.0 V, check the wiring harness between the ECU connector to the
battery for a short to high source.
4. Check the battery voltage.
Use a multimeter to measure the voltage on the battery from the positive terminal to the negative terminal.
47540694 28/04/2014
55.16 [55.DTC] / 242
A. If the voltage reading is correct, the charging circuit is good. Try to update the ECU software. If the fault is still
present, replace the ECU.
B. If the voltage reading is incorrect, replace the battery.

47540694 28/04/2014
55.16 [55.DTC] / 243
3285-Sensor Supply Voltage 3 - High

Context:
voltages are monitored by a hardware comparator to ensure they remain within a given range.
Cause:
1. Faulty wiring.
2. Faulty battery.
3. Faulty ECU.
Solution:

ground.
47540694 28/04/2014
55.16 [55.DTC] / 244

47540694 28/04/2014
55.16 [55.DTC] / 245
3293-Fuel Metering Unit: maximum positive deviation of rail

pressure exceeded
Cause:
The fault is cause by a problem in the high pressure fuel supply.
1. Leakage in the high pressure system.

2. Injection nozzle stuck in open position.
3. Low efficiency of high pressure pump.
4. Internal leakage of injector.
5. Leaking pressure control valve.
6. Low pressure at High pressure pump inlet due clogged filter.
7. Leaking low pressure tubes.
8. Electric pre supply pump defective or gear pump defective.
Solution:
1. Check low pressure system for clogging (specially fuel filter).

Refer to the Operator’s Manual to check the fuel filter system.
2. Check tubing between pre supply and gear pump.
3. Check feeding of pre supply pump (possibly low due to clogged tubes at tank outlet).
4. Check high pressure part for leakages (internal / external).
5. Check PCV for tightness in closed position (100% PWM).
6. Check high pressure pump for efficiency.
7. Check injectors for tightness.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 246
3301-Fuel high pressure pump is at minimum delivery and the Rail

pressure is not reducing
Context:
The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too high with a closed Metering
Unit (High Pressure Pump Regulator - solenoid valve). The rail pressure is monitored by various fault paths during
active pressure control by the metering unit. The fault path at hand detects an excessive negative rail pressure gov-
ernor deviation (too high rail pressure) at zero delivery of fuel volume flow through the metering unit. The monitoring
is only active if the high pressure governor is operating in closed loop control, the engine is not in overrun, the fuel
system temperature is above 29.96 °C (85.93 °F), the current injection quantity is above 0.0 g (0.00 oz) per cycle and
the monitoring has not been inhibited by other faults. If the negative rail pressure governor deviation is below the
engine speed dependent limit from a curve established by the ECU and the rail pressure governor set-point value of
the fuel volume flow is below threshold (parameter established by the ECU) over 8 seconds, this error will occur.
Cause:
1. Faulty high pressure pump regulator solenoid/valve, stuck open.

2. Pressure too high, low pressure side.
Solution:
1. Check for high pressure pump regulator (solenoid/valve) errors.
A. If high pressure pump regulator (solenoid/valve) errors exist, follow troubleshooting procedure for existing high
pressure pump regulator (solenoid/valve) error.
B. If no high pressure pump regulator (solenoid/valve) errors exist, locate and repair high pressure condition in
low pressure side of fuel system.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 247
3305-Cannot maintain rail pressure above the minimum pressure

of 200 Bar
Context:
The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too low. The rail pressure is
monitored by various fault paths during active pressure control by the metering unit. The fault path at hand detects if
the rail pressure has fallen below a minimum pressure threshold. The monitoring is only active if the high pressure
governor is operating in closed loop control and the monitoring has not been inhibited by other faults. If the rail pres-
sure is below the engine speed dependent limit from a curve, established by the ECU, over 2.5 seconds this error will
occur. This error is the result of a leak in the high or low pressure side of the fuel rail system. On the high pressure
side check for worn or stuck open injector, worn high pressure pump or leaking pressure relief valve. On the low
pressure side check for low fuel pressure before or after the gear pump, clogged fuel filter or leakage.
47540694 28/04/2014
55.16 [55.DTC] / 248
3309-Maximum Fuel rail pressure exceeded

Context:
The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too high. The rail pressure is
monitored by various fault paths during active pressure control by the metering unit. The fault path at hand detects
if the rail pressure has exceeded a maximum pressure threshold. The monitoring is only active if the high pressure
sure exceeds the maximum pressure 150000 kPa (21755.7 psi) over 1 second, this error will occur.
Cause:
The Fuel Rail/System Pressure is too high.

Solution:
47540694 28/04/2014
55.16 [55.DTC] / 249
3334-Timeout of CAN Message TSC1 Speed

Context:
Cause:

3. Failure of ECM.
Solution:

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 250
3335-Timeout of CAN message TSC1-PE torque (when inactive)

Context:
The Engine Control Unit (ECU) did not receive a Controller Area Network (CAN) message from the Power Take-Off
(PTO) controller within the allotted time limit. The Controller Area Network (CAN) is made up of a twisted pair of
wires, identified as CAN HI (yellow) and CAN LO (green). These two wires are used to form a "linear bus" network,
in that the wires run in parallel from one end of the vehicle to the other, and each module is connected to both wires
as a "node". These two wires are connected together at each end of the network using a 120 ohms resistor, which is
Cause:

Solution:

pin C to pin D.
47540694 28/04/2014
55.16 [55.DTC] / 251
pin 25.


47540694 28/04/2014
55.16 [55.DTC] / 252
3338-Timeout of CAN message TSC1-VE speed (when inactive)

Context:
Cause:

Solution:

pin C to pin D.
47540694 28/04/2014
55.16 [55.DTC] / 253
pin 25.

A. If the readings are incorrect, the resistor has failed. Replace the ECU.
B. If the readings are correct, continue with Step 7.

47540694 28/04/2014
55.16 [55.DTC] / 254
3339-Timeout of CAN message TSC1-VE speed (when active)

Context:
Cause:

Solution:

pin C to pin D.
47540694 28/04/2014
55.16 [55.DTC] / 255
pin 25.


47540694 28/04/2014
55.16 [55.DTC] / 256
3350-Terminal 50 - always on, starting circuit signal is active for

an excessive time period
Context:
The Engine Control Unit (ECU) monitors the status signal of terminal 50 (T50), which is used to crank the engine with
the starter motor. This fault becomes active if the T50 digital input signal is active for an excessive time period.
Cause:
The crank signal is active for a long period of time.
1. Faulty wiring
Solution:
A. If fault is still present and active, continue with step 2.
B. If the fault is no longer present or inactive, continue with step 4.

2. Inspect the wiring harness and connectors.
Verify the wiring harness from the key switch to the ECU is not damaged and connections are properly connected.
A. If there is no damage and the connectors are properly connected, continue to step 3.
B. If damaged wiring is found, repair the damaged wiring. Retest the circuit(s).
3. Check the key switch crank position signal for a short to a high source.
Disconnect the wiring harness connector from the ECU.
Use a multimeter to check for voltage from the ECU wiring harness connector pin 08 to chassis ground.
B. If there is voltage there is a short to voltage in the wiring harness. Locate and repair the fault between the ECU
and key switch.
4. Check the wiring harness to relevant components and control modules.
47540694 28/04/2014
55.16 [55.DTC] / 257
3358-CAN transmit timeout

Context:
Cause:

3. Failure of ECM.
Solution:

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 258
3361-ECM EEPROM - General Error

Context:
The Engine Control Unit (ECU) has detected that substitute values for the Electrically Erasable Programmable Read-
Only Memory (EEPROM) are used. If a failure is detected, this fault sets and should reset immediately if the EEPROM
operates correctly. This failure can be the result of wrong programming / flashing of the ECU or an internal defect.
Cause:
1. Faulty software.
2. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 259
3362-Torque to Quantity Map - Not Plausible

Context:
The engine control unit (ECU) has detected an error. This failure can be the result of wrong programming / flashing
of the ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace
the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 260
3368-Torque limitation due to performance limiter, may be triggered

by inducement
Context:
The Engine Control Unit (ECU) has detected an active power reduction due to the OBD performance limiter. This
error is for informational purposes and is initiated by a power reduction due to the OBD performance limiter because
of inhibited injection being active causing a torque limitation greater than 25 % of the desired torque for longer than
60 seconds and is reset once the torque limitation due to the OBD performance limiter because of inhibited injection
is less than 25 % of the desired torque over 10 seconds. Though no action is necessary due to this error, if the power
reduction occurred due to an actual defect, the error triggering the torque limitation should also be in fault memory.
Follow the troubleshooting procedure for that error.
47540694 28/04/2014
55.16 [55.DTC] / 261
3369-Torque reduction due to smoke reduction

Context:
The Engine Control Unit (ECU) has detected an active power reduction due to smoke limitation. This error is for
informational purposes and is initiated by a power reduction due to smoke limitation being active causing a torque
limitation greater than 25 % of the desired torque for longer than 60 seconds and is reset once the torque limitation
due to smoke limitation is less than 25 % of the desired torque over 10 seconds. Though no action is necessary due
to this error, if the power reduction occurred due to an actual defect, the error triggering the torque limitation should
also be in fault memory. Follow the troubleshooting procedure for that error.
47540694 28/04/2014
55.16 [55.DTC] / 262
3370-Torque limitation due to engine protection

Context:
The Engine Control Unit (ECU) has detected an active power reduction due to engine mechanics protection. This error
is for informational purposes and is initiated by a power reduction due to engine mechanics protection being active
causing a torque limitation greater than 25 % of the desired torque for longer than 60 seconds and is reset once the
torque limitation due to engine mechanics protection is less than 25 % of the desired torque over 10 seconds. Though
no action is necessary due to this error, if the power reduction occurred due to an actual defect, the error triggering
the torque limitation should also be in fault memory. Follow the troubleshooting procedure for that error.
47540694 28/04/2014
55.16 [55.DTC] / 263
3371-Torque limitation due to Fuel quantity Limitation

Context:
The Engine Control Unit (ECU) has detected an active power reduction due to limiting fuel quantity. This error is for
informational purposes and is initiated by a power reduction due to limiting fuel quantity being active causing a torque
limitation greater than 25 % of the desired torque for longer than 60 seconds and is reset once the torque limitation
due to limiting fuel quantity is less than 25 % of the desired torque over 10 seconds. Though no action is necessary
due to this error, if the power reduction occurred due to an actual defect, the error triggering the torque limitation
should also be in fault memory. Follow the troubleshooting procedure for that error.
47540694 28/04/2014
55.16 [55.DTC] / 264
3374-Unit injector NEMA codes are invalid

Context:
The engine control unit (ECU) has determined that the EEPROM Adjustment Value Checksum is invalid. For every
individual unit injector an injection quantity adjustment (NEMA) can be programmed in the EEPROM for the entire
operating range. The monitoring function at hand checks if the EEPROM block holding these quantity adjustment
codes can be read successfully and if the cylinder individual checksums of the codes are correct. This monitoring
function is carried out at every ECU initialization (reset). Healing can, therefore, only occur by resetting the ECU.
This error will occur if the injector quantity adjustment code in the EEPROM of at least one cylinder contains an
invalid checksum and the injection quantities will not be corrected with the adjustment values. This error is cleared by
resetting (re-initializing) the ECU with a successful read of the injector quantity adjustment values form the EEPROM.
This error may be the result of an invalid NEMA code being programmed. Try to flash the ECU correctly with correct
NEMA codes and a proper dataset, if defect persists, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 265
3390-Engine Air Filter Restriction

Context:
The instrument cluster detects a signal to ground on X-C23 pin 11 indicating that the air filter restriction switch has
been tripped. The instrument cluster will illuminate the air filter restriction lamp while this fault is active.
Cause:
The instrument cluster detects a signal to ground indicating that the air filter restriction switch has been tripped.
1. Clogged air filter.

2. Signal wire short circuit to minus battery or chassis ground.
3. Faulty air filter restriction switch.
Solution:

2. Inspect the engine air filter.
Inspect the engine air filter. Replace the filter as required.
A. The filter is OK and does not need to be replaced. Go to step 3.
B. The filter is in poor condition or is clogged. Replace the filter. Return to step 1 to confirm elimination of the fault.
Inspect the instrument cluster and the air filter restriction switch connections. All connections should be secure,
Inspect the harness from the instrument cluster and the air filter restriction switch. Verify that the harness is free
4. Check the air filter restriction circuit.
Disconnect the signal wire from air filter restriction switch.
Access the fault code screen on the Electronic Service Tool. The air filter restriction fault code should no longer
be active.
A. The fault code is no longer active. Go to step 4.
B. Fault code 3390 is still active. Go to step 5.

5. Check air filter restriction switch.
47540694 28/04/2014
55.16 [55.DTC] / 266
Remove the air filter restriction switch from the air filter housing.
Measure the resistance across the switch. The resistance should be greater than 20,000 Ω.
A. The resistance is greater than 20,000 Ω. Inspect the wiring around the sensor. Go to step 5.
B. The resistance is less than 20,000 Ω. Replace the air filter restriction switch. Return to step 1 to confirm
Measure the resistance from X-C23 pin 16 to chassis ground. The resistance should be greater than 20,000 Ω.
A. The resistance is greater than 20,000 Ω. Temporarily replace the instrument cluster and retest. Go to step 1
B. The resistance is less than 20,000 Ω. There is a short to chassis ground in the signal wire. Repair or replace
the wire as required. Return to step 1 to confirm elimination of fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 267
3390-Engine Air Filter Restriction

Context:
The instrument cluster detects a signal to ground on pin 11 indicating that the air filter restriction switch has been
tripped.
Cause:
The instrument cluster detects a signal to ground indicating that the air filter restriction switch has been tripped.
1. Clogged air filter.

2. Signal wire short circuit to minus battery or chassis ground.
3. Faulty air filter restriction switch.
Solution:

2. Inspect the engine air filter.
Inspect the engine air filter. Replace the filter if needed.
A. The filter is OK and does not need to be replaced. Go to step 3.
B. The filter is in poor condition or is clogged. Replace the filter. Return to step 1 to confirm elimination of the fault.
Inspect the instrument cluster and the air filter restriction switch connections. All connections should be secure,
Inspect the harness from the instrument cluster to the air filter restriction switch. Verify that the harness is free of
4. Test the air filter restriction circuit.
Disconnect the signal wire from air filter restriction switch.
Access the fault code screen on the Electronic Service Tool. The air filter restriction fault code should no longer
be active.
A. The fault code is no longer active. Go to Step 4.
B. Fault code 3390 is still active. Go to step 5.

5. Check air filter restriction switch.
47540694 28/04/2014
55.16 [55.DTC] / 268
Remove the air filter restriction switch from the air filter housing.
Measure the resistance across the switch. The resistance should be greater than 20,000 Ω.
A. The resistance is greater than 20,000 Ω. Inspect the wiring around the sensor. Go to Step 5.
B. The resistance is less than 20,000 Ω. Temporarily replace the air filter restriction switch and retest. Return to
step 1 to confirm elimination of fault.
6. Measure the resistance of the signal wire to chassis ground.
Measure the resistance between X-C23 pin 11 and chassis ground. The resistance should be greater than
A. The resistance is greater than 20,000 Ω. Temporarily replace the instrument cluster and retest. Return to step
1 to confirm elimination of the fault.
B. The resistance is less than 20,000 Ω. There is a short to chassis ground in the signal wire. Repair or replace
the wire as required. Return to step 1 to confirm elimination of fault.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 269
3402-Rail pressure sensor: maximum rail pressure exceeded

Context:
The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too high. The rail pressure is
monitored by various fault paths during active pressure control by the metering unit. The fault path at hand detects
if the rail pressure has exceeded a maximum pressure threshold. The monitoring is only active if the high pressure
sure exceeds the maximum pressure 1800 bar (26100 psi) over 1 second, this error will occur.
Cause:
The Fuel Rail/System Pressure is too high.

Solution:
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 270
3403-ECU Power Stages: Starter relay HS power stage over

temperature
Context:
The ECU has sensed that the starter is continuously energized.
Cause:
The ECU has sensed that the starter is continuously energized.
1. A short circuit in the starter relay circuit.

2. Faulty crank relay.
3. Failure of the ECU.
Solution:
Verify that there are no fault codes pertaining to high battery voltage to the ECU or high engine temperatures.
B. Fault code 3403 is recorded with along with high engine temperature fault codes such as high coolant temper-
ature and/or high transmission temperature and/or high hydraulic oil temperature. Troubleshoot these codes
first. Return to step 1 to confirm elimination of the fault.
C. Fault code 3403 is recorded. No other fault codes are active. Go to step 2.
Inspect the ECM, the starter, and the starter relay connections. All connections should be secure, tight, free of
Inspect the harness from the ECM to the starter and starter relay. Verify that the harness is free of damage,
3. Measure the voltage on the starter relay circuit.
and free of paint, oil and, dirt. The voltage should be less than 0.5 V. Wiggle the harness during measurement to
reveal an intermittent condition.
and free of paint, oil and, dirt. The voltage should be less than 0.5 V. Wiggle the harness during measurement to
reveal an intermittent condition.
47540694 28/04/2014
55.16 [55.DTC] / 271
A. Both voltage measurements are less than 0.5 V. Temporarily replace the ECU and retest. Return to step 1 to
B. One or both voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source
in the wiring. Repair or replace the harness as required. Verify the crank relay has not failed. Return to step 1
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 272
3405-ECU Power stages: Open load temperature error on the

Turbocharger PWM output power stage
Context:
ECU Power stages: Open load temperature error on the Turbocharger PWM output power stage.
Cause:
The ECU detects an open circuit in the turbocharger waste gate signal wire.
1. Faulty wiring.
2. Faulty electric valve.
3. Faulty ECU.
Solution:

Inspect the ECU and the electric valve. All connections should be secure, tight, free of corrosion, abrasion and
damage.
Inspect the harness from the ECU to the electric valve. Verify that the harness is free of damage, corrosion,
3. Measure the voltage at the actuator connector.
Disconnect the electric valve connector.
Measure the voltage from +Battery pin to chassis ground. The voltage should be approximately 12 V. Wiggle the
A. The voltage is between 10 V and 14.8 V. Go to step 4.
B. The voltage is less than 10 V. There is a problem in the battery supply to the valve. Check fuses. Repair as
4. Measure the resistance through the valve.
Disconnect the Electric Valve connector.
Measure the resistance through the motor windings. The resistance should be less than 100 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 273
B. The resistance is greater than 100 Ω. There is an open circuit in the valve windings. Temporarily replace the
valve and retest. Return to step 1 to confirm elimination of fault.
Fabricate a jumper wire that will connect the electric valve connector pin 1 to chassis ground.
Connect the jumper wire between the electric valve connector pin 1 and chassis ground. The chassis ground
connection must be clean and free of paint, oil, and dirt.
Measure the resistance between ECU connector X-016 pin 4 and chassis ground. The resistance should be less
than 10 Ω. Wiggle the wire during measurement to reveal an intermittent condition.
A. The resistance is less than 10 Ω. Temporarily replace the ECU and retest. Return to step 1 to confirm elimi-
nation of the fault.
B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the wire as
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 274
3406-ECU Power stages: Over temperature error on the

Turbocharger PWM output power stage
Context:
The ECU detects an excess current draw on the turbocharger waste gate signal wire.
Cause:
1. Faulty wiring.
2. Faulty electric valve.
3. Faulty ECU.
Solution:

Inspect the ECU and the Electric Valve. All connections should be secure, tight, free of corrosion, abrasion and
damage.
Inspect the harness from the ECU to the Electric Valve. Verify that the harness is free of damage, corrosion,
3. Measure the voltage at the actuator connector.
Measure the voltage between the +Battery pin and chassis ground. The voltage should be approximately 12 V.
A. The voltage is between 10 V and 14.8 V. Go to Step 4.
B. The voltage is less than 10 V. There is a problem in the battery supply to the valve. Check fuses. Repair as
required. Return to Step 1 to confirm elimination of fault.
C. The voltage is greater than 14.9 V. There is a problem in the battery supply to the valve. Troubleshoot the high
voltage problem. Refer to FC3051 Engine Control Unit (ECU) - No power (55.015).
4. Measure the resistance through the valve to chassis ground.
47540694 28/04/2014
55.16 [55.DTC] / 275
Measure the resistance through the electric valve pin 1 to chassis ground. The resistance should be greater than
20,000 Ω.
B. The resistance is less than 20,000 Ω. There is an internal short to chassis ground. Temporarily replace the
Electric Valve and retest. Return to Step 1 to confirm elimination of the fault.
Measure the resistance from the ECU connector X-016 pin 4 to chassis ground. The resistance should be greater
than 20,000 Ω. Wiggle the wire during measurement to reveal an intermittent condition.
B. The resistance is less than 10 Ω. There is a short circuit in the signal wire to chassis ground. Repair or replace
the wire as required. Return to Step 1 to confirm elimination of fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 276
3408-Lambda sensor: Oxygen concentration implausibly high

Context:
The expected O2 concentration is calculated using actual air flow and actual fuel injection. The calculated value is
outside of the normal operating range.
Cause:
The expected O2 concentration is calculated using actual air flow and actual fuel injection. The calculated value is
outside of the normal operating range.
1. Leakage or block in the exhaust gas system.

2. Blocked fuel lines to the injector.
3. Problem in the injection system.
4. Problem in the wiring to the Lambda sensor.
NOTE: When testing the oxygen sensor a high impedance digital volt meter must be used. A normal analogue
multi-meter will draw too much current and either burn out the sensor or give false readings.
NOTE: When replacing the oxygen sensor, re-flash the control module to allow for the new sensor adjustments to
be learned.
5. Faulty Lambda sensor.
6. Faulty ECU.
Solution:
1. Verify the fault code is still present and in an active state.
A. If the fault is no longer active or present, check for an intermittent fault.
B. If the fault is still present and active, continue with step 2.

2. Check the turbo exhaust system.
Check the turbo and exhaust line for leaks and improper attachment.
A. The exhaust system is free of leaks and improper attachment. Go to step 3.
B. The exhaust system has leaks and is need of repair. Repair the exhaust system as required. Return to step 1
3. Check the fuel injection system.
Check the fuel lines to the injectors for leaks, blocks or improper attachment.
A. The fuel lines are free of leaks, blocks and improper attachment. Go to step 4.
B. The fuel lines have leaks and are in need of repair. Repair the fuel lines as required. Return to step 1 to confirm
4. Place the ignition switch in the OFF position. Disconnect the engine harness from the oxygen sensor. Inspect all
connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks.
A. If any damage is found, repair or replace connections, pins, or wiring. Return to step 1 to confirm elimination
of the fault.
B. If no damage is found, reconnect the wiring harness to the sensor. Continue with step 5.
5. Measure the voltage at the sensor.
Disconnect the Lambda sensor connector X-014.
47540694 28/04/2014
55.16 [55.DTC] / 277
Measure the voltage between X-014 pin 4 and X-014 pin 2. The voltage should be approximately 12 V. Wiggle
A. The voltage is between 11 V and 14.8 V. Go to step 6.
B. The voltage is less than 11 V. There is a problem in the battery supply to the sensor. Check fuses. Repair as
required. Return to step 1 to confirm elimination of the fault.
6. Measure the resistance through the wire harness
Disconnect the ECU connector X-012 and the Lambda sensor connector X-014.
Measure the resistance between X-012 pin 7 and X-014 pin 3. The resistance should be less than 10 Ω. Wiggle
B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair as required. Go to step 1 to
7. Measure the resistance of the harness to chassis ground
Disconnect the ECU connector X-012 and the Lambda sensor connector X-014.
Measure the resistance between X-012 pin 7 and chassis ground. The resistance should be greater than 20,000 Ω.
Measure the resistance between X-012 pin 64 and chassis ground. The resistance should be greater than
Measure the resistance between X-012 pin 63 and chassis ground. The resistance should be greater than 10 Ω.
A. The resistance is greater than 20,000 Ω. Temporarily replace the Lambda sensor and retest. Return to step 1
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the wiring harness. Repair
as required. Go to step 1 to confirm elimination of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 278
3409-Oil pressure too low

Context:
The ECU has detected a low oil pressure condition.
Cause:
Engine speed is greater than 500 RPM and the oil pressure switch did not close. The oil pressure switch will close to
indicate to the ECU that the engine is running with the proper oil pressure.
1. Low engine oil level.

2. Faulty engine lubrication system.
3. Faulty electrical wiring, open circuit in the signal wire to the ECU.
4. Faulty oil press switch.
5. Faulty ECU.
Solution:

2. Check the engine oil level.
Check the engine oil level. Refer to the operators manual for the proper oil level.
A. The oil level is correct. Go to step 3.
B. The oil level is not correct. Refer to the operators manual for the proper oil level. Repair as required. Return
Inspect the ECU and the oil pressure switch connections. All connections should be secure, tight, free of corrosion,
Inspect the harness from the ECU to the oil pressure switch. Verify that the harness is free of damage, corrosion,
Disconnect ECU connector X-016 and the oil pressure switch connector.
Measure the resistance between X-016 pin 6 and oil pressure switch connector pin 1. The resistance should be
47540694 28/04/2014
55.16 [55.DTC] / 279
B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair as required. Return to
step 1 to confirm elimination of fault.
5. Measure the resistance through the oil pressure switch.
Disconnect the oil pressure switch connector.
Start the engine. Set engine speed to 800 RPM.
While the engine is running, measure the resistance through the switch to chassis ground. The chassis ground
connection should be clean and free of oil, paint and dirt. The resistance should be less than 10 Ω.
B. The resistance is greater than 10 Ω. There is a problem with the oil pressure switch. Temporarily replace the
oil pressure switch and retest. Return to step 1 to confirm elimination of fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 280
3410-Permanent governor deviation for valve

Context:
The positive limit of throttle valve governor deviation has been exceeded.
Cause:
Desired throttle valve position can not be reached due to sticking throttle valve. Possible throttle valve position sensor
mismatched.
1. Faulty wiring.
2. Throttle valve binding inside assembly.
Solution:
Inspect the ECU and the TVA valve connections. All connections should be secure, tight, free of corrosion, abra-
sion and damage.
Inspect the harness from the ECU to the TVA valve. Verify that the harness is free of damage, corrosion, abrasion
or incorrect attachment.
A. If the fault code is no longer active or present, OK to return the machine to service.
B. If the fault code is present and active, temporarily replace the throttle valve assemble and retest. return to step
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 281

Context:
The negative limit of throttle valve governor deviation has been exceeded.
Cause:
mismatched
1. Faulty wiring.
Solution:
Inspect the ECU and the TVA valve connections. All connections should be secure, tight, free of corrosion, abra-
sion and damage.
A. If the fault is no longer active or present, OK to return the machine to service.
B. If the fault is still present and active, temporarily replace the throttle valve assemble and retest. return to step
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 282
3414-Short circuit in cylinder 1 glow plug

Solution:
A. A glow plug fault code is not recorded again. OK to return the machine to service.
B. A fault code pertaining to the glow plugs is active. Fault code 3414, 3415, 3416 or 3417 is recorded again. Go
to step 2.
Wiring connections Circuit Name Wiring connections GCU

X-012 pin 22 GCU Diagnostics X-013 pin 3
X-012 pin 41 Glow plug ground X-013 pin 5
X-012 pin 52 GCU Control ST X-013 pin 8
X-017 pin 58 Glow Plug Cylinder 3 X-013 pin 1
Battery supply X-013 pin 4
Inspect the ECU, GCU and the glow plug connections. All connections should be secure, tight, free of corrosion,
Inspect the harness from the GCU to the glow plugs. Verify that the harness is free of damage, corrosion, abrasion
3. Measure the resistance through the glow plug wire.
Disconnect GCU connector X-013. Measure the resistance between the glow plug wire on connector X-013 and
chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance
should be approximately 1 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
GCU connector A-011 connector Cylinder

X-013 pin 1 X-017 pin 58 Cyl. 3
X-013 pin 2 X-017 pin 61 Cyl. 1
X-013 pin 6 X-017 pin 57 Cyl. 4
X-013 pin 7 X-017 pin 60 Cyl. 2
A. The resistance is approximately 1 Ω. Temporarily replace the GCU and retest. Return to step 1 to confirm
B. The resistance is less than 0.75 Ω. Go to step 4.
C. The resistance is greater than 20,000 Ω. There is an open circuit in the glow plug wire or the glow plug. Repair
4. Measure the resistance at the glow plug.
47540694 28/04/2014
55.16 [55.DTC] / 283
Disconnect the glow plug connector.
Measure the resistance between the glow plug and chassis ground. The chassis ground connection must be clean
and free of paint, oil and dirt. The resistance should be approximately 1 Ω.
A. The resistance is approximately 1 Ω. There is a problem in the wiring to the glow plug. Repair or replace as
B. The resistance is less than 0.75 Ω. Temporarily replace the glow plug and retest. Return to step 1 to confirm
C. The resistance is greater than 20,000 Ω. There is an open circuit in the glow plug. Temporarily replace the
glow plug and retest. Return to step 1 to confirm elimination of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 284

Solution:
to step 2.


X-013 pin 1 X-017 pin 58 Cyl. 3
X-013 pin 2 X-017 pin 61 Cyl. 1
X-013 pin 6 X-017 pin 57 Cyl. 4
X-013 pin 7 X-017 pin 60 Cyl. 2
47540694 28/04/2014
55.16 [55.DTC] / 285
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 286

Solution:
to step 2.


X-013 pin 1 X-017 pin 58 Cyl. 3
X-013 pin 2 X-017 pin 61 Cyl. 1
X-013 pin 6 X-017 pin 57 Cyl. 4
X-013 pin 7 X-017 pin 60 Cyl. 2
47540694 28/04/2014
55.16 [55.DTC] / 287
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 288

Solution:
to step 2.


X-013 pin 1 X-017 pin 58 Cyl. 3
X-013 pin 2 X-017 pin 61 Cyl. 1
X-013 pin 6 X-017 pin 57 Cyl. 4
X-013 pin 7 X-017 pin 60 Cyl. 2
47540694 28/04/2014
55.16 [55.DTC] / 289
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 290
3418-ECU Power stages: SCB error on the Turbocharger PWM

output power stage
Context:
ECU Power stages: Short to battery error on the Turbocharger PWM output power stage.
Cause:
The ECU detects a short to battery in the turbocharger waste gate signal wire.
1. Faulty wiring
2. Faulty electric valve (WG)
3. Faulty ECU
Solution:
A. Fault code 3418 is not recorded again. OK to return the machine to service.

Inspect the ECU and the Electric Valve (WG). All connections should be secure, tight, free of corrosion, abrasion
and damage.
Inspect the harness from the ECU to the Electric Valve (WG). Verify that the harness is free of damage, corrosion,
3. Measure the voltage at the actuator signal line.
Disconnect the Electric Valve (WG) connector and the ECU connector.
Measure the voltage between ECU connector X-016 pin 4 to chassis ground. The voltage should be less than
B. The voltage is greater than 0.5 V. There is a short circuit to another power source. Repair or replace the
Measure the resistance through the motor windings. The resistance should be greater than 10 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 291
A. The resistance is greater than 10 Ω. Temporarily replace the ECU and retest. Return to step 1 to confirm
B. The resistance is less than 10 Ω. There is an short circuit in the valve windings. Temporarily replace the valve
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 292
3419-ECU Power stages: SCG error on the Turbocharger PWM

output power stage
Context:
ECU Power stages: Short to ground error on the Turbocharger PWM output power stage.
Cause:
The ECU detects a short to ground in the turbocharger waste gate signal wire.
1. Faulty wiring
2. Faulty electric valve (WG)
3. Faulty ECU
Solution:

Inspect the ECU and the Electric Valve (WG). All connections should be secure, tight, free of corrosion, abrasion
and damage.
Inspect the harness from the ECU to the Electric Valve (WG). Verify that the harness is free of damage, corrosion,
3. Measure the resistance at the actuator signal line.
Disconnect the Electric Valve (WG) connector and the ECU connector.
greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
as required. Return to step 1 to confirm elimination of fault.
Measure the resistance between the Electric Valve pin 1 to chassis ground. The resistance should be greater than
20,000 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 293
A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU and retest. Return to step 1 to confirm
B. The resistance is less than 20,000 Ω. There is an short circuit in the valve windings. Temporarily replace the
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 294
3420-CAN Bus Received frames: DFC of Auxiliary Engine Shutdown

Switch Message
Context:
This failure is an informational fault. No intervention necessary. Check failure source for engine shut off. Follow
troubleshooting of this root fault.
47540694 28/04/2014
55.16 [55.DTC] / 295
3425-Turbocharger: Over boost deviation at P2 too high in pressure

charger regulator
Context:
The boost pressure exceeds the maximum limit for a period greater than 5.0 s.
Cause:
The Engine Control Unit (ECU) is detecting inaccurate boost pressure.
1. Faulty wiring.
2. Faulty boost pressure sensor.
3. Faulty EVGT actuator.
4. Faulty ECU.
Solution:
B. If fault code is no longer present, return unit to proper operation.

2. Check for other faults present. Verify no other faults are associated to the boost pressure sensor.
A. If faults are present, correct those errors first. Then determine if this fault has been resolved.
B. If no other faults are present, continue with step 3.

3. Check for other faults present. Verify no other faults that are associated to the EVGT actuator.

4. Check ECU for proper operation. If no other errors are present and all wiring is correct, download the latest version
of the software.
A. If fault code is no longer present, return unit to proper operation.
B. If fault code is still active, replace the ECU.

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 296
3426-Low efficiency in DPF filter

C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Context:
The ECU has detected a high differential pressure (low flow rate) across the particulate filter. Black smoke may be
visible at the exhaust. This is an indication of a cracked, clogged or improperly installed particulate filter. Repair or
replace the particulate filter as required.
47540694 28/04/2014
55.16 [55.DTC] / 297
3427-Diesel particulate filter (DPF): Signal range check flow

resistance of the particulate filter - low
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Context:
The engine control unit (ECU) has detected the DPF filter flow resistance is low. Check that the DPF filter is installed
properly. If the DPF filter is not installed properly, refit the DPF filter correctly. If damaged is determined, replace the
DPF filter. This fault will clear at the end of the next regeneration cycle.
47540694 28/04/2014
55.16 [55.DTC] / 298
3428-Diesel Particulate Filter Pressure sensor: not plausibility error

C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Context:
The ECU has detected a pressure variance that is outside the acceptable pressure range. This is an indication of a
cracked, clogged or improperly installed differential pressure sensor. Verify that the sensor is not damaged. Verify
the air lines leading to the sensor are installed properly and are free of cracks, kinks and holes. Repair or replace the
air lines or sensor as required. Repair or replace the particulate filter as required.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 299
3429-Diesel Particulate filter Pressure sensor: hoseline plausibility

error
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Context:
The ECU has detected a pressure variance that is outside the acceptable pressure range. This is an indication of a
cracked, clogged or improperly installed differential pressure sensor. Verify that the sensor is not damaged. Verify
the air lines leading to the sensor are installed properly and are free of cracks, kinks and wholes. Repair or replace
the air lines or sensor as required. Repair or replace the particulate filter as required.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 300
3430-EGR Inducement less severe derating level

Context:
Legislations require special measures to induce proper functionality of the Exhaust Gas Recirculation (EGR) system.
The EGR system related faults are monitored and trigger different warnings and reactions. The inducements start
with a driver warning, then a torque reduction follows. If the fault is not fixed, a creep mode with a strongly reduced
maximum vehicle speed is activated. A failure which will trigger an inducement is ‘EGR valve blocked’. If at least one
fault belonging to 'EGR valve blocked’ group is set, the timer for inducement level 1 (torque reduction) is increased.
When timer exceeds 0 s and at least one error belonging to the triggered group is active, level 1 for "EGR valve
blocked" group is set.
Cause:
The Engine Control Unit (ECU) has detected a fault with the EGR valve and inducement level 1, due to the EGR valve
being blocked.
1. EGR system failure.
Solution:
1. Check for other fault codes relating the to the EGR valve.
A. If other EGR valve fault codes are present, continue with troubleshooting other active EGR fault codes.
B. If other fault codes are not present, clear fault code and return machine to service.
47540694 28/04/2014
55.16 [55.DTC] / 301
3431-Exhaust Gas Recirculation (EGR) inducement most severe

derating level
Context:
maximum vehicle speed is activated. A failure which will trigger an inducement is ‘EGR valve blocked’. If at least one
fault belonging to 'EGR valve blocked’ group is set, the timer for inducement level 3 (creep mode) is increased. When
timer exceeds 4 h and at least one error belonging to the triggered group is active, level 3 for "EGR valve blocked"
group is set.
Cause:
The Engine Control Unit (ECU) has detected a fault with the EGR valve and inducement level 3, due to the EGR valve
being blocked.
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 302
3432-Exhaust Gas Recirculation (EGR) inducement warning

Context:
maximum vehicle speed is activated. A failure which will trigger an inducement is ‘EGR valve blocked’.
Cause:
The Engine Control Unit (ECU) has detected a fault with the EGR valve being blocked.
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 303
3433-Diesel Particulate Filter (DPF) inducement less severe

derating level
Context:
The EGR system related faults are monitored and trigger different warnings and reactions. The inducement starts with
a driver warning, then a torque reduction follow. If the fault is not fixed, a creep mode with a strongly reduced maximum
vehicle speed is activated. A failure which will trigger an inducement is Diesel Particulate Filter ‘DPF inducement’. If
at least one error belonging to '(DPF) inducement’ group is set and the engine is running, the timer for inducement
level 1 (less severe torque reduction) is increased. When timer exceeds 0 s and at least one error belonging to the
triggered group is active, level 1 for ‘DPF inducement’ group is set.
Cause:
The Engine Control Unit (ECU) has detected a fault with the diesel particulate filter (DPF) and inducement level, due
to ‘DPF inducement’ has been activated.
1. DPF system failure.
Solution:
1. Check for other fault codes relating the to the DPF system.
A. If other DPF fault codes are present, continue with troubleshooting other active EGR fault codes.
47540694 28/04/2014
55.16 [55.DTC] / 304
3434-Diesel Particulate Filter (DPF) inducement most severe

derating level
Context:
vehicle speed is activated. A failure which will trigger an inducement is Diesel Particulate Filter ‘DPF inducement’.
If at least one error belonging to 'DPF inducement’ group is set and the engine is running, the timer for inducement
level 3 (more severe torque reduction) is increased. When timer exceeds 4 h and at least one error belonging to the
triggered group is active, level 3 for "DPF inducement’ group is set.
Cause:
The Engine Control Unit (ECU) has detected a fault with the diesel particulate filter (DPF) and inducement level, due
to ‘DPF inducement’ has been activated.
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 305
3435-Diesel Particulate Filter (DPF) inducement warning

Context:
vehicle speed is activated. A failure which will trigger an inducement is Diesel Particulate Filter ‘DPF inducement’.
Cause:
The Engine Control Unit (ECU) has detected a fault with the diesel particulate filter (DPF).
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 306
3517-Ambient air temperature sensor failure (of humidity sensor) -

signal too high
Context:
The engine control unit (ECU) generated an error from a fault associated with the humidity/temperature sensor. This
error could result from a signal out of range or a signal that is erratic or intermittent. When the ECU determines that
the humidity/temperature sensor value is not valid, it will substitute a value of 39.96 °C (103.93 °F).
Cause:
The humidity/temperature sensor signal to the ECU is shorted to greater than 5.0 V.
1. Faulty electrical wiring or connections.

2. Faulty ECU.
Solution:
2. Verify proper operation of the humidity/temperature sensor. Use electronic service tool (EST) to check the voltage
range. The proper voltage range is 2.0 V to 4.9 V.
A. If the voltage reading is greater than 4.9 V. Continue with step 3.
B. If the voltage reading is within the proper limits, the fault may have been intermittent. Return machine to proper
operation.
3. Disconnect the humidity/temperature sensor from the engine sensor harness. Use electronic service tool (EST)
to check the voltage range.
A. If there is 5.0 V. There is an open or short in the sensor ground circuit. Continue with step 5.
B. If there is greater than 5.0 V. Leave humidity/temperature sensor disconnected and continue with step 4.
4. Disconnect ECU connector. Use electronic service tool (EST) to check the voltage range.
A. If there is 5.0 V. There is a short in the sensor supply circuit. Locate and repair the damaged wires or replace
the harness.
B. If there is greater than 5.0 V. The ECU has failed internally. Replace the ECU.
5. Use a multi-meter to check for voltage between humidity/temperature sensor connector, pin 4, to ground. There
should be no voltage.
A. If there is no voltage, continue with step6.
B. If there is voltage, the short is in this wire.Locate and repair shorted wire.
6. Use a multi-meter to check for voltage between humidity/temperature sensor connector, pin 1, to ground. There
should be no voltage.
A. If there is no voltage, the sensor has failed. Replace the sensor.
B. If there is voltage, the short is in this wire.Locate and repair shorted wire.
47540694 28/04/2014
55.16 [55.DTC] / 307
3518-Ambient air temperature sensor failure (of humidity sensor) -

signal too low
Context:
The engine control unit (ECU) generated an error from a fault associated with the Humidity/temperature sensor. This
error could result from a signal out of range or a signal that is erratic or intermittent. When the ECU determines that
the Humidity/temperature sensor value is not valid, it will substitute a value of 39.96 °C (103.93 °F).
Cause:
The Humidity/temperature sensor signal to the ECU is shorted to ground.
1. Faulty electrical wiring or connections.

2. Faulty ECU.
Solution:
2. Verify proper operation of the Humidity/temperature sensor. Use electronic service tool (EST) to check the voltage
range. The proper voltage range is 2.0 V to 4.9 V.
A. If the voltage reading is low , less than 2.0 V. Continue with step 3.
B. If the voltage reading is within the proper limits, fault may have been intermittent. Return machine to proper
operation.
3. Disconnect the Humidity/temperature sensor from the engine sensor harness. Use a multi-meter to check between
Humidity/temperature sensor connector, pin 1, and ground. There should not be continuity to ground.
A. If there is continuity. There is a short to ground in the sensor supply circuit. Continue with step 4.
B. If there is not continuity. Leave humidity/temperature sensor disconnected and continue with step 5.
4. Disconnect connector 1 at the ECU. Use multi-meter to check the harness side of pin 68 to ground. There should
not be continuity to ground.
A. If there is continuity. There is a short between connector 1, pin 68 and pin 1 of the Humidity/temperature sensor
connector. Locate and repair the damaged wires or replace the harness.
B. If there is no continuity. The ECU has failed internally. Replace the ECU.
5. Disconnect the ECU connector. Use a multi-meter to check for continuity between connector 1, pin 26, to ground.
A. If there is continuity, the short is in this wire.Locate and repair shorted wire.
B. If there is no continuity, reconnect Humidity/temperature sensor connector and continue with step 6.
6. Use a multi-meter to check for continuity between the harness side of connector 1, pin 26, to ground.
A. If there is continuity, the sensor has failed. Replace the sensor.
B. If there is no continuity, the ECU has failed internally. Replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 308
3616-Torque limitation due to turbo charger protection high altitude

operation related
Context:
The Engine Control Unit (ECU) has detected an active power reduction due to turbo charger protection. This error is
for informational purposes and is initiated by a power reduction due to turbo charger protection being active causing
a torque limitation greater than 25 % of the desired torque for longer than 60 seconds and is reset once the torque
limitation due to turbo charger protection is less than 25 % of the desired torque over 10 seconds. Though no action
is necessary due to this error, if the power reduction occurred due to an actual defect, the error triggering the torque
limitation should also be in fault memory. Follow the troubleshooting procedure for that error.
47540694 28/04/2014
55.16 [55.DTC] / 309
3648-EVGT Boost pressure monitoring for over boost

Context:
The positive limit of EGR valve governor deviation has been exceeded.
Cause:
Desired EGR valve position can not be reached due to sticking EGR valve. Possible EGR valve position sensor
mismatched
1. Faulty wiring
2. Throttle valve binding inside assembly
Solution:
(2) To check for fault codes: Start and operate machine.
B. Fault code 3648 is active and recorded again. Go to Step 2.

(1) Inspect the ECU and the TVA valve connections. All connections should be secure, tight, free of corrosion,
(2) Inspect the harness from the ECU to the TVA valve. Verify that the harness is free of damage, corrosion,
A. OK – The connectors are secure and the harness is free of damage. Go to Step 3.
B. NOT OK – The connectors or the harness has damage. Repair or replace the harness or connectors as re-
quired. Return to Step 1 to confirm elimination of fault.
B. If the fault is still present and active, temporarily replace the throttle valve assemble and retest. return to Step
47540694 28/04/2014
55.16 [55.DTC] / 310
3650-Battery voltage: SRC high for battery voltage sensor

Context:
The Engine Control Unit (ECU) monitors the battery voltage.
Cause:
The battery supply to the ECU is above the threshold.
1. Faulty wiring.
3. Faulty ECU.
Solution:
Inspect the wiring harness from the battery to the alternator.

ground.
A. If the voltage reading is correct, connect the wiring harness to the ECU. Continue with Step 4.
NOTE: Use a multimeter or diagnostic screen to check the battery voltage.
4. Check the alternator output.
Start the engine.
47540694 28/04/2014
55.16 [55.DTC] / 311
Increase the engine RPM and monitor the battery voltage.
B. If the voltage reading is greater than 18.0 V, the alternator and/or regulator has failed. Replace the alternator.
47540694 28/04/2014
55.16 [55.DTC] / 312
3651-Battery voltage: SRC low for battery voltage sensor

NOTE: This fault can occur due to a cold start with low battery voltage, engine speed less than 300 RPM and coolant
temperature less than 0 °C (32 °F).
Context:
The Engine Control Unit (ECU) monitors the battery voltage.
Cause:
The battery supply to the ECU is below the threshold.
1. Faulty wiring.
2. Faulty battery.
4. Faulty ECU.
Solution:

ground.
B. If the voltage reading is less than 10.0 V, check the wiring harness between the ECU connector to the battery
for a short to low source.
47540694 28/04/2014
55.16 [55.DTC] / 313
Start the engine.
B. If the voltage reading is less than 10.0 V, continue with Step 5.

A. If the voltage reading is correct, the alternator and/or regulator has failed. Check the alternator belt for damage.
If no damage is found, replace the alternator.
B. If the voltage reading is less than 10.0 V, recharge the battery. If the battery can not hold a charge, replace
the battery.
47540694 28/04/2014
55.16 [55.DTC] / 314
3652-CAN Bus: Bus off of CAN node A

Context:
Cause:

Solution:

pin C to pin D.
A. If the CAN bus readings are incorrect, continue with Step 5.
B. If the CAN bus readings are correct, continue with Step 7.
47540694 28/04/2014
55.16 [55.DTC] / 315
pin 25.
A. If the CAN bus readings are incorrect, check the CAN bus wiring and terminating resistor between the ECU to
the vehicle controllers.
B. If the CAN bus readings are correct, continue with Step 6.

A. If the readings are incorrect, the resistor has failed. Replace the ECU.
B. If the readings are correct, continue with Step 7.

47540694 28/04/2014
55.16 [55.DTC] / 316
3655-Torque limitation, Engine protection: General report of the

event of torque limitations
Context:
This is an information fault code only. The fault code is logged and indicates that engine torque has been limited.
Troubleshoot the fault codes that cause the reduction in power.
47540694 28/04/2014
55.16 [55.DTC] / 317
3656-Torque limitation, Engine protection: Torque limitation caused

by particulate filter
Context:
This is an information fault code only. The fault code is logged and indicates that engine torque has been limited due
to a restriction in the particulate filter. Troubleshoot the fault codes that cause the reduction in power.
47540694 28/04/2014
55.16 [55.DTC] / 318
3657-Timeout Error of CAN-Receive-Frame CM1BC

Context:
The ECU is not receiving messages on the CAN bus.
Cause:
The ECU is not receiving messages on the CAN bus.
1. Open circuit or short circuit in CAN bus system.

2. Failure of instrument cluster.
3. Failure of ECM.
Solution:

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 319
3659-Battery voltage: Power stage diagnosis could be disabled

due to high battery voltage
NOTICE: Check alternator output voltage, if above 18 V troubleshoot the charging system before proceeding.
Solution:
1. Verify that the fault code present on EST.
Access the Electronic Service Tool fault code screen and monitor the fault codes.
Verify that there are no fault codes pertaining to high battery voltage to the ECU or high fluid temperatures.
A. Fault code 3659 is active with other fault codes such as FC3051 or FC3518 or FC3007 and FC1002. Trou-
bleshoot these fault codes before troubleshooting FC3668.
B. Fault code 3659 is not recorded again. OK to return the machine to service.
C. Fault code 3659 is active and recorded again. Go to step 2.

2. Measure the ECU unswitched input voltage
Turn ignition switch OFF.
Disconnect Engine Control Unit (ECU) connector X-012 from engine controller.
Measure the voltage from pins 1, 3, 5, and 28 on ECU connector X-012 to ground (ECU connector X-012 pins 2,
4, and 6). The voltage should be approximately 14.5 V.
A. The voltage is correct. Temporarily replace the ECU and retest. Return to step 1 to confirm elimination of the
fault.
B. The voltage is greater than 15 V. Temporarily replace the alternator and retest. Return to step 1 to confirm
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 320
3660-Battery voltage: Power stage diagnosis could be disabled

due to low Battery voltage
NOTICE: Check alternator output voltage, if below 10 V troubleshoot the charging system before proceeding.
Solution:
1. Verify that the fault code is present on EST.
Use the Electronic Service Tool to verify that the fault code is ACTIVE.

2. Measure the ECU unswitched input voltage
Turn ignition switch OFF.
Disconnect Engine Control Unit (ECU) connector X-012 from engine controller.
Measure the voltage from pins 1, 3, 5, and 28 on ECU connector X-012 to ground (ECU connector X-012 pins 2,
4, and 6). The voltage should be approximately 14.5 V.
A. The voltage is correct. Temporarily replace the ECU and retest. Return to step 1 to confirm elimination of the
fault.
B. The voltage is less than 10 V. Temporarily replace the alternator and retest. Return to step 1 to confirm elimi-
nation of fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 321
3663-EGR command saturation over higher threshold

Context:
Cause:
mismatched.
1. Faulty wiring.
2. EGR valve binding inside assembly.
Solution:
Inspect the ECU and the EGR valve connections. All connections should be secure, tight, free of corrosion, abra-
sion and damage.
Inspect the harness from the ECU to the EGR valve. Verify that the harness is free of damage, corrosion, abrasion
B. If the fault code is still present and active, temporarily replace the EGR valve assemble and retest. Return to
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 322
3664-EGR command saturation over lower threshold

Context:
The negative limit of EGR valve governor deviation has been exceeded.
Cause:
mismatched.
1. Faulty wiring.
Solution:
sion and damage.
B. If the fault code is still present and active, temporarily replace the EGR valve assemble and retest. Return to
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 323

Context:
Cause:
mismatched.
1. Faulty wiring.
Solution:
sion and damage.
B. If the fault is still present and active, temporarily replace the EGR valve assemble and retest. Return to step 1
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 324

Context:
The negative limit of EGR valve governor deviation has been exceeded.
Cause:
mismatched.
1. Faulty wiring.
Solution:
sion and damage.
B. If the fault is still present and active, temporarily replace the EGR valve assemble and retest. Return to step 1
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 325
3667-Open load error for power stage

Context:
ECU Power stages : Open load error on the EGR valve power stage.
Cause:
The ECU detects an open circuit in the EGR valve drive circuit. Electrical problem in the EGR valve actuator.
1. Faulty wiring.
2. Faulty EGR valve.
3. Faulty ECU.
Solution:

Inspect the ECU and the EGR valve. All connections should be secure, tight, free of corrosion, abrasion and
damage.
3. Measure the resistance through the wiring harness
Disconnect the EGR Valve connector. Disconnect the ECU connector.
Measure the resistance between ECU connector X-016 pin 50 and EGR valve motor plus pin. The resistance
Measure the resistance between ECU connector X-016 pin 35 and EGR valve motor minus pin. The resistance
Measure the resistance between ECU connector X-016 pin 9 and EGR position sensor supply pin. The resistance
Measure the resistance between ECU connector X-016 pin 39 and EGR position sensor signal pin. The resistance
Measure the resistance between ECU connector X-016 pin 24 and EGR position sensor ground pin. The resis-
tance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
47540694 28/04/2014
55.16 [55.DTC] / 326
B. The resistance is greater than 10 Ω. There is an open circuit in the wire. Repair or replace the wire as required.
4. Measure the resistance through the valve
Disconnect the EGR valve connector.
Measure the resistance through the motor windings. The resistance should be less than 100 Ω.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 327
3668-Over temperature error for H-bridge

Context:
ECU Power stages: Over temperature error on the turbocharger PWM output power stage.
Cause:
1. Faulty wiring.
3. Faulty ECU.
Solution:
1. Verify that the fault code present on EST.
Access the Electronic Service Tool fault code screen and monitor the fault codes.
Verify that there are no fault codes pertaining to high battery voltage to the ECU or high fluid temperatures.
A. Fault code 3668 is active with other fault codes such as FC3051 or FC3518 or FC3007 and FC1002. Trou-
bleshoot these fault codes before troubleshooting this code.

damage.
3. Measure the resistance through the wiring harness.
Disconnect the EGR Valve connector. Disconnect the ECU connector.
Measure the resistance between ECU connector X-016 pin 50 and EGR valve motor plus pin. The resistance
4. Measure the resistance through the wiring harness to chassis ground.
Disconnect the EGR valve connector. Disconnect the ECU connector.
47540694 28/04/2014
55.16 [55.DTC] / 328
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the wire as
Disconnect the electric valve connector.
Measure the resistance through the electric valve pin 1 to chassis ground. The resistance should be greater than
20,000 Ω.
electric valve and retest. Return to step 1 to confirm elimination of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 329
3669-Short circuit to battery on Out1 error for H-bridge

Context:
Short circuit to battery on Out1 error for H-bridge. The ECU had detected a short circuit to an external power source.
Cause:
The EGR valve drive circuit is shorted to positive battery.
1. Wiring shorted to positive battery source.

2. Faulty ECU.
Solution:

damage.
3. Measure the voltage through the wiring harness
Measure the voltage from ECU connector X-016 pin 50 to chassis ground. The voltage should be less than 0.5 V.
A. The voltage is less than 0.5 V. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination
of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 330

Context:
Cause:
The EGR valve drive circuit is shorted to positive battery.

2. Faulty ECU
Solution:

damage.
Turn the key switch OFF.
Turn the key switch ON.
A. The voltage is less than 0.5 V. Temporarily replace the ECU and retest. Return to step 1 to confirm elimination
of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 331
3671-Short circuit to ground on Out1 error for H-bridge

Context:
The ECU had detected a short circuit to minus battery or chassis ground on Out1 error for H-bridge.
Cause:
The EGR valve drive circuit or wiring is shorted to minus battery or chassis ground.
1. Wiring shorted to minus battery or chassis ground.

2. Faulty ECU.
Solution:

damage.
3. Measure the resistance of the harness to chassis ground.
greater than 20,000 Ω . Wiggle the harness during measurement to reveal an intermittent condition.
or replace the harness as required. Return to Step 1 to confirm elimination of the fault.
4. Measure the resistance of the valve to chassis ground.
Measure the resistance between the EGR valve, motor plus pin and chassis ground. The resistance should be
47540694 28/04/2014
55.16 [55.DTC] / 332
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the solenoid valve. Tem-
porarily replace the valve and retest. Return to Step 1 to confirm elimination of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 333

Context:
Cause:
The EGR valve drive circuit or wiring is shorted to minus battery or chassis ground.

2. Faulty ECU.
Solution:

damage.
or replace the harness as required. Return to step 1 to confirm elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 334
porarily replace the valve and retest. Return to step 1 to confirm elimination of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 335
3673-Short circuit over load error for H-bridge

Context:
The ECU had detected a short circuit in the ERG valve drive circuit.
Cause:
The ECU had detected a short circuit in the ERG valve drive circuit.
1. Wiring shorted.
2. Faulty ECU.
Solution:

damage.
Measure the resistance between ECU connector X-016 pin 50 and ECU connector X-016 pin 35. The resistance
B. The resistance is less than 20,000 Ω. There is a short circuit in the wiring harness. Repair or replace the
47540694 28/04/2014
55.16 [55.DTC] / 336
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 337
3674-Under voltage error for H-bridge

Context:
Under voltage error for H-bridge.
Cause:
The ECU had detected a high fluctuations in the system voltage.
1. Bad battery or battery connections.

2. Faulty alternator or charging circuit.
3. Faulty ECU.
Solution:

2. Inspect the battery cable connections.
Verify that the battery terminals and battery cables are free of corrosion, abrasion and incorrect attachment.
Verify that the battery chassis ground connection is clean and fastened securely to the frame. The chassis con-
nection point should be free of paint, rust, dirt and debris.
A. The cables and battery connections are secure and free of corrosion, abrasion and incorrect attachment. Go
to step 3.
B. The battery connections or battery cables are in need of repair. Repair as required. Return to step 1 to confirm
Inspect the ECU. All connections should be secure, tight, free of corrosion, abrasion and damage.
A. The connectors are secure and the harness is free of damage. Temporarily replace the ECU and retest. Return
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 338
3675-DFC for long time valve drift at closed position

Context:
The Exhaust Gas Regeneration (EGR) Valve actuator is monitored for long time drift by comparing first and last learned
voltage compensation. Check the EGR valve is not blocked or clogged. Remove the EGR valve and inspect for any
carbon build up. If there is carbon build up, clean the EGR valve. Once the EGR valve has been cleaned, reinstall
EGR valve and clear any codes. Restart the machine and operate. If the fault code reoccurs, replace the EGR valve.
47540694 28/04/2014
55.16 [55.DTC] / 339
3676-DFC for valve position sensor voltage SRC high

Context:
DFC for valve position sensor voltage SRC high.
Cause:
The ECU had detected an open circuit in the EGR position sensor.
1. Faulty wiring.
3. Faulty ECU.
Solution:

damage.
Disconnect the ECU connector, X-016 and the EGR valve connector.
Fabricate a jumper wire 20 cm (8 in).
Use the jumper wire to connect ECU connector X-016 pin 9 to X-016 pin 39.
Measure the resistance between ERG valve sensor supply and EGR valve sensor signal. The resistance should
Use the jumper wire to connect ECU connector X-016 pin 24 to X-016 pin 39.
Measure the resistance between ERG valve sensor ground and EGR valve sensor signal. The resistance should
B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as
47540694 28/04/2014
55.16 [55.DTC] / 340
4. Measure for stray voltage to chassis ground.
Disconnect the ECU connector, X-016. Disconnect the EGR valve connector.
A. The voltage is less than 0.5 V. Go to Step 4.
B. The voltage is greater than 0.5 V. There is a short circuit in the wiring to another voltage source. Repair or
replace the harness as required. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance through the position sensor
Disconnect the EGR valve.
Measure the resistance between the EGR position sensor supply pin and the EGR position sensor signal pin.
The resistance should be less than 10,000 Ω. If possible, move the valve while monitoring the resistance. The
resistance should change at an even rate.
Measure the resistance between the EGR position sensor supply ground and the EGR position sensor signal pin.
The resistance should be less than 10,000 Ω. If possible, move the valve while monitoring the resistance. The
resistance should change at an even rate.
A. The resistance is less than 10,000 Ω and the resistance changes at an even rate when the valve is moved.
Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault.
B. The resistance is greater than 10,000 Ω or the resistance did not change at a smooth rate. There is an open
circuit in the valve position sensor. Temporarily replace the EGR valve and retest. Return to Step 1 to confirm
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 341
3677-DFC for valve position sensor voltage SRC low

Context:
The ECU had detected a short circuit to ground in the EGR position sensor.
Cause:
The ECU had detected a short circuit to ground in the EGR position sensor.
1. Faulty wiring.
3. Faulty ECU.
Solution:

damage.
Disconnect the ECU connector, X-016 and the EGR valve connector.
B. The resistance is less than 20,000 Ω. There is an short circuit to chassis ground in the wiring. Repair or replace
4. Measure resistance of the position sensor to chassis ground.
47540694 28/04/2014
55.16 [55.DTC] / 342
Measure the resistance between the EGR position sensor supply pin and chassis ground. The resistance should
be greater than 20,000 Ω.
Measure the resistance between the EGR position sensor signal pin and chassis ground. The resistance should
Measure the resistance between the EGR position sensor ground pin and chassis ground. The resistance should
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the position sensor. Tem-
porarily replace the EGR valve and retest. Return to step 1 to confirm elimination of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 343
3680-Injection cut off: Injection cut off demand (ICO) for shut off
coordinator
Context:
This fault is triggered when the Engine Control Unit (ECU) has an internal failure that concerns the reliability of the
accelerator pedal signal, fuel injection parameters or engine speed failures are detected. Another fault will be active
when this fault occurs. Refer to other fault present. Correct that fault, and erase fault codes.
47540694 28/04/2014
55.16 [55.DTC] / 344
3688-Water sensor in the fuel filter: WIF sensor check is failed

Context:
The Engine Control Unit (ECU) has senses when the fuel filter water tank is full. The fuel filter separates any water
from the fuel, and collects it in a special tank.
Cause:
The water in fuel sensor check has failed.

2. Faulty sensor.
Solution:
1. Check the fault is still present and in an active state.
B. If fault is no longer present or inactive, check for intermittent fault.

Inspect the wiring harness from the ECU to the water in fuel sensor.
A. If the connectors are secure and the wiring harness is free of damage, the sensor has failed. Replace the
sensor.

47540694 28/04/2014
55.16 [55.DTC] / 345
3689-Faulty diagnostic data transmission or protocol error

Context:
The ECU has detected a faulty diagnostic data transmission or protocol error from the glow plug control unit.
Cause:
The ECU has detected a faulty diagnostic data transmission or protocol error from the glow plug control unit.
1. Battery voltage to the GCU.

2. Wiring problem in the glow plug system.
3. Faulty GCU.
4. Faulty ECU.
Solution:

Inspect the ECU, GCU and glow plug connections. All connections should be secure, tight, free of corrosion,
3. Measure the voltage to the GCU.
Disconnect the GCU connector X-013.
Measure the voltage from X-013 pin 4 to chassis ground. The voltage should be approximately 12 V. Wiggle the
A. The voltage is between 11 - 14.8 V. Go to step 3.
B. The voltage is less than 11 V. There is a problem in the battery supply to the GCU. Check fuses. Verify battery
connections from the starter motor. Repair as required. Return to step 1 to confirm elimination of the fault.
4. Measure the resistance of the glow plug ground wire and signal wires.
Disconnect the glow plug connector, X-013. Disconnect ECU connector X-012.
47540694 28/04/2014
55.16 [55.DTC] / 346
Measure the resistance between the X-013 pin 5 and ECU connector X-012 pin 41. The resistance should be less
than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Pay particular attention
to the splice area, SP-203.
A. The resistance is less than 10 Ω. Temporarily replace the GCU and retest. Return to step 1 to confirm elimi-
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 347
3691-No load error for low voltage system

Solution:

Disconnect GCU connector X-013. Measure the resistance between the glow plug wire on connector X-013 to
B. The resistance is greater than 1.5 Ω. Go to step 4.


X-013 pin 1 X-017 pin 58 Cyl. 3
X-013 pin 2 X-017 pin 61 Cyl. 1
X-013 pin 6 X-017 pin 57 Cyl. 4
X-013 pin 7 X-017 pin 60 Cyl. 2
A. The resistance is approximately 1 Ω. There is an open circuit in the wiring to the glow plug. Repair or replace
B. The resistance is greater than 1.5 Ω. Temporarily replace the glow plug and retest. Return to step 1 to confirm
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 348
3692-Over temperature error on ECU power stage for glow plug

low voltage system
Context:
The GCU detects an over temperature error.
Cause:
Over temperature error on GCU power stage for glow plug low voltage system. Pre-glow and post-glow functions
may be disabled while this code is active. There may be starting issues such as black smoke and hard starts while
this code is active and the engine is cold.
1. High system voltage.

2. High engine temperatures.
3. Faulty wiring.
4. Faulty GCU.
5. Faulty ECU.
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 349
Measure the resistance between X-013 pin 5 and ECU connector X-012 pin 41. The resistance should be less
than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Pay particular attention
to the splices.
A. The resistance is less than 10 Ω Go to step 5.
B. The resistance is less than 0.5 Ω There is a short circuit in the wiring or glow plug. Go to step 6.
Disconnect the glow plug connector at the glow plug.

X-013 pin 1 X-017 pin 58 Cyl. 3
X-013 pin 2 X-017 pin 61 Cyl. 1
X-013 pin 6 X-017 pin 57 Cyl. 4
X-013 pin 7 X-017 pin 60 Cyl. 2
A. The resistance is approximately 1 Ω. There is a short circuit in the wiring to the glow plug. Repair or replace
B. The resistance is less than 0.5 Ω There is a short circuit in the glow plug. Temporarily replace the glow plug
and retest. Return to step 1 to confirm elimination of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 350
3693-Short circuit to battery error for low voltage system

Solution:

B. The resistance is greater than 1.5 Ω. Go to step 4.


X-013 pin 1 X-017 pin 58 Cyl. 3
X-013 pin 2 X-017 pin 61 Cyl. 1
X-013 pin 6 X-017 pin 57 Cyl. 4
X-013 pin 7 X-017 pin 60 Cyl. 2
A. The resistance is approximately 1 Ω. There is an open circuit in the wiring to the glow plug. Repair or replace
B. The resistance is greater than 1.5 Ω. Temporarily replace the glow plug and retest. Return to step 1 to confirm
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 351
3694-Short circuit to ground error for low voltage system

Context:
The GCU detects an over temperature error.
Cause:
Over temperature error on GCU power stage for glow plug low voltage system. Pre-glow and post-glow functions
may be disabled while this code is active. There may be starting issues such as black smoke and hard starts while
this code is active and the engine is cold.

3. Faulty wiring.
4. Faulty GCU.
5. Faulty ECU.
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 352
B. The resistance is less than 0.5 Ω There is a short circuit in the wiring or glow plug. Go to step 6.
Disconnect the glow plug connector at the glow plug.

X-013 pin 1 X-017 pin 58 Cyl. 3
X-013 pin 2 X-017 pin 61 Cyl. 1
X-013 pin 6 X-017 pin 57 Cyl. 4
X-013 pin 7 X-017 pin 60 Cyl. 2
A. The resistance is approximately 1 Ω. There is a short circuit in the wiring to the glow plug. Repair or replace
B. The resistance is less than 0.5 Ω There is a short circuit in the glow plug. Temporarily replace the glow plug
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 353
3695-Failure in glow plug cylinder 1

Solution:
to step 2.


X-013 pin 1 X-017 pin 58 Cyl. 3
X-013 pin 2 X-017 pin 61 Cyl. 1
X-013 pin 6 X-017 pin 57 Cyl. 4
X-013 pin 7 X-017 pin 60 Cyl. 2
47540694 28/04/2014
55.16 [55.DTC] / 354
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 355

Solution:
to step 2.


X-013 pin 1 X-017 pin 58 Cyl. 3
X-013 pin 2 X-017 pin 61 Cyl. 1
X-013 pin 6 X-017 pin 57 Cyl. 4
X-013 pin 7 X-017 pin 60 Cyl. 2
47540694 28/04/2014
55.16 [55.DTC] / 356
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 357

Solution:
to step 2.


X-013 pin 1 X-017 pin 58 Cyl. 3
X-013 pin 2 X-017 pin 61 Cyl. 1
X-013 pin 6 X-017 pin 57 Cyl. 4
X-013 pin 7 X-017 pin 60 Cyl. 2
47540694 28/04/2014
55.16 [55.DTC] / 358
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 359

Solution:
to step 2.


X-013 pin 1 X-017 pin 58 Cyl. 3
X-013 pin 2 X-017 pin 61 Cyl. 1
X-013 pin 6 X-017 pin 57 Cyl. 4
X-013 pin 7 X-017 pin 60 Cyl. 2
47540694 28/04/2014
55.16 [55.DTC] / 360
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 361
3699-EEPROM: Error in EEPROM block EEPData1, SD correction

can not be calculated
Context:
The engine control unit (ECU) has detected an error during the last EEPROM write operation. The hardware encap-
or not found. This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Try to
flash the ECU correctly with the proper data set. If the error persists, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 362
3702-Injection control: Detection of failed engine start

Context:
The engine did not start due a problem with engine speed or rail pressure. Troubleshoot the reasons why the engine
could not maintain a stating speed or insufficient fuel rail pressure.
47540694 28/04/2014
55.16 [55.DTC] / 363
3703-Injection control: check of minimum rail pressure

Context:
This fault has been generated due to the injector control pressure is too low. Check for more specific failures related
to the rail pressure system. If no other faults are active, check the rail injectors are not damaged. Also, check for any
rail or injector leakages. If any damages or leakages are found, repair or replace necessary components.
47540694 28/04/2014
55.16 [55.DTC] / 364
3704-Injector adjustment programming: Check of missing injector

adjustment value programming
Context:
This fault has been generated due to the injector programming being incorrect. This failure can be the result of wrong
programming / flashing of the ECU or an internal defect. Using the Electronic Service Tool (EST), Easy-Engine soft-
ware, check the injector code matches the injector code used for that cylinder. Reprogram the engine control unit
(ECU) to the proper injector code. Try to flash the ECU correctly with the proper data set. If the error persists, replace
the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 365
3705-Injector adjustment programming: check of missing injector

Context:
the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 366
3706-Injector adjustment programming: check of missing injector

Context:
the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 367
3707-Lambda sensor: Open circuit at the lambda sensor Nernst

cell pin
NOTE: When testing the oxygen sensor a high impedance digital volt meter must be used. A normal analogue multi-
meter will draw too much current and will burn out the sensor or give false readings.
NOTE: When replacing the oxygen sensor, re-flash the control module to allow for the new sensor adjustments to be
learned.
Context:
The engine control unit has detected an intermittent signal on the oxygen sensors voltage line at connector X-012 pin
63. This sensor is the primary measurement device for the fuel control to the ECU to know if the engine is too rich or
too lean.
Cause:
The oxygen sensor signal is not plausible.

2. Faulty oxygen sensor.
3. Faulty control unit or software.
Solution:

2. Place the key switch OFF. Disconnect the engine harness from the oxygen sensor at connector X-014. Inspect all
A. If any damage is found, repair or replace connections, pins, or wiring.
3. Test the oxygen sensor for proper operation. Run the machine for approximately 10.0 min to allow the sensor to
warm up. Place the machine off. Use a back probe pin to connect the positive multi-meter lead to connector X-014
pin 3 on the oxygen sensor. Place the negative lead to chassis ground. Have someone start the machine. Rev
the engine and monitor the voltage. The voltage range should vary between 0.1 - 0.9 V.
A. If the voltage is not in range the sensor has failed. Replace the sensor.
B. If the sensor is in range, continue with step 4.

4. Check for a grounded circuit. Place the key switch in the OFF position. Disconnect the engine harness from the
oxygen sensor at connector X-014 and at ECU connector X-012. Use a multi-meter to check for continuity from
the engine harness side of connector X-012 pin 63 to chassis ground. There should be no continuity.
A. If there is continuity, the damaged wiring is in the engine harness between connector X-014 pin 6 and connector
X-012 pin 63. Locate and repair the damaged wiring harness.
B. If there is no continuity, leave both connectors disconnected. Continue with step 5.

5. Check for a open circuit. Leave the key switch in the OFF position. Use a multi-meter to check for continuity from
the engine harness side of connector X-014 from pin 6 to connector X-012 pin 63. There should be continuity.
A. If there is no continuity, the damaged wiring is in the engine harness between connector X-014 pin 6 and
connector X-012 pin 63. Locate and repair the damaged wiring harness.
B. If there is continuity, re-flash ECU software. Check to verify the fault has cleared. If the fault has not cleared.
Replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 368
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 369
3708-Lambda sensor: Open circuit at the lambda sensor pump

current pin
NOTE: Two people may be required to perform this test correctly.
learned.
Context:
The engine control unit has detected an intermittent signal on the oxygen current pump line at connector X-012 pin
too lean.
Cause:

Solution:

2. Place the ignition switch in the OFF position. Disconnect the engine harness from the oxygen sensor at connector
X-014. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks.


47540694 28/04/2014
55.16 [55.DTC] / 370
Replace the ECU.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 371
3709-Lambda sensor: Open circuit at the lambda sensor virtual

ground pin
learned.
Context:
The engine control unit has detected an intermittent signal on the oxygen sensors ground line at connector X-012 pin
too lean.
Cause:

Solution:



47540694 28/04/2014
55.16 [55.DTC] / 372
Replace the ECU.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 373
3710-Lambda sensor: Fault to indicate dynamics of the sensor

signal too small
NOTE: When testing the lambda sensor a high impedance digital volt meter must be used. A normal analogue multi-
NOTE: When replacing the lambda sensor, re-flash the control module to allow for the new sensor adjustments to be
learned.
Context:
The engine control unit (ECU) has detected the measured oxygen concentration is incorrect. This sensor is the pri-
mary measurement device for the fuel control to the ECU to know if the engine is too rich or too lean.
Cause:

Solution:


4. Check the wiring harness for any short or open circuits. Disconnect the engine harness from the oxygen sensor
at connector X-014 and the ECU at connector X-012. Using a multi-meter to test the wiring harness, refer to the
table below for test results.
Test Type From To Result

Continuity X-014 pin 3 X-012 pin 7 Continuity
Short Circuit X-014 pin 4 X-014 pin 3 No continuity
X-014 pin 1
X-014 pin 5
X-014 pin 2
X-014 pin 6
47540694 28/04/2014
55.16 [55.DTC] / 374
A. If any of the above tests fail. Locate and repair damaged wiring harness.
B. If the all the above test are correct, continue with step 5.
5. Check the injection system for any leaks or damages.
A. If the injectors or system has any leakages, repair or replace damage component.
B. If the injection system is in good condition, continue with step 6.

6. Check the EGR valve. Remove the EGR valve, and check if the valve is stuck open.
A. If the EGR valve is stuck open, clean or replace the EGR valve.
B. If the EGR valve is in good condition, place the EGR valve back onto the machine. Re-flash the ECU software.
Check to verify the fault has cleared. If the fault has not cleared. Replace the ECU.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 375
3711-SCB error of the LSU Heater Power stage

learned.
Context:
The heater power stage of oxygen sensor is monitored for a short circuit to battery, as long as the heater is working.
Cause:
The oxygen sensor circuit is shorted to a high voltage source.

Solution:

2. Place the ignition switch OFF. Disconnect the engine harness from the oxygen sensor at connector X-014. Inspect
all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks.

4. Check wiring for shorted to power source. Place the ignition switch in the OFF position. Disconnect the engine
harness from the oxygen sensor at connector X-014 and at ECU connector X-012. Place the ignition switch ON.
Use a multi-meter to check for voltage from the engine harness side of connector X-014 pin 3 to chassis ground.
A. If there is voltage, the damaged wiring is in the engine harness between connector X-014 pin 3 and connector
B. If there is no voltage, leave both connectors disconnected. Continue with step 5.

5. Check to see if the wiring is shorted to the relay circuit. Place the ignition switch in the OFF position. Use a
multi-meter to measure the resistance from the engine harness side of connector X-014 from pin 3 to pin 4. The
resistance should be greater than 10.0 Ω.
A. If the resistance is below 10.0 Ω, the damaged wiring is in the engine harness between connector X-014 pin 3
and connector pin 4. Locate and repair the damaged wiring harness.
B. If the resistance is greater than 10.0 Ω, continue with step 6.
47540694 28/04/2014
55.16 [55.DTC] / 376
6. Check to see if the wiring is open. Place the ignition switch in the OFF position. Use a multi-meter to measure the
resistance from the engine harness side of connector X-014 from pin 3 to connector X-012 pin 7. The resistance
should be less than 10.0 Ω.
A. If the resistance is greater than 10.0 Ω, the damaged wiring is in the engine harness between connector X-014
pin 3 and connector X-012 pin 7. Locate and repair the damaged wiring harness.
B. If the resistance is less than 10.0 Ω, continue with step 7.

7. Check software version is at the most current status. If the software version is not up to date, re-flash software
and recheck fault is present.
A. If the fault code is still active and present, replace the ECU.
B. If the fault code has cleared, return machine to proper service.

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 377
3712-Lambda sensor: SCG error of the LSU heater power stage

learned.
Context:
The heater power stage of the oxygen sensor is monitored against short circuit to ground, as long as the heater is
working.
Cause:
The oxygen sensor circuit is shorted to a ground source.

Solution:


4. Check wiring for shorted to ground source. Place the key switch in the OFF position. Disconnect the engine
harness from the oxygen sensor at connector X-014 and at ECU connector X-012. Place the key switch ON. Use
a multi-meter to measure the resistance from the engine harness side of connector X-014 pin 3 to chassis ground.
There should be approximately 1000 Ω.
A. If there is less than 1000 Ω, the damaged wiring is in the engine harness between connector X-014 pin 3 and
B. If there is approximately 1000 Ω, leave both connectors disconnected. Continue with step 5.
5. Check to see if the wiring is open. Place the key switch in the OFF position. Use a multi-meter to measure the
resistance from the engine harness side of connector X-014 from pin 3 to connector X-012 pin 7. The resistance
should be less than 10.0 Ω.
A. If the resistance is greater than 10.0 Ω, the damaged wiring is in the engine harness between connector X-014
pin 3 and connector X-012 pin 7. Locate and repair the damaged wiring harness.
B. If the resistance is less than 10.0 Ω, continue with step 6.
47540694 28/04/2014
55.16 [55.DTC] / 378

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 379
3713-Lambda sensor: Open Load error of the LSU Heater Power

stage
learned.
Context:
The heater power stage of the oxygen sensor is monitored against open load condition, as long as the heater is
working.
Cause:
The oxygen sensor circuit is has an open circuit condition.

Solution:


4. Check for an open circuit. Place the key switch in the OFF position. Disconnect the engine harness from the
connector X-012 pin 7, wire E070 yellow. Locate and repair the damaged wiring harness.
Replace the ECU.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 380
3714-Lambda sensor: Fault code to indicate SRC High error for

O2 calibration
Context:
The oxygen signal measured during calibration must be lower than 0.2 V.
Cause:
The oxygen signal is greater than 0.2 V during calibration.

3. Problems with injection system or EGR.
Solution:



X-014 pin 1
X-014 pin 5
X-014 pin 2
X-014 pin 6
47540694 28/04/2014
55.16 [55.DTC] / 381

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 382
3715-Lambda sensor: SRC Low error for O2 calibration

Context:
Cause:

Solution:



X-013 pin 1
X-013 pin 5
X-013 pin 2
X-013 pin 6
47540694 28/04/2014
55.16 [55.DTC] / 383

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 384
3716-Lambda sensor: O2 value above the max threshold

Context:
Cause:

Solution:

X–468. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks.


X-468 pin 1
X-468 pin 5
X-468 pin 2
X-468 pin 6
47540694 28/04/2014
55.16 [55.DTC] / 385

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 386
3720-Lambda sensor: Low battery voltage at the SPI chip

Context:
The SPI chip reports a "very low battery voltage" defect. The voltage is less than 9.0 V.
Cause:
A low voltage source has been detected.

3. Faulty ECU.
Solution:

B. If no damage is found, leave the connector disconnected. Continue with step 3.

3. Check the wiring harness. Disconnect the engine harness from the ECU at connector X-012. Place the ignition
switch OFF. Using a multi-meter to test the wiring harness, refer to the table below for test results.

Resistance X-012 pin 64 X-014 pin 1 Continuity
B. If the all the above test are correct, replace the oxygen sensor. Use EST to reset the ECU oxygen sensor
learning values. Recheck fault has cleared. If fault is still present, replace the ECU.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 387
3721-Lambda sensor: Fault check to indicate SPI chip error of

lambda sensor
Context:
The engine control unit (ECU) has detected the initialization register value of the SPI chip is different from the value
written into the chip in the previous cycle. The SPI chip internal to the ECU is defective. Replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 388
3722-Lambda sensor: LSU sensor temperature Ri exceeds the

maximum limit
Context:
The Lambda Sensor measures O2 concentration only correctly, when the measuring cell is in a certain temperature
range. The temperature is estimated by the inner resistance of the heater. If the estimated temperature is higher than
a threshold, a failure is reported.
Cause:
The calculated temperature (based on inner resistance) of the sensor exceeds 929.96 °C (1705.9 °F).
1. Disconnected oxygen sensor.

Solution:



learning values.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 389
3723-Lambda sensor: LSU sensor temperature Ri is below the

minimum limit
Context:
The Lambda Sensor measures O2 concentration only correctly, when the measuring cell is in a certain temperature
range. The temperature is estimated by the inner resistance of the heater. If the estimated temperature is higher than
a threshold, a failure is reported.
Cause:
The calculated temperature (based on inner resistance) of the sensor is below or equal to 719.96 °C (1327.9 °F).
1. Disconnected oxygen sensor.

Solution:



learning values.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 390
3724-Lambda sensor: Short to battery at IA, IP, UN, VG

Context:
The SPI chip reports a "short circuit to battery" defect at any of the lines for Nernst Cell (UN), Virtual Ground (VG), or
Pump Cell (IA,IP)
Cause:
There is a short to high source in the oxygen sensor circuit.

2. Short to voltage on lines UN, VG, IA, IP.
3. Open load in VG.
Solution:


switch ON. Using a multi-meter to test the wiring harness, refer to the table below for test results.

Voltage X-014 pin 1 Ground No voltage
B. If the all the above tests are correct, continue with step 4.
4. Check for an open circuit. Place the ignition switch OFF. Use a multi-meter to check for continuity on the engine
harness from connector X-012 pin 85 to connector X-014 pin 2. There should be continuity.
A. If there is no continuity, there is an open circuit in the engine harness between connector X-012 pin 85 to
connector X-014 pin 2. Locate and repair damaged wiring.
B. If there is continuity, replace the oxygen sensor. Use EST to reset the ECU oxygen sensor learning values.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 391
3725-Lambda sensor: Short to ground at IA, IP, UN, VG

Context:
The SPI chip reports a "very low battery voltage" defect (i.e. Voltage is less than 9.0 V).
Cause:
A low voltage source has been detected.

3. Faulty ECU.
Solution:



learning values. Recheck fault has cleared. If fault is still present, replace the ECU.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 392
3727-Low oil viscosity

Context:
This fault is the result of the oil viscosity breaking down below a first threshold. Once this fault is present, it remains
active until the oil is changed. Change the engine oil, and clear any fault codes present.
47540694 28/04/2014
55.16 [55.DTC] / 393
3728-Too low oil viscosity

Context:
This fault is the result of the oil viscosity breaking down below a second threshold. Once this fault is present, it remains
active until the oil is changed. Change the engine oil, and clear any fault codes present.
47540694 28/04/2014
55.16 [55.DTC] / 394
3735-Fuel Metering Unit: over temperature of device driver of

metering unit

3. Faulty wiring.
4. Faulty fuel metering unit.
5. Faulty ECU.
Solution:
B. Fault code 3735 is recorded again. There are also fault codes for high battery voltage or high engine temper-
atures. Troubleshoot these codes before troubleshooting fault code 3735.
C. Fault code 3735 is recorded and is active. Go to step 2.

Inspect the ECU and fuel metering unit connections. All connections should be secure, tight, free of corrosion,
Inspect the harness from the ECU to the fuel metering unit. Verify that the harness is free of damage, corrosion,
3. Measure the resistance to chassis ground.
Disconnect the ECU connector X-012. Disconnect the fuel metering unit connector.
Measure the resistance from X-012 pin 60 to chassis ground. The resistance should be greater 20,000 Ω. Wiggle
Measure the resistance from X-012 pin 15 to chassis ground. The resistance should be greater 20,000 Ω. Wiggle
B. The resistance is less than 20,000 Ω. there is a short circuit to chassis ground in the wiring. Repair or replace
the wiring as required. Return to step 1 to confirm elimination of the fault.
4. Measure the resistance of the fuel metering unit to chassis ground.
Disconnect the fuel metering unit connector.
47540694 28/04/2014
55.16 [55.DTC] / 395
Measure the resistance from the fuel metering unit supply pin to chassis ground. The resistance should be greater
B. The resistance is less than 20,000 Ω. there is a short circuit to chassis ground in the wiring. Repair or replace
the wiring as required. Return to step 1 to confirm elimination of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 396
3736-O2 concentration is outside the predefined window during

Heater coupling detection
Context:
The heat up of the oxygen sensor is monitored by the ECU. If insufficient heater performance from the oxygen sensor
is detected for too long this fault code will occur. Replace the oxygen sensor.
47540694 28/04/2014
55.16 [55.DTC] / 397
3737-Lambda sensor: Over temperature error of the LSU Heater

Power stage
meter will draw too much current and either burn out the sensor or give false readings.
learned.
Context:
The heater power stage of Lambda sensor is monitored against over temperature (too high current).
Cause:
The SPI chip reports a "over temperature" defect.
1. Faulty electrical wiring or connection

2. Faulty oxygen sensor
Solution:



Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 398
3738-ECU Internal: Diagnostic fault check

Context:
This failure can be the result of corrupted data or internal failure of the engine control unit (ECU). Try to flash the ECU
correctly with the proper data set. If the error persists, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 399
3739-Power stages, Injector: Loss of synchronization sending

bytes to the MM from CPU
Context:
The engine control unit (ECU) has detected a processing error during ECU start up. Try to flash the ECU correctly
with the proper data set. If the error persists, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 400
3740-Power stages, Injector: DFC to set a torque limitation once an

error is detected before MoCSOP's error reaction is set
Context:
If this fault is occurs, check for any other faults associated with the injectors. If other faults are present, correct those
faults first. Clear any faults codes that exist and recheck this fault has cleared. If no other codes are present, try to
flash the ECU correctly with the proper data set. If the error persists, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 401
3741-Power stages, Injector: Wrong set response time

Context:
If the engine control unit (ECU) times out during start up, this fault will occur. Try to flash the ECU correctly with the
proper data set. If the fault persists, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 402
3742-Power stages, Injector: Too many SPI errors during MoCSOP

Context:
If the during start up the engine control unit (ECU) detects a faulty communication over SPI during the shut off path
test, this fault will occur. Try to flash the ECU correctly with the proper data set. If the fault persists, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 403
3743-Power stages, Injector : Diagnostic fault check to report the

error in under voltage monitoring
Context:
If the engine control unit (ECU) detects under voltage in the ECU during start up, this fault will occur. Try to flash the
ECU correctly with the proper data set. If the fault persists, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 404
3745-Power stages, Injector: Diagnostic fault check to report that

WDA is not working
Context:
The Engine Control Unit (ECU) has detected a processing error during ECU start up. Try to flash the ECU correctly
47540694 28/04/2014
55.16 [55.DTC] / 405
3746-Power stages, Injector: OS timeout in shutoff path test.

Failure setting the alarm task period.
Context:
47540694 28/04/2014
55.16 [55.DTC] / 406
3747-Power stages, Injector: Diagnostic fault check to report that

the positive test failed
Context:
47540694 28/04/2014
55.16 [55.DTC] / 407
3748-Power stages, Injector: Diagnostic fault check to report the

timeout in the shutoff path test
Context:
47540694 28/04/2014
55.16 [55.DTC] / 408
3750-Injection control: Error in the plausibility of the injection

energizing time
Context:
The energizing time request from the injectors is monitored by the Engine Control Unit (ECU).
Cause:
Implausible injection energizing time.
1. Faulty ECU.
Solution:
A. If the fault is still active, try to update the ECU software with the proper data set. If the fault is still is present,
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 409
3751-Injection control: Error in the plausibility of the start of

energizing angles
Context:
The start of energizing time for the injectors is monitored by the Engine Control Unit (ECU).
Cause:
Implausible start of injection energizing time.
1. Faulty ECU.
Solution:
A. If the fault is still active, try to update the ECU software with the proper data set. If the fault is still present,
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 410
3752-Zero Fuel Calibration (ZFC): Error in the plausibility of the

energizing times of the zero fuel quantity calibration
Context:
The Engine Control Unit (ECU) monitors the Zero Fuel quantity Calibration (ZFC) to correct pilot injection quantity.
Cause:
Implausible reading of ZFC quantity calibration.
1. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 411
3753-Level 2 Monitoring: Diagnostic fault check to report the error

due to injection quantity correction
Context:
The Engine Control Unit (ECU) monitors the injection cycle. Each injection part causes a pressure oscillation in the
rail. This can influence the quantity of the next injection.
Cause:
The injection cycle quantity is incorrect.
1. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 412
3754-Level 2 Monitoring: Diagnostic fault check to report the

plausibility error in rail pressure monitoring
Context:
The Engine Control Unit (ECU) monitors the fuel pressure in the common rail.
Cause:
Fuel pressure is out of range.
1. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 413
3755-Level 2 Monitoring: Diagnostic fault check to report the error

due to torque comparison
Context:
The Engine Control Unit (ECU) monitors total requested engine torque, and is compared to a maximal allowed engine
torque.
Cause:
The requested engine torque is out of range.
1. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 414
3756-Level 2 Monitoring: Diagnosis fault check to report the

demand for normal mode due to an error in the post injection 2
quantity
Context:
The Engine Control Unit (ECU) monitors the injection cycle.
Cause:
The efficiency of post injection 2 is out of range.
1. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 415
3757-Level 2 Monitoring: Diagnosis fault check to report the error

to demand for an ICO due to an error in the post injection 2 shut-off
Context:
Cause:
Post injection 2 quantity exceeds limit.
1. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 416
3758-Level 2 Monitoring: Diagnosis fault check to report the

error to demand for an ICO due to an error in the post injection
3 efficiency factor
Context:
Cause:
Post injection 3 efficiency is plausible.
1. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 417
3759-Level 2 Monitoring: Diagnosis of current path limitation

forced by Engine Control Unit (ECU) monitoring level 2
Context:
The Engine Control Unit (ECU) has detected an internal fault with the torque request.
Cause:
The calculated engine torque is greater than the acceptable engine torque.
1. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 418
3760-Level 2 Monitoring: Diagnosis air path limitation due to a

functional control unit monitoring forced by Engine Control Unit
(ECU) monitoring level 2
Context:
Cause:
The calculated (inner) engine torque is greater than the acceptable (inner) engine torque.
1. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 419
3761-Level 2 Monitoring: Diagnosis quantity path limitation due to

a functional control unit monitoring (level 2)
Context:
Cause:
The calculated engine torque is greater than the acceptable engine torque.
1. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 420
3762-Level 2 monitoring: Reported overvoltage of supply

Context:
The Engine Control Unit (ECU) monitors the battery voltage to the ECU.
Cause:
The battery supply to the ECU is above the threshold.
1. Faulty wiring.
3. Faulty ECU.
Solution:

Use a multimeter to measure the voltage on the wiring harness side of the ECU connector pin 1 to pin 2.
Use a multimeter to measure the voltage on the wiring harness side of the ECU connector pin 28 to chassis ground.

Start the engine.
47540694 28/04/2014
55.16 [55.DTC] / 421
B. If the voltage reading is greater than 18.0 V, the alternator and/or regulator has failed. Replace the alternator.
47540694 28/04/2014
55.16 [55.DTC] / 422
3763-Level 2 monitoring: Reported under voltage of supply

NOTE: This fault can occur due to a cold start with low battery voltage, engine speed less than 300 RPM and coolant
temperature less than 0 °C (32 °F).
Context:
The Engine Control Unit (ECU) monitors the battery voltage supply to the ECU..
Cause:
The battery supply to the ECU is below the threshold.
1. Faulty wiring.
2. Faulty battery.
4. Faulty ECU.
Solution:

Use a multimeter to measure the voltage on the wiring harness side of the ECU connector pin 28 to chassis ground.
B. If the voltage reading is less than 10.0 V, check the wiring harness between the ECU connector to the battery
for a short to low source.
47540694 28/04/2014
55.16 [55.DTC] / 423
Start the engine.
B. If the voltage reading is less than 10.0 V, continue with Step 5.

A. If the voltage reading is correct, the alternator and/or regulator has failed. Check the alternator belt for damage.
If no damage is found, replace the alternator.
B. If the voltage reading is less than 10.0 V, recharge the battery. If the battery can not hold a charge, replace
the battery.
47540694 28/04/2014
55.16 [55.DTC] / 424
3764-Main Relay: Early opening defect of main relay

Context:
The Engine Control Unit (ECU) has detected the main relay is opening too early. The main relay is controlled by the
ECU. The main relay is switched off by the ECU, after the After-run has finished.
Cause:
The main relay operation is incorrect.
1. The main relay has failed.

2. The wiring harness has failed.
3. The ECU has failed.
Solution:
1. Verify the fault is active.
A. If the fault code is present, continue with Step 2.
B. If the fault is not present, the fault may be intermittent and not currently active. Continue with Step 6.
NOTE: Check the battery cables. If the cables were interrupted during shutdown this fault could occur.
Inspect the harness from the main relay to the ECU.
Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment.
A. The connectors are secure and the harness is free of damage. Continue with Step 3.
B. The connectors or the harness has damage. Repair or replace the harness or connectors as required.
3. Check the main relay.
Disconnect the main relay.
Use a multimeter to perform the following check.
From To Value
Relay terminal 86 Relay terminal 85 There should be continuity.
A. If the relay test passes, leave the relay removed. Continue with Step 4.
B. If there is no continuity, replace the relay.

4. Check the main relay control circuit.
Use a multimeter to perform the following check.
From To Value
Relay cavity pin 85 Chassis ground There should be no continuity.
A. If the wiring harness test fails, continue with Step 5.
B. If the wiring harness test passes, check the voltage supply circuit.
5. Check the wiring harness.
47540694 28/04/2014
55.16 [55.DTC] / 425
Use a multimeter to perform the following checks.
From To Value
ECU wiring harness connector pin 28 Chassis ground There should be no continuity.
Relay cavity pin 85 ECU wiring harness connector pin 28 There should be continuity.
A. If the wiring harness test passes, verify the ECU is working properly.
B. If the wiring harness test fails, locate and repair the broken conductor.
6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals,
breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.
A. If you find damage or the display indicates other than normal display readings, then repair the damage discov-
ered during the inspection or locate and repair the other than normal display condition and verify that the error
has been resolved.
B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue
operation.
47540694 28/04/2014
55.16 [55.DTC] / 426
3766-Diesel particulate filter pressure sensor: Fault check for the

pressure sensor plausibility
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Context:
The exhaust differential pressure is measured between the intake and exhaust of the diesel particulate filter in the
exhaust. This fault is a result of the differential pressure being inaccurate. The pressure value is above 2.5 kPa
(0.4 psi). Check the differential pressure sensor hoses, and connections. If all the connections are good, and no
damage is found. Replace the differential pressure sensor.
47540694 28/04/2014
55.16 [55.DTC] / 427
3767-ECU internal: Diagnostic fault check to report 'WDA active'

due to errors in query-/response communication
Context:
The Engine Control Unit (ECU) has detected an internal failure. Try to flash the ECU correctly with the proper data
set. If the error persists, replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 428
3768-ECU Internal: Diagnostic fault check to report 'ABE active'

due to under voltage detection
Context:
47540694 28/04/2014
55.16 [55.DTC] / 429
3769-ECU Internal: Diagnostic fault check to report 'ABE active'

due to overvoltage detection
Context:
47540694 28/04/2014
55.16 [55.DTC] / 430
3770-ECU internal: Diagnostic fault check to report 'WDA/ABE

active' due to unknown reason
Context:
47540694 28/04/2014
55.16 [55.DTC] / 431
3771-Oxidation Catalyst: Up and down stream temperature sensors

in Oxidation catalysts exchanged
Solution:
(2) To check for fault codes: Start and operate machine.
B. Fault code 3771 is active and recorded again. Go to Step 2.

RAPH12SSL0028FA 1
(1) ECU connector X-016 (3) Exhaust temperature sensor #2

Down stream sensor
X-007
(2) Exhaust temperature sensor #1
Up stream sensor
X-006
(1) Inspect the ECU and the exhaust sensors. All connections should be secure, tight, free of corrosion, abrasion
and damage.
(2) Inspect the harness from the ECU to the exhaust sensors. Verify that the harness is free of damage, corrosion,
47540694 28/04/2014
55.16 [55.DTC] / 432
3. Verify the exhaust sensors are installed properly
RAPH12SSL0429BA 2
Legend
(1) Exhaust temperature sensor #2 (2) Exhaust temperature sensor #1
Downstream sensor Upstream sensor
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 433
3772-Turbocharger: Over boost deviation at P2 too high in pressure

charge regulator
Context:
The Engine Control Unit (ECU) monitors the boost pressure value.
Cause:
The ECU is detecting inaccurate boost pressure.
1. Faulty wiring.
3. Faulty wastegate actuator.
4. Faulty ECU.
Solution:

2. Check for other faults present. Verify no other faults are associated to the boost pressure sensor.

3. Check for other faults present. Verify no other faults that are associated to the wastegate actuator.

4. Check the wiring harness. Inspect the wiring harness from the ECU to the boost pressure sensor. Inspect the
wiring harness from the ECU to the wastegate actuator.
A. If there is no damage, continue with step 5.
B. If damage is found in the wiring harness or connections, repair faulty wiring.

5. Check ECU for proper operation. If no other errors are present and all wiring is correct, download the latest version
of the software.
A. If fault code is no longer present, return unit to proper operation.
B. If fault code is still active, replace the ECU.

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 434
3773-Turbocharger: Underboost detected in pressure charger

regulator
Context:
Underboost is detected when the positive boost pressure deviation exceeds 0.4 bar (5.8 psi) for a period greater than
5.0 s while the following conditions are met: Injection quantity is greater than 2.0 ml (0.1 US fl oz), and there are no
active boost pressure sensor fault codes.
Cause:
The ECU has detected a failure in boost pressure.
1. Faulty wiring.
3. Clogged air filter/intake system.
4. Faulty turbocharger.
Solution:

2. Check the air filter. Remove and inspect the air filter.
A. If the air filter is restricted, clean or replace the air filter.
B. If the air filter is free of restrictions, continue with step 3.

3. Check the intake system. Check for signs of restriction in the intake system.
A. If the intake is clogged, clean out intake system. If intake is damaged, replace the intake system.
B. If intake is free of restrictions, continue with step 4.

4. Check the boost pressure sensing circuit. Disconnect the engine sensor harness from the boost pressure sensor.
Place the ignition switch ON. Use a multi-meter to check for voltage from engine sensor harness side of connector
pin 4 to chassis ground. There should be no voltage.
A. If there is voltage, repair or replace wiring in the engine sensor harness.
B. If there is no voltage, leave connector disconnected. Continue with step 5.

5. Check the boost pressure sensing circuit. Place the ignition switch OFF. Disconnect the engine sensor harness
from the ECU. Use a multi-meter to check for continuity from engine sensor harness side of connector pin 4 to
connector pin 34. There should be continuity.
A. If there is no continuity, repair or replace wiring in the engine sensor harness.

6. Check condition of turbocharger. Remove connectors from the turbocharger. Visually inspect the blades and
turbocharger housing for any damage.
A. If any damaged is found, replace the turbocharger.
B. If the turbocharger is in good condition, test complete

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 435
47540694 28/04/2014
55.16 [55.DTC] / 436
3786-Diesel particulate filter signal range check is high

C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Context:
The engine control unit (ECU) has detected the soot level in the DPF filter is exceeding the threshold limit, or the flow
resistance is high. If this fault occurs, black smoke should be visible at the exhaust pipe. Check that the DPF filter is
mounted properly and is not cracked. If the DPF filter is not mounted properly, refit the DPF filter correctly. If damaged
is determined, replace the DPF filter. This fault will clear at the end of the next regeneration cycle.
47540694 28/04/2014
55.16 [55.DTC] / 437
3787-Diesel particulate filter (DPF) : Signal range check flow

resistance of the particulate filter - very high
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Context:
The engine control unit (ECU) has detected the soot level in the DPF filter is exceeding the threshold limit, or the flow
resistance is high. Check that the DPF filter is mounted properly and is not cracked. If the DPF filter is not mounted
properly, refit the DPF filter correctly. If damaged is determined, replace the DPF filter. This fault will clear at the end
of the next regeneration cycle.
47540694 28/04/2014
55.16 [55.DTC] / 438
3789-Regeneration duration exceeds maximum allowed duration

C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Context:
The engine control unit (ECU) has detected the regeneration cycle did not complete in time. This could be a cause
of exhaust restrictions, differential pressure sensor measuring wrong. Check the exhaust for any kind of restrictions.
Check rear differential pressure sensor hose is not clogged. Perform the manual regeneration procedure.
47540694 28/04/2014
55.16 [55.DTC] / 439
3790-Diesel particulate filter: Signal range check flow resistance of

the particulate filter - max
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Context:
The flow resistance, dependent on soot mass stored in the particulate filter, should not exceed a defined limit. If this
limit is exceeded, the diesel particulate filter is clogged, or a problem in the filter mounting should be assumed.
Cause:
The engine control unit (ECU) has detected the filtered flow is above maximum limit.
1. Diesel Particulate Filter (DPF) is clogged or not installed correctly.

2. Exhaust restriction
3. Faulty differential pressure sensor
Solution:

2. Check the condition of the diesel particulate filter. Place the ignition switch OFF. Make sure the filter is installed
correctly.
A. If the filter is not installed correctly, properly install the filter.
B. If the filter is installed correctly, continue with step 3.

3. Check the differential pressure sensor is installed correctly. Place the ignition switch OFF. Visually inspect the
differential pressure Sensor for physical damage, proper electrical connection and proper mechanical connection.
Ensure any tubes and/or hoses connected to the sensor are in good working condition and properly connected
at all ends. Visually inspect the entire exhaust system for bent, crushed or otherwise damaged tubes which may
cause an exhaust system restriction.
A. If any damage is found, repair or replace as necessary.
B. If no damage is found, continue with step 4.

4. Place the ignition switch ON. Run the diesel particulate filter regeneration cycle. Place the ignition switch OFF for
1.0 min. Test drive the machine. Check if the fault code is still active or inactive.
A. If the fault code is inactive, the test is complete.
B. If the fault code is still active, continue with step 5.

5. Check the differential pressure sensor electrical circuit. Place the ignition switch OFF. Disconnect the engine
harness from the differential pressure sensor at connector X-005 and at the ECU connector X-012. Check for
continuity from the engine harness from connector X-005 pin 1 to connector X-012 pin 14. There should be should
be continuity.
A. If there is no continuity, locate and repair wiring in the engine harness between connector X-005 pin 1 to con-
nector X-012 pin 14.
47540694 28/04/2014
55.16 [55.DTC] / 440
6. Check the differential pressure sensor electrical circuit. Disconnect the engine harness from the differential pres-
sure sensor at connector X-005 and at the ECU connector X-012. Check for continuity from the engine harness
from connector X-005 pin 3 to connector X-012 pin 58. There should be continuity.

7. Check the differential pressure sensor electrical circuit. Disconnect the engine harness from the differential pres-
sure sensor at connector X-005 and at the ECU connector X-012. Check for continuity from the engine harness
from connector X-005 pin 2 to connector X-012 pin 36. There should be no continuity.
B. If there is continuity, replace the differential pressure sensor

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 441
3794-Intake air pressure sensor: Plausibility check for air pressure

at the upstream of intake valve sensor
Context:
The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure sensor. The Boost
Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related
to the pressure sensing function of the device. This error could result from a signal out of range or a signal that is
either erratic or intermittent.
Cause:
The Boost Pressure sensor signal to the ECU is incorrect.

2. Faulty sensor.
Solution:

2. Inspect the harness between the boost pressure sensor and the ECU. Verify that the harness is free of damage,
corrosion, abrasion, or incorrect attachment.
A. If any damage is found in the wiring harness, repair or replace as required.
B. If no damage is found, continue with step 3

3. Check for a short to voltage. Place the key switch ON. Disconnect the engine harness from the boost pressure
sensor at connector X-017. Use a multi-meter to check for voltage from the engine harness side of connector
X-017 pin 18 to chassis ground. There should be no voltage.
A. If there is voltage, there is a short to voltage in the engine harness between connector X-017 pin 18 and con-
nector X-016 pin 40. Locate and repair damaged wiring.
B. If there is no voltage, continue with step 4.

4. Check for an open circuit. Place the key switch OFF. Disconnect the engine harness from the ECU at connector
X-016. Use a multi-meter to check for continuity from the engine harness connector X-017 pin 18 to connector
X-016 pin 40. There should be continuity.
A. If there is no continuity, there is an open circuit in the engine wiring harness between connector X-017 pin 18
and connector X-016 pin 40. Locate and repair damaged wiring.
B. If there is continuity, replace the boost pressure sensor.

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 442
3795-Intake air pressure sensor: Plausibility check for air pressure

at the upstream of intake valve sensor
Context:
The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure sensor. The Boost
Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related
to the pressure sensing function of the device. This error could result from a signal out of range or a signal that is
either erratic or intermittent.
Cause:
The Boost Pressure sensor signal to the ECU is incorrect.

2. Faulty sensor.
Solution:

2. Inspect the harness between the boost pressure sensor and the ECU. Verify that the harness is free of damage,
corrosion, abrasion, or incorrect attachment.
A. If any damage is found in the wiring harness, repair or replace as required.
B. If no damage is found, continue with step 3

3. Check for a short to ground. Place the key switch OFF. Disconnect the engine harness from the boost pressure
sensor at connector X-017. Use a multi-meter to check for continuity from the engine harness side of connector
X-017 pin 18 to chassis ground. There should be no continuity.
A. If there is continuity, there is a short to ground condition in the engine harness between connector X-017 pin
18 and connector X-016 pin 40. Locate and repair damaged wiring.
B. If there is no continuity, continue with step 4.

4. Check for an open circuit. Place the key switch ON. Use a multi-meter to check for voltage from the engine harness
connector X-017 pin 17 to chassis ground. There should be approximately 5.0 V.
A. If there is no voltage, there is an open circuit in the engine wiring harness between connector X-017 pin 18 and
connector X-016 pin 40. Locate and repair damaged wiring.
B. If there is 5.0 V, replace the boost pressure sensor.

Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 443
3796-Diesel particulate filter pressure sensor hose line error

C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Context:
The engine control unit (ECU) has detected the filtered differential pressure signal is below 1.0 kPa (0.1 psi). This
fault is a cause of a hose connection upstream from the diesel particulate filter not being attached, or is clogged.
Check mounting of the hose lines, and check the hose line is free of clogs.
47540694 28/04/2014
55.16 [55.DTC] / 444
3797-Diesel particulate filter pressure sensor: SRC high for

differential pressure sensor
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Solution:

Inspect the ECU and the differential pressure sensor connections. All connections should be secure, tight, free of
Inspect the harness from the ECU to the differential pressure sensor. Verify that the harness is free of damage,
3. Test the circuit.
Disconnect the differential pressure sensor.
Fabricate a jumper wire that will connect between X-005 pin 2 and X-005 pin 3.
Turn the ignition switch ON. Monitor the fault code screen on the EST.
Connect the jumper wire between X-005 pin 2 and X-005 pin 3. Fault code 3797 should no longer be active. Fault
code 3798 is now active.
A. Fault code 3797 is no longer active. Fault code 3798 is now active. Temporarily replace the differential pressure
sensor and retest. Return to step 1 to confirm elimination of the fault code.
B. Fault 3797 is still active. Go to step 4.

4. Test the ECU.
Use a wire removal tool to remove X-012 pin 58 from the ECU connector.
Fabricate a jumper wire long enough to connect between chassis ground and X-012 pin 58. The chassis ground
connection should be clean and free of corrosion, paint, oil and dirt.
Turn the ignition switch ON. Monitor the fault code screen on the EST.
Connect the jumper wire between X-012 pin 58 and chassis ground. The fault code should change from fault code
3797 to fault code 3798.
A. The fault code changed from fault code 3797 to fault code 3798. There is a problem in the wiring from the ECU
to the sensor. Repair or replace the wire as needed. Return to step 1 to confirm elimination of the fault code.
47540694 28/04/2014
55.16 [55.DTC] / 445
B. The fault code did not change to 3798. Temporarily replace the ECU and retest. Return to step 1 to confirm
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 446
3798-Diesel particulate filter pressure sensor: SRC low for

differential pressure sensor
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Solution:

Inspect the ECU and the differential pressure sensor connections. All connections should be secure, tight, free of
Inspect the harness from the ECU to the differential pressure sensor. Verify that the harness is free of damage,
3. Create an open circuit at the sensor and test
Disconnect the differential pressure sensor.
Turn the ignition switch ON. Monitor the fault code screen on the EST. The fault code should change from fault
code 3798 to fault code 3797.
Connect the jumper wire between X-005 pin 2 and X-005 pin 3.
A. The fault code changed from fault code 3798 to fault code 3797. Temporarily replace the differential pressure
sensor and retest. Return to step 1 to confirm elimination of the fault code.
B. The fault code did not change to 3797. Go to step 4.

4. Create an open circuit at the ECU and test
Use a wire removal tool to remove X-012 pin 58 from the ECU connector.
Turn the ignition switch ON. Monitor the fault code screen on the EST. The fault code should change from FC3798
to an open circuit fault code 3797.
A. The fault code changed from a short circuit fault code 3798 to an open circuit fault code 3797. There is a
problem in the wiring from the ECU to the sensor. Repair or replace the wire as needed. Return to step 1 to
confirm elimination of the fault code.
B. The fault code did not change to fault code 3797. Temporarily replace the ECU and retest. Return to step 1 to
Mechanical Units
47540694 28/04/2014
55.16 [55.DTC] / 447
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 448
3799-Pressure Relief valve: pressure relief valve is forced to open,

perform pressure shock
Context:
This code is not an actual failure. A rail pressure shock test was detected. Clear code and return machine to proper
use.
47540694 28/04/2014
55.16 [55.DTC] / 449
3800-Pressure relief valve: Quantity balance check if a successful

PRV opening is ensured
Context:
This code is not a failure fault, the engine control unit (ECU) has detected the pressure shock was rejected because
fuel quantity is not in range. To determine mechanical wear out, the pressure relief valve can be forced open by
a pressure shock, when the metering valve of the high pressure fuel pump is set to maximum possible quantity.
Pressure shock is only possible in a defined engine speed range depending on rail pressure.
47540694 28/04/2014
55.16 [55.DTC] / 450
3801-Turbine upstream pressure sensor: SRC high for turbine

upstream pressure sensor
Context:
The engine control unit (ECU) has detected the inlet turbo temperature sensor sensed voltage is above 6.55 V.
Cause:
The inlet turbo temperature sensor signal is shorted to a high voltage source.

2. Faulty sensor.
3. Faulty control unit.
Solution:

Inspect the ECU and the inline turbine temperature sensor connections. All connections should be secure, tight,
Inspect the harness from the ECU to the inline turbine temperature sensor. Verify that the harness is free of
3. Measure the resistance between the signal wires.
Turn the ignition switch OFF
Disconnect ECU connector X-012. Disconnect the inline turbine temperature connector.
Fabricate a jumper wire 20 cm (8 in) long. Use the jumper wire to short the inline turbine temperature sensor
connector X-005 pin 1 to pin 2. Wiggle the harness during measurement to reveal an intermittent condition.
B. The resistance is greater than 10 Ω there is an open circuit in the sensor wires. Repair or replace the wires as
4. Measure the resistance of the signal wire to battery.
Disconnect ECU connector X-012. Disconnect the inline turbine temperature connector.
47540694 28/04/2014
55.16 [55.DTC] / 451
A. The voltage is less than 0.2 V, go to step 5.
B. The voltage is greater than 0.2 V, the wire is shorted to another voltage source. Repair or replace the wire as
required. Go to step 1 to confirm elimination of the fault.
5. Measure the resistance of the sensor.
Disconnect the inline turbine temperature connector.
Measure the resistance of the inline turbine temperature sensor pin 1 to pin 2. The resistance should be approxi-
mately 175 - 250 Ω.
A. The resistance is within the specified range. Temporarily replace the ECU and retest. Return to step 1 to
B. The resistance is not within the specified range. Temporarily replace the inline turbine temperature and retest.
Return to step 1 to confirm the elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 452
3802-Turbine upstream pressure sensor: SRC low for turbine

upstream pressure sensor
Context:
The engine control unit ( ECU) has detected the inline turbine temperature sensor voltage is less than 0.0 V.
Cause:
The inline turbine temperature sensor signal is shorted to a ground source.

2. Faulty sensor.
Solution:

Inspect the ECU and the Inline Turbine Temperature Sensor connections. All connections should be secure, tight,
Inspect the harness from the ECU to the Inline Turbine Temperature Sensor. Verify that the harness is free of
Disconnect ECU connector X-012. Disconnect the inline turbine temperature sensor connector.
Measure the resistance between ECU connector X-012 pin 82 to X-012 pin 81. The resistance should be greater
B. The resistance is less than 20,000 Ω there is a short circuit between the sensor wires. Repair or replace the
wires as required. Return to step 1 to confirm elimination of fault.
Measure the resistance between ECU connector X-012 pin 82 to chassis ground. The resistance should be greater
47540694 28/04/2014
55.16 [55.DTC] / 453
B. The resistance is less than 20,000 Ω there is a short circuit between the sensor signal wire and chassis ground.
Repair or replace the signal wire as required. Return to step 1 to confirm elimination of fault.
Disconnect the inline turbine temperature sensor connector.
Measure the resistance between the inline turbine temperature sensor pin 1 and chassis ground. The resistance
should be greater than 20,000 Ω.
the elimination of the fault.
B. The resistance is less than 20,000 Ω the sensor has a short circuit to chassis ground. Temporarily replace the
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 454
3803-ECU internal: Error R2S2 module (low level chip driver for
the power stage chips)
Context:
The engine control unit (ECU) has detected an internal communication failure of several signals in the ECU due, for
example, to the supply voltage over the threshold. This failure can be the result of wrong programming / flashing of
the ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace
the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 455
3808-Fuel Metering Unit: set point of metering unit in idle mode

not plausible
Context:
This fault is a result of a leak on the high or low pressure side of the high side pressure pump. Check for worn or
stuck open injector, worn high pressure pump or leaking pressure control valve. Check for low fuel pressure before
or after the gear pump, clogged fuel filter or leakage, or faulty fuel pump.
47540694 28/04/2014
55.16 [55.DTC] / 456
3810-Fuel pressure sensor: Rail pressure raw value is intermittent

Context:
The engine control unit (ECU) has detected an intermittent fault in rail pressure signal.
Cause:
There is a loose connection in the rail pressure circuit.
1. Faulty wiring or connection

2. Faulty sensor
Solution:
1. Disconnect the engine sensor harness from the rail pressure sensor. Inspect connector housing body/latch, pins,
and wiring harness for damage.
sound electrical connection.
B. If no damaged is determine, continue with step 2.

2. Check the rail pressure sensor. Inspect connector housing body/latch, pins.
A. If damage is determined after careful inspection, replace the sensor. Re-flash the ECU.
B. If no damaged is found. Clear fault and return machine to proper operation.
47540694 28/04/2014
55.16 [55.DTC] / 457
3811-ECU sensor supply monitor : ECU internal: Error sensor

supplies 1
Context:
voltages are monitored to ensure they remain within a given range. This check for voltage limits is done autonomously
by the hardware.
Cause:
1. Faulty wiring.
2. Faulty battery.
3. Faulty ECU.
Solution:
2. Check for fault codes related to the oil pressure sensor.
Check for fault codes related to the Throttle Valve Actuator (TVA) position sensor.
Check for fault codes related to the Exhaust Gas Recirculation (EGR) position sensor.
Check for fault codes related to the boost pressure sensor.
Check for fault codes related to the rail pressure sensor.
Check for fault codes related to the exhaust gas pressure sensor.
Check for fault codes related to the camshaft speed sensor.
A. If other fault codes are not present, continue with Step 3.
B. If any other fault codes are present, troubleshoot that fault first. Then determine if this fault code has been
corrected.

47540694 28/04/2014
55.16 [55.DTC] / 458
ground.

47540694 28/04/2014
55.16 [55.DTC] / 459
3812-Physical range check high for ECU temperature sensor

Context:
High temperatures can damage the Engine Control Unit (ECU) processor, one or more sensors can be provided to
monitor ECU temperatures.
Cause:
The ECU has sensed the internal voltage is greater than 129.96 °C (265.93 °F).
1. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 460
3813-Physical range check low for ECU temperature sensor

Context:
Extremely low temperatures can damage the Engine Control Unit (ECU) processor, one or more sensors can be
provided to monitor ECU temperatures.
Cause:
The ECU has sensed the internal voltage is less than -40.00 °C (-40.00 °F).
1. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 461
3814-ECU temperature sensor: SPI error ECU temperature sensor

(LM71)
Context:
Erratic temperatures can damage the Engine Control Unit (ECU) processor, one or more sensors can be provided to
monitor ECU temperatures.
Cause:
The ECU has sensed the internal voltage is not plausible.
1. Faulty ECU.
Solution:
replace the ECU.
47540694 28/04/2014
55.16 [55.DTC] / 462
3815-Low efficiency in DPF filter

C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Context:
The engine control unit (ECU) has detected an error associated with the diesel particulate filter (DPF). If this fault
occurs, black smoke should be visible at the exhaust pipe. Check that the DPF is mounted properly and is not cracked.
If the filter is not mounted properly, refit the filter correctly. If damaged is determined, replace the filter.
47540694 28/04/2014
55.16 [55.DTC] / 463

Context:
The positive limit of throttle valve governor deviation has been exceeded.
Cause:
mismatched.
1. Faulty wiring.
Solution:
A. If the fault is no longer active or present, return the machine to service.
B. If the fault is still present and active, continue with Step 2.

Inspect the ECU connector and the throttle valve actuator connector X-016. All connections should be secure,
A. The connectors are secure and the harness is free of damage. Inspect the TVA for sticking or jammed valve.
47540694 28/04/2014
55.16 [55.DTC] / 464

Context:
The negative limit of throttle valve governor deviation has been exceeded.
Cause:
mismatched.
1. Faulty wiring.
Solution:
A. If the fault is no longer active or present, return the machine to service.
B. If the fault is still present and active, continue with Step 2.

Inspect the ECU connector and the throttle valve actuator connector X-016. All connections should be secure,
A. The connectors are secure and the harness is free of damage. Inspect the TVA for sticking or jammed valve.
47540694 28/04/2014
55.16 [55.DTC] / 465
3818-Open load error for power stage

Context:
ECU Power stages: Open load error on the TVA valve power stage.
Cause:
The ECU detects an open circuit in the TVA valve drive circuit. Electrical problem in the TVA valve actuator.
1. Faulty wiring.
2. Faulty TVA valve.
3. Faulty ECU.
Solution:
To check for fault code: Start and operate the machine.

Inspect the ECU and the TVA valve. All connections should be secure, tight, free of corrosion, abrasion and
damage.
3. Measure the resistance through the wiring harness
Disconnect the TVA Valve connector. Disconnect the ECU connector.
Measure the resistance between ECU connector X-016 pin 49 and TVA valve motor plus pin. The resistance
Measure the resistance between ECU connector X-016 pin 34 and TVA valve motor minus pin. The resistance
Measure the resistance between ECU connector X-016 pin 8 and TVA position sensor supply pin. The resistance
Measure the resistance between ECU connector X-016 pin 53 and TVA position sensor signal pin. The resistance
Measure the resistance between ECU connector X-016 pin 37 and TVA position sensor ground pin. The resistance
47540694 28/04/2014
55.16 [55.DTC] / 466
4. Measure the resistance through the valve
Disconnect the TVA valve connector.
Measure the resistance through the motor windings. The resistance should be approximately 3 Ω.
A. The resistance is approximately 3 Ω. Temporarily replace the ECU and retest. Return to step 1 to confirm
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 467
3820-Over temperature error for H-bridge

Context:
ECU Power stages : Over temperature error on the TVA PWM output power stage
Cause:
The ECU detects an excess current draw on the TVA signal wire.
1. Faulty wiring.
3. Faulty ECU.
Solution:
A. Fault code 3820 is active with other fault codes such as fault code 3051 or 3518 or 3007 and 1002. Trou-
bleshoot these fault codes before troubleshooting fault code 3818.

damage.
3. Measure the resistance through the wiring harness.
Measure the resistance between ECU connector X-016 pin 49 and TVA valve motor plus pin. The resistance
Return to Step 1 to confirm elimination of fault.
4. Measure the resistance through the wiring harness to chassis ground.
47540694 28/04/2014
55.16 [55.DTC] / 468
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the wire as
Measure the resistance through the Electric Valve pin 1 to chassis ground. The resistance should be greater than
20,000 Ω.
Electric Valve and retest. Return to step 1 to confirm elimination of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 469

Context:
Cause:
The TVA valve drive circuit is shorted to positive battery.

2. Faulty ECU.
Solution:

damage.
3. Measure the voltage through the wiring harness.
Disconnect the TVA valve connector. Disconnect the ECU connector.
of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 470

Context:
Cause:
The TVA valve drive circuit is shorted to positive battery.

2. Faulty ECU.
Solution:

damage.
of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 471

Context:
Cause:
The TVA valve drive circuit or wiring is shorted to minus battery or chassis ground.

3. Faulty ECU.
Solution:

damage.
Measure the resistance from ECU connector X-016 pin 49 to chassis ground. The resistance should be greater
Measure the resistance from the TVA valve, motor plus pin to chassis ground. The resistance should be greater
than 20,000 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 472
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 473

Context:
Cause:
The TVA valve drive circuit or wiring is shorted to minus battery or chassis ground.

2. Faulty ECU.
Solution:

damage.
than 20,000 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 474
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 475
3825-Short circuit over load error for H-bridge

Context:
The ECU had detected a short circuit in the TVA valve drive circuit.
Cause:
1. Wiring shorted.
3. Faulty ECU.
Solution:

damage.
Disconnect the TVA valve connector. Disconnect the TVA connector.
than 20,000 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 476
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 477
3826-Temperature dependent over current error for H-bridge

Context:
Cause:
1. Wiring shorted.
3. Faulty ECU.
Solution:

damage.
Disconnect the TVA valve connector. Disconnect the TVA connector.
than 20,000 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 478
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 479
3827-Under voltage error for H-bridge

Context:
Under voltage error for H-bridge.
Cause:
The ECU had detected a high fluctuations in the system voltage.
1. Bad battery or battery connections.

3. Faulty ECU.
Solution:
B. Fault code 3827 is recorded with other fault codes such as fault code 1014 or 3051. Clean and inspect the
battery. Troubleshoot these fault codes first.

2. Inspect the battery cable connections.
Verify that the battery terminals and battery cables are free of corrosion, abrasion and incorrect attachment.
Verify that the battery chassis ground connection is clean and fastened securely to the frame. The chassis con-
nection point should be free of paint, rust, dirt and debris.
A. The cables and battery connections are secure and free of corrosion, abrasion and incorrect attachment. Go
to step 3.
B. The battery connections or battery cables are in need of repair. Repair as required. Return to step 1 to confirm
ECU. All connections should be secure, tight, free of corrosion, abrasion and damage.
A. The connectors are secure and the harness is free of damage. Temporarily replace the ECU and retest. Return
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 480
3830-DFC for valve position sensor physical SRC high

Context:
The engine control unit (ECU) monitors the electrical signal of the throttle valve actuator (TVA) position sensor.
Cause:
The calculated TVA position is above the maximum physical range.
1. Faulty wiring
2. Faulty TVA sensor
Solution:

2. Place the key switch OFF. Check the wiring harness from the TVA sensor to the ECU. Inspect all connectors, pins,
and wiring harness for broken connectors, corrosion, bent pins or wire breaks.
3. Place the key switch OFF. Disconnect the wiring harness from the TVA sensor at connector X-017 and the ECU
at connector X-016 Insert a jumper wire between connector X-016 pin 8 and pin 53. Use a multi-meter to check
for continuity from the harness side of connector X-017 pin 41 and pin 42. There should be continuity.
A. If there is continuity, leave connectors disconnected. Continue with step 4.
B. If there is no continuity, there is an open circuit in the wiring harness. Locate and repair damaged wiring.
4. Place the key switch OFF. Insert a jumper wire between connector X-016 pin 53 and pin 37. Use a multi-meter to
check for continuity from the harness side of connector X-017 pin 42 and pin 43. There should be continuity.
5. Remove the jumper wire. Check for a short to voltage in the wiring harness. Place the key switch ON. Use a
multi-meter to check for voltage from the harness side of connector:
X-016 pin 8 to chassis ground
A. If there is no voltage, the wiring harness is good. Replace the TVA sensor.
B. If there is voltage, there is a short to voltage in the wiring harness. Locate and repair damaged wiring.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 481
3831-DFC for valve position sensor physical SRC low

Context:
Cause:
The calculated TVA position is below the minimum physical range.
1. Faulty wiring
2. Faulty TVA sensor
Solution:

at connector X-016. Use a multi-meter to check for continuity from the harness side of connector:
A. If there is no continuity, the wiring harness is in good condition. Replace the TVA sensor.
B. If there is continuity, there is a short circuit to ground condition in the wiring harness. Locate and repair dam-
aged wiring.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 482
3834-ECU Power stages: Throttle valve actuator power stage: SRC

High
Context:
Cause:
The sensed voltage is higher than 5.2 V.
1. Faulty wiring.
2. Faulty TVA sensor.
Solution:

2. Place the ignition switch in the OFF position. Check the wiring harness from the TVA sensor to the ECU. Inspect
all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks.
at connector X-016 Insert a jumper wire between connector X-016 pin 8 and pin 53. Use a multi-meter to check
for continuity from the harness side of connector X-017 pin 41 and pin 42. There should be continuity.
4. Place the key switch OFF. Insert a jumper wire between connector X-016 pin 53 and pin 37. Use a multi-meter to
check for continuity from the harness side of connector X-017 pin 42 and pin 43. There should be continuity.
5. Remove the jumper wire. Check for a short to voltage in the wiring harness. Place the key switch ON. Use a
multi-meter to check for voltage from the harness side of connector:
A. If there is no voltage, the wiring harness is good. Replace the TVA sensor.
B. If there is voltage, there is a short to voltage in the wiring harness. Locate and repair damaged wiring.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 483
3835-ECU Power stages: Throttle valve actuator power stage: SRC

low
Context:
Cause:
The signal circuit is below 0.0 V.
1. Faulty wiring.
2. Faulty TVA sensor.
Solution:

at connector X-016. Use a multi-meter to check for continuity from the harness side of connector:
A. If there is no continuity, the wiring harness is in good condition. Replace the TVA sensor.
B. If there is continuity, there is a short circuit to ground condition in the wiring harness. Locate and repair dam-
aged wiring.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 484
3838-Oxidation catalyst upstream temperature shorted to high

source
Context:
The engine control unit (ECU) has detected the exhaust gas temperature sensor #1 sensed voltage is above 5.2 V.
Cause:
The exhaust gas temperature sensor #1 signal is shorted to a high voltage source.

2. Faulty sensor.
Solution:

Inspect the ECU and the Exhaust Gas Temperature Sensor connections. All connections should be secure, tight,
Inspect the harness from the ECU to the Exhaust Gas Temperature Sensors. Verify that the harness is free of
Disconnect ECU connector X-012. Disconnect the Temperature Sensor #1 connector.
Fabricate a jumper wire 20 cm (8 in) long. Use the jumper wire to short the Exhaust Gas Temperature Sensor
connector X-006 pin 1 to pin 2.
47540694 28/04/2014
55.16 [55.DTC] / 485
Disconnect the Temperature Sensor #1 connector.
Measure the resistance of the Exhaust Gas Temperature Sensor pin 1 to pin 2. The resistance should be approx-
imately 175 - 250 Ω.
B. The resistance is not within the specified range. Temporarily replace the temperature sensor and retest. Return
to step 1 to confirm the elimination of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 486
3839-Oxidation catalyst upstream temperature shorted to low

source
Context:
The engine control unit ( ECU) has detected the exhaust gas temperature sensor #1 sensed voltage is less than 0.0 V.
Cause:
The exhaust gas temperature sensor #1 signal is shorted to a ground source.

2. Faulty sensor.
Solution:

Inspect the ECU and the exhaust gas temperature sensor connections. All connections should be secure, tight,
Inspect the harness from the ECU to the exhaust gas temperature sensors. Verify that the harness is free of
Turn the key switch OFF
Disconnect ECU connector X-012. Disconnect the temperature sensor #1 connector.
than 20,000 Ω Wiggle the harness during measurement to reveal an intermittent condition.
47540694 28/04/2014
55.16 [55.DTC] / 487
Disconnect the temperature sensor #1 connector.
Measure the resistance of the exhaust gas temperature sensor #1 pin 1 to chassis ground. The resistance should
sensor and retest. chassis ground. Return to step 1 to confirm elimination of fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 488
3840-Diesel particulate filter upstream temperature sensor shorted

to high source
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Context:
The engine control unit (ECU) has detected the exhaust gas temperature sensor #2 sensed voltage is above 6.55 V.
Cause:
The exhaust gas temperature sensor #2 signal is shorted to a high voltage source.

2. Faulty sensor.
Solution:

Fabricate a jumper wire 20 cm (8 in) long. Use the jumper wire to short the exhaust gas temperature sensor
connector X-477 pin 1 to pin 2.
47540694 28/04/2014
55.16 [55.DTC] / 489
Disconnect the temperature sensor #2 connector.
Measure the resistance of the exhaust gas temperature sensor pin 1 to pin 2. The resistance should be approxi-
mately 175 - 250 Ω.
B. The resistance is not within the specified range. Temporarily replace the temperature sensor and retest. Return
to step 1 to confirm the elimination of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 490
3841-Diesel particulate filter upstream temperature sensor shorted

to low source
C232 TIER 4 [NDM451672 - ] NA
C238 TIER 4 [NCM425510 - ] NA
L225 TIER 4 [NDM461085 - ] NA
L230 TIER 4 [NCM449907 - ] NA
Context:
The engine control unit ( ECU) has detected the exhaust gas temperature sensor #2 sensed voltage is less than 0.0 V.
Cause:
The exhaust gas temperature sensor #2 signal is shorted to a ground source.

2. Faulty sensor.
Solution:

Turn the key switch OFF
47540694 28/04/2014
55.16 [55.DTC] / 491
Disconnect temperature sensor #2 connector.
Measure the resistance of the exhaust gas temperature sensor pin 1 to chassis ground. The resistance should be
A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU and retest. Go to step 1 to confirm the
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 492
3842-Turbine upstream temperature sensor shorted to high source

Context:
The engine control unit (ECU) has detected the inlet turbo temperature sensor sensed voltage is above 3.59 V.
Cause:
The inlet turbo temperature sensor signal is shorted to a high voltage source.

2. Faulty sensor.
Solution:

Inspect the ECU connector X-012 and the inline turbine temperature sensor connector. All connections should be
Inspect the harness from the ECU connector X-012 to the inline turbine temperature sensor connector. Verify that
the harness is free of damage, corrosion, abrasion and incorrect attachment.
Fabricate a jumper wire 20 cm (8 in) long. Use the jumper wire to short the inline turbine temperature sensor
connector pin 1 to pin 2.
Measure the resistance between the ECU connector X-012 pin 81 and pin 82. Wiggle the harness during mea-
required. Go to step 1 to confirm elimination of fault.
47540694 28/04/2014
55.16 [55.DTC] / 493
Measure the resistance between the component side of the inline turbine temperature sensor connector pin 1 to
pin 2. The resistance should be approximately 175 - 250 Ω.
B. The resistance is not within the specified range. Temporarily replace the inline turbine temperature sensor and
retest. Return to step 1 to confirm the elimination of the fault.
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 494
3843-Turbine upstream temperature sensor shorted to low source

Context:
The engine control unit ( ECU) has detected the inline turbine temperature sensor sensed voltage is less than 460 mV.
Cause:
The inline turbine temperature sensor signal is shorted to a ground source.

2. Faulty sensor.
Solution:

Inspect the ECU connector X-012 and the inline turbine temperature sensor connector. All connections should be
Inspect the harness from the ECU connector X-012 to the inline turbine temperature sensor connector. Verify that
the harness is free of damage, corrosion, abrasion and incorrect attachment.
Measure the resistance between ECU connector X-012 pin 82 and pin 81. The resistance should be greater than
20,000 Ω Wiggle the harness during measurement to reveal an intermittent condition.
greater than 20,000 Ω Wiggle the harness during measurement to reveal an intermittent condition.
47540694 28/04/2014
55.16 [55.DTC] / 495
Measure the resistance of the inline turbine temperature sensor connector pin 1 to chassis ground. The resistance
Mechanical Units
EH Units
47540694 28/04/2014
55.16 [55.DTC] / 496
3844-Zero fuel calibration by lambda (ZFL) : DFC reporting error

state on comparing energizing time to max value injector 1
Context:
This fault has been generated due to the injector (1, 2, 3 or 4) programming being incorrect. This failure can be the
result of wrong programming / flashing of the ECU or an internal defect of the injector. Using the Electronic Service
Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder. Repro-
gram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper data
set. If the error persists, replace the injector.
47540694 28/04/2014
55.16 [55.DTC] / 497

Context:
47540694 28/04/2014
55.16 [55.DTC] / 498

Context:
47540694 28/04/2014
55.16 [55.DTC] / 499

Context:
47540694 28/04/2014
55.16 [55.DTC] / 500

state on comparing energizing time to min value injector 1
Context:
This fault has been generated due to the injector (cylinder 1, 2, 3 or 4) programming being incorrect. This failure can
be the result of wrong programming / flashing of the ECU or an internal defect of the injector. Using the Electronic
Service Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder.
Reprogram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper
data set. If the error persists, replace the injector.
47540694 28/04/2014
55.16 [55.DTC] / 501

Context:
This fault has been generated due to the injector 2 (cylinder 3) programming being incorrect. This failure can be the
47540694 28/04/2014
55.16 [55.DTC] / 502

Context:
47540694 28/04/2014
55.16 [55.DTC] / 503

Context:
47540694 28/04/2014
55.16 [55.DTC] / 504
3852-Lambda sensor: The maximum allowed time for blow out is

exceeded
Context:
The heat up of the oxygen sensor is monitored by the ECU. If insufficient heater performance from the oxygen sensor
is detected for too long this fault code will occur. Replace the oxygen sensor.
47540694 28/04/2014
55.16 [55.DTC] / 505
3870-CAN message not received from Vehicle Controller

Context:
Cause:

3. Failure of ECM.
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 506
3899-Info: Engine temperature exceeded pre-warn level

Context:
This fault is caused when the engine temperature is getting to high. This fault can be caused by a cooling system
problem, high environmental temperatures or due to heavy engine use. If the environmental temperature is not too
high and the machine has not been used heavily, let the engine cool down. Then check the cooling system has the
correct amount of coolant. Make sure the radiator is not clogged or is restricted of air flow. Also, check the thermostat
is not stuck. Once everything has been checked, if everything is correct, erase the fault code.
47540694 28/04/2014
55.16 [55.DTC] / 507
3900-Info: Engine temperature exceeded warn level

Context:
47540694 28/04/2014
55.16 [55.DTC] / 508
3906-Injector: Number of injections is limited by quantity balance

of high pressure pump
Context:
47540694 28/04/2014
55.16 [55.DTC] / 509
3910-Fuel metering unit: Error check for loose contact between

metering unit and ECU
Context:
The engine control unit (ECU) has detected a loose contact in the wiring of the metering unit. This can result in a
malfunction of the metering unit and lead to fuel pressure oscillations. Check all connections between fuel metering
unit to the ECU are good. Remove connectors and check that the pins are not bent or corroded. Check the wiring
harness is not damaged. If any damaged or issues are found, repair/replace damaged connectors, or wiring. Use a
multi-meter to measure the resistance of the fuel metering solenoid from pin 1 to pin 2. There should be approximately
3.2 Ω. If the coil resistance is not correct, replace the fuel metering unit.
47540694 28/04/2014
55.16 [55.DTC] / 510
3915-Pressure Relief Valve: Averaged rail pressure is outside the

expected range with open PRV
Context:
The engine control unit (ECU) has determined that the Pressure Relief Valve (PRV) is not opening completely or there
is a restriction at the PRV connections. Remove the PRV valve and check for any damages. If PRV is damaged,
replace the valve.
47540694 28/04/2014
55.16 [55.DTC] / 511
4043-Hydraulic Oil Temperature Sender Short To Ground

Context:
The hydraulic oil temperature signal is shorted to ground.
Cause:
The hydraulic oil temperature signal, X-C23 pin 16 has a short circuit. The oil temperature sensor resistance is less
than 25 Ω.
1. Faulty wiring or connections from the hydraulic oil temperature sensor to the instrument cluster.
2. Faulty sensor.
3. Faulty instrument cluster
Solution:
(1) Start and operate machine.
(2)Use the Electronic Service Tool to view active fault codes. Prior to clearing fault codes write down all fault
codes, number of occurrences, and engine hours at last occurrence.

(1) Inspect Instrument Cluster connector X-C23 and the Hydraulic Oil Temperature Sensor connections. All con-
nections should be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster to the Hydraulic Oil Temperature Sensor. Verify that the har-
ness is free of damage, corrosion, abrasion and incorrect attachment.
RAPH12SSL0141FA 1
Schematic Legend
(1) Instrument Cluster connector (2) Hydraulic oil temperature sensor
X-C23 pin 16
3. Measure the temperature of the signal wire to chassis ground.
47540694 28/04/2014
55.16 [55.DTC] / 512
(2) Disconnect the Instrument Cluster connector X-C23 and the hydraulic oil temperature sensor connector.
(3) Measure the resistance from Hydraulic Oil Temperature Sensor signal wire X-C23 pin 16 to chassis ground.
The resistance should be greater than 20,000 Ω . Wiggle the harness during measurement to reveal an intermittent
condition.
as required. Return to Step 1 to confirm elimination of the fault.
4. Measure the resistance of the Temperature Sensor
(1) Measure the resistance of the temperature sensor to chassis ground.

110 °C (230 °F) 130 Ω
105 °C (221 °F) 151 Ω
100 °C (212 °F) 175 Ω
95 °C (203 °F) 202 Ω
92 °C (198 °F) 223 Ω
88 °C (190 °F) 258 Ω
85 °C (185 °F) 280 Ω
81 °C (178 °F) 323 Ω
78 °C (172 °F) 358 Ω
74 °C (165 °F) 412 Ω
68 °C (154 °F) 511 Ω
16 °C (61 °F) 4250 Ω
A. The resistance measurements are within the values from the table. The measured resistance is greater than
30 Ω. Temporarily replace the Instrument Cluster and retest. Go to Step 1.
B. The resistance measurements are not within range. The measured resistance is less than 30 Ω. Temporarily
replace the temperature sensor and retest. Go to Step 1 to confirm elimination of fault.
EH Units F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 513
4044-Hydraulic Oil Temperature Sender Open Circuit

Context:
The instrument cluster detects an open circuit in the hydraulic oil temperature signal.
Cause:
The hydraulic oil temperature signal, X-C23 pin 16 has an open circuit. The oil temperature sensor resistance is
1. Faulty wiring or connections from the hydraulic oil temperature sensor to the instrument cluster.
2. Faulty hydraulic oil temperature sensor.
Solution:
(1) Start and operate machine.
(2)Use the Electronic Service Tool to view active fault codes. Prior to clearing fault codes write down all fault
codes, number of occurrences, and engine hours at last occurrence.

(1) Inspect Instrument Cluster connector X-C23 and the hydraulic oil temperature sensor connections. All connec-
tions should be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the instrument cluster to the hydraulic oil temperature sensor. Verify that the harness
is free of damage, corrosion, abrasion and incorrect attachment.
RAPH12SSL0141FA 1
Schematic Legend
(1) Instrument Cluster connector (2) Hydraulic oil temperature sensor
X-C23 pin 16
3. Measure the resistance of the temperature signal wire.
47540694 28/04/2014
55.16 [55.DTC] / 514
(1) Turn the key switch OFF. Disconnect the Instrument cluster connector X-C23 and the Hydraulic Oil Temperature
Sensor connector.
(2) Measure the resistance from Hydraulic Oil Temperature Sensor pin 1 to X-C23 pin 16. The resistance should
(3) Measure the resistance from Hydraulic Oil Temperature Sensor pin 2 to chassis ground. The resistance should
B. The resistance is greater than 10 Ω. There is an open circuit in the wire. Repair or replace the harness as
4. Measure the resistance of the temperature signal wire to battery.
(2) Measure the voltage from X-C23 pin 16 to chassis ground. The voltage should be less than 0.5 V. Wiggle the
A. The voltage is less than 0.5 V. Go to Step 5.
harness as required. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance of the temperature sensor.
(1) Measure the resistance of the temperature sensor.

110 °C (230 °F) 130 Ω
105 °C (221 °F) 151 Ω
100 °C (212 °F) 175 Ω
95 °C (203 °F) 202 Ω
92 °C (198 °F) 223 Ω
88 °C (190 °F) 258 Ω
85 °C (185 °F) 280 Ω
81 °C (178 °F) 323 Ω
78 °C (172 °F) 358 Ω
74 °C (165 °F) 412 Ω
68 °C (154 °F) 511 Ω
16 °C (61 °F) 4250 Ω
A. The resistance measurements are within the values from the table. The measured resistance is less than
10,000 Ω. Temporarily replace the Instrument Cluster and retest. Go to Step 1.
B. The resistance measurements were not within range. The measured resistance is greater than 10,000 Ω.
Temporarily replace the temperature sensor and retest. Go to Step 1 to confirm elimination of fault.
EH Units F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 515

47540694 28/04/2014
55.16 [55.DTC] / 516
4055-Park Brake Valve (On/Off) - Solenoid Supply Open Circuit

Context:
The UCM has sensed an open circuit in the park brake solenoid circuit. Diagnostic Trouble Code 4055 has an error
priority of Red.
Ground drive is disabled while Diagnostic Trouble Code 4055 is active.
Cause:
The UCM has sensed an open circuit in the park brake solenoid circuit. The fault is active when UCM pin voltage,
X-CN3A pin 4 is less than 1 V or greater than 8 V.
1. Open wire in the circuit.

2. The park brake valve solenoid has failed.
3. The UCM has an internal failure.
Solution:

Inspect the UCM and the park brake solenoid connections. All connections should be secure, tight, free of corro-
Inspect the harness from the UCM to the park brake solenoid. Verify that the harness is free of damage, corrosion,
3. Measure the resistance through the solenoid wire.
Measure the resistance between X-CN3A pin 4 and chassis ground. The resistance should be less than 100 Ω.
A. The resistance is less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimi-
B. The resistance is greater than 100 Ω. There is an open circuit. Go to step 4.

4. Measure the resistance through the solenoid.
Disconnect the brake valve solenoid connector X-BRK.
47540694 28/04/2014
55.16 [55.DTC] / 517
Measure the resistance across the solenoid terminals. The resistance should be less than 100 Ω.
B. The resistance is greater than 100 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest.
5. Measure the resistance through the solenoid ground wire.
Leave connector X-BRK disconnected.
Measure the resistance between the solenoid ground wire, 960, BK and chassis ground. The resistance should
A. The resistance is less than 10 Ω. There is an open circuit between connector X-CN3A and connector X-BRK.
Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault.
B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid ground wire. Repair or replace
the harness as required. Return to step 1 to confirm elimination of the fault.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 518
4056-Park Brake Valve (On/Off) - Solenoid Supply Short to Ground

Context:
There is a problem in the park brake solenoid circuit. Diagnostic Trouble Code 4056 has an error priority of Red.
Cause:
The UCM has sent a signal to the park brake solenoid to energize, but no voltage is detected. The fault is active when
the hydraulics are enabled, the park brake is disabled, and the current for the park brake solenoid is greater than 3 A.
1. A wire has a short circuit to chassis ground.

2. The park brake valve has failed.
Solution:

Disconnect the park brake solenoid connector X-BRK.
47540694 28/04/2014
55.16 [55.DTC] / 519
Disconnect the brake valve solenoid connector X-BRK.
Measure the resistance across the solenoid terminals. The resistance should be between 7 Ω and 10 Ω.
A. The resistance is between 7 Ω and 10 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm
B. The resistance is less than 5 Ω. There is a short circuit in the solenoid. Replace the solenoid and retest. Return
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 520
4057-Park Brake Valve (On/Off) - Solenoid Supply Short to Power

Context:
The UCM has sent a signal to the park brake valve solenoid to de-energize, but voltage is still detected on the output
pin. Diagnostic Trouble Code 4057 has an error priority of Red.
Cause:
The UCM has sent a signal to the park brake valve solenoid to de-energize, but voltage is still detected on the output
pin. The fault is active while the hydraulics are disabled or the park brake is enabled and the voltage on the park
brake solenoid pin, X-CN3A pin 4 is greater than 8 V.
1. The solenoid signal wire has a short circuit to another voltage source.
Solution:

3. Measure the voltage on the solenoid wire.
Disconnect the park brake solenoid connector X-BRK.
of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 521
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 522
4061-Forward Pump Control Valves (Directional) - Solenoid Right

(A) Supply Open Circuit
Context:
The UCM has sensed improper Right Drive Pump Forward Solenoid current. Diagnostic Trouble Code 4061 has an
error priority of Red.
Forward ground drive is disabled while Diagnostic Trouble Code 4061 is active.
Cause:
The UCM has sensed improper Right Drive Pump Forward Solenoid current, X-CN3B pin 32. The fault is active while
the hydraulics are enabled and solenoid resistance is greater than normal.

2. Right Drive Pump Forward solenoid has failed in the open position.
Solution:

Inspect the UCM and the Right Drive Pump Forward connections. All connections should be secure, tight, free of
Inspect the harness from the UCM to the Right Drive Pump Forward solenoid. Verify that the harness is free of
Fabricate a jumper wire that will connect between the Right Drive Pump Forward solenoid connector X-17 pin 1
and X-17 pin 2.
Disconnect UCM connectors X-CN3B and X-CN2B.
Use the jumper wire to short X-17 pin 1 to X-17 pin 2.
Measure the resistance between X-CN3B pin 32 and X-CN2B pin 25. The resistance should be less than 10 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 523
B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal or solenoid ground line.
4. Test the UCM.
Leave the jumper wire installed between X-17 pin 1 and X-17 pin 2.
Reconnect UCM connectors X-CN3B and X-CN2B.
Activate the hydraulics while monitoring the fault code screen. Fault code 4061 should no longer be active. Fault
code 4062 should become active.
A. Fault code 4062 is active and fault code 4061 is no longer active. Temporarily replace the solenoid and retest.
B. Fault code 4061 is still active. Fault code 4062 did not become active. Temporarily replace the UCM and retest.
47540694 28/04/2014
55.16 [55.DTC] / 524
4062-Forward Pump Control Valves (Directional) - Solenoid Right

(A) Supply Short to Ground
Context:
The UCM has sent a signal to the Right Forward Ground Drive Solenoid to energize, but no voltage detected. Diag-
nostic Trouble Code 4062 has an error priority of Red.
Cause:
The UCM has sent a signal to the Right Forward Ground Drive Solenoid to energize, but no voltage detected. The
fault is active while the hydraulics are enabled and Aux Override is disabled, the park brake is off and the solenoid
output pin, X-CN3B pin 32 current is high.

2. Right Drive Pump Forward Solenoid has failed.
3. UCM has an internal failure.
Solution:

Inspect the UCM and the Right Drive Pump Forward connections. All connections should be secure, tight, free of
Inspect the harness from the UCM to the Right Drive Pump Forward solenoid. Verify that the harness is free of
Disconnect UCM connector X-CN3B, X-CN2B and the Right Drive Pump Forward solenoid connector X-17.
Measure the resistance between X-CN3B pin 32 and chassis ground. The resistance should be greater than
A. Both resistance measurements are greater than 20,000 Ω. Go to step 4.
47540694 28/04/2014
55.16 [55.DTC] / 525
B. One or both resistance measurements is less than 20,000 Ω. There is a short circuit to chassis ground. Repair
or replace the harness as required. Return step 1 to confirm elimination of the fault.
4. Test the UCM.
Reconnect UCM connectors X-CN3B and X-CN2B. Leave the Right Drive Pump Forward solenoid connector X-17
disconnected.
47540694 28/04/2014
55.16 [55.DTC] / 526
4071-Forward Pump Control Valves (Directional) - Solenoid Left

(B) Supply Open Circuit
Context:
The UCM has sensed improper Left Drive Pump Forward Solenoid current. Diagnostic Trouble Code 4071 has an
Cause:
The UCM has sensed improper Left Drive Pump Forward Solenoid current, X-CN3B pin 33. The fault is active while
1. An open wire in the circuit.

2. Left Drive Pump Forward solenoid has failed in the open position.
Solution:

Inspect the UCM and the Left Drive Pump Forward connections. All connections should be secure, tight, free of
Inspect the harness from the UCM to the Left Drive Pump Forward solenoid. Verify that the harness is free of
Fabricate a jumper wire that will connect between the Left Drive Pump Forward solenoid connector X-13 pin 1 and
X-13 pin 2.
47540694 28/04/2014
55.16 [55.DTC] / 527
4. Test the UCM.
Reconnect UCM connector X-CN3B and X-CN2B.
47540694 28/04/2014
55.16 [55.DTC] / 528
4072-Forward Pump Control Valves (Directional) - Solenoid Left (B)

Supply Short to Ground
Context:
The UCM has sent a signal to the Left Drive Pump Forward Solenoid to energize, but there is no voltage detected.
Cause:
The UCM has sent a signal to the Left Drive Pump Forward Solenoid to energize, but there is no voltage detected. The
fault is activate while the hydraulics are enabled and Aux Override is disabled and Parking Brake is off and solenoid
output pin, X-CN3B pin 33 current is high.
1. Shorted wire in the circuit.

2. The Left Drive Pump Forward Solenoid has failed.
Solution:

Inspect the UCM and the Left Drive Pump Forward connections. All connections should be secure, tight, free of
Inspect the harness from the UCM to the Left Drive Pump Forward solenoid. Verify that the harness is free of
Disconnect UCM connector X-CN3B, X-CN2B and the Left Drive Pump Forward solenoid connector X-13.
47540694 28/04/2014
55.16 [55.DTC] / 529
4. Test the UCM.
Reconnect UCM connectors X-CN3B and X-CN2B. Leave the Left Drive Pump Forward solenoid connector X-13
disconnected.
47540694 28/04/2014
55.16 [55.DTC] / 530
4081-Forward Pump Control Valves (Directional) - Common

Solenoid Return Short to Power
Context:
Forward Ground Drive is disabled while Diagnostic Trouble Code 4081 is active.
Cause:
UCM has sensed higher than normal voltage on the Forward Ground Drive Valve Solenoids ground line. The fault is
active while Hydraulics are disabled and solenoid voltage feedback is greater than 5 V.

Solution:

Inspect the UCM, the Right Drive Pump Forward and the Left Drive Pump Forward connections. All connections
should be secure, tight, free of corrosion, abrasion and damage.
Inspect the harness from the UCM to the Right Drive Pump Forward solenoid and Left Drive Pump Forward sole-
noid. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment.
3. Measure the voltage of the solenoid wires to chassis ground.
Disconnect solenoid connector X-17 and X-13. Disconnect UCM connector X-CN2B and X-CN3B.
Measure the voltage from X-17 pin 1 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness
47540694 28/04/2014
55.16 [55.DTC] / 531
A. All voltage measurement are less than 0.5 V. Go to step 4.
B. One or more voltage measurements is greater than 0.5 V. There is an short circuit to another voltage source.
Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.
4. Test the UCM.
Reconnect UCM connectors X-CN2B and X-CN3B. Leave connectors X-17 and X-13 disconnected.
A. Fault code 4083 is active and fault code 4081 is no longer active. Temporarily replace both solenoids and
47540694 28/04/2014
55.16 [55.DTC] / 532
4082-Forward Pump Control Valves (Directional) - Pumps Forward

Solenoids Short to Ground
Context:
The UCM has sensed that the solenoid return voltage is low. Diagnostic Trouble Code 4082 has an error priority of
Red.
Cause:
The UCM has sensed that the solenoid return voltage is low. The fault is active while the hydraulics are disabled and
solenoid return voltage feedback is low.

2. Failure of UCM.
Solution:

3. Measure the resistance of the solenoid wires to chassis ground.
Disconnect solenoid connector X-17 and X-13. Disconnect UCM connector X-CN2B and X-CN3B.
47540694 28/04/2014
55.16 [55.DTC] / 533
B. One or more resistance measurements is less than 20,000 Ω. There is an short circuit to chassis ground.
4. Test the UCM.
47540694 28/04/2014
55.16 [55.DTC] / 534
4083-Forward Pump Control Valves (Directional) - Common

Solenoid Return Open Circuit
Context:
The UCM has sensed improper Forward Pump Control Valve solenoid current. Diagnostic Trouble Code 4083 has
Forward ground drive operating mode is disabled while Diagnostic Trouble Code 4083 is active.
Cause:
The UCM has sensed improper Forward Pump Control Valve solenoid current, X-CN2B pin 25. The fault is active
when the hydraulics are enabled and solenoid return current is incorrect.
1. Open wire in solenoid ground circuit.

Solution:

Fabricate a jumper wire that will connect between the Right Drive Pump Reverse solenoid connector X-18 pin 1
and X-18 pin 2.
Disconnect UCM connectors X-CN2A and X-CN1A.
Disconnect connectors X-18 and X-16.
Measure the resistance between X-CN2A pin 8 and X-CN1A pin 19. The resistance should be less than 10 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 535
A. Both resistance measurements are less than 10 Ω. Go to step 4.
B. One or both resistance measurements is greater than 10 Ω. There is an open circuit in the solenoid signal or
solenoid ground line. Check splice SP-098. Repair or replace the harness as required. Return to step 1 to
4. Test the UCM.
47540694 28/04/2014
55.16 [55.DTC] / 536
4309-Park Brake Button - Park Brake Button Timeout (30 sec)

Context:
Diagnostic Trouble Code 4309 has an error priority of White. White errors are not displayed on the instrument cluster
codes.
Cause:
The UCM has sensed that the signal has failed. The fault is active when the voltage on the park brake input, X-CN2B
pin 22 is greater than 10 V for more than 30 s.
1. Signal wire has a short circuit to another voltage source.

2. Failure of the park brake switch.
Solution:

Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion,
Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion,
Disconnect UCM connector X-CN2B. Disconnect right joystick harness X-406.
Measure the voltage between X-406 pin B to chassis ground. The voltage should be less than 0.5 V. Wiggle the
B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Verify wire is not shorted to
another voltage source. Repair or replace the harness or connectors as required. Return to step 1 to confirm
47540694 28/04/2014
55.16 [55.DTC] / 537
4. Test the switch.
Leave connector X-406 disconnected.
Verify that the parking brake switch is in the OFF position.
Measure the resistance between park brake switch pin A and pin B. The resistance should be greater than
20,000 Ω.
A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm
B. The resistance is less than 20,000 Ω. The switch has an internal short circuit. Replace the switch and retest.
Small EH machines
Case models
New Holland models
Medium EH machines
Case models
New Holland models
47540694 28/04/2014
55.16 [55.DTC] / 538
4361-Reverse Pump Control Valves (Directional) - Solenoid Right

Context:
The UCM has sensed improper Right Drive Pump Reverse Solenoid current. Diagnostic Trouble Code 4361 has an
Reverse ground drive is disabled while Diagnostic Trouble Code 4361 is active.
Cause:
The UCM has sensed improper Right Drive Pump Reverse Solenoid current, X-CN2A pin 8. The fault is active while
1. An open wire in circuit.

2. The Right Drive Pump Reverse solenoid has failed in the open position.
3. The UCM has internal failure.
Solution:

Inspect the UCM and the Right Drive Pump Reverse connections. All connections should be secure, tight, free of
Inspect the harness from the UCM to the Right Drive Pump Reverse solenoid. Verify that the harness is free of
Fabricate a jumper wire that will connect between the Right Drive Pump Reverse solenoid connector X-18 pin 1
and X-18 pin 2.
47540694 28/04/2014
55.16 [55.DTC] / 539
Check splice SP-099. Repair or replace the harness as required. Return to step 1 to confirm elimination of the
fault.
4. Test the UCM.
Reconnect UCM connector X-CN2A and X-CN1A.
47540694 28/04/2014
55.16 [55.DTC] / 540
4362-Reverse Pump Control Valves (Directional) - Solenoid Right

(A) Supply Short to Ground
Context:
The UCM has sent a signal to the Right Reverse Ground Drive Solenoid to energize, but no voltage detected. Diag-
Cause:
The UCM has sent a signal to the Right Reverse Ground Drive Solenoid to energize, but there is no voltage detected.
The fault is active when hydraulics are enabled and Aux Override is disabled and Park Brake is off and solenoid output
pin, X-CN2A pin 8 current is high.

2. The Right Drive Pump Reverse Solenoid has failed.
Solution:

Inspect the UCM and the Right Drive Pump Reverse connections. All connections should be secure, tight, free of
Inspect the harness from the UCM to the Right Drive Pump Reverse solenoid. Verify that the harness is free of
Disconnect UCM connector X-CN2A, X-CN1A and Right Drive Pump Reverse solenoid connector X-18.
47540694 28/04/2014
55.16 [55.DTC] / 541
4. Test the UCM.
Reconnect UCM connectors X-CN2A and X-CN1A. Leave the Right Drive Pump Reverse solenoid connector X-18
disconnected.
47540694 28/04/2014
55.16 [55.DTC] / 542
4371-Reverse Pump Control Valves (Directional) - Solenoid Left

Context:
The UCM has sensed improper Left Drive Pump Reverse Solenoid current. Diagnostic Trouble Code 4371 has an
Cause:
the UCM has sensed improper Left Drive Pump Reverse Solenoid current, X-CN2A pin 14. The fault is active while

2. The Left Drive Pump Reverse solenoid has failed in the open position.
Solution:

Inspect the UCM and the Left Drive Pump Reverse connections. All connections should be secure, tight, free of
Inspect the harness from the UCM to the Left Drive Pump Reverse solenoid. Verify that the harness is free of
Fabricate a jumper wire that will connect between the Left Drive Pump Reverse solenoid connector X-16 pin 1 and
X-16 pin 2.
47540694 28/04/2014
55.16 [55.DTC] / 543
4. Test the UCM.
Reconnect UCM connector X-CN2A and X-CN1A.
47540694 28/04/2014
55.16 [55.DTC] / 544
4372-Reverse Pump Control Valves (Directional) - Solenoid Left (B)

Context:
The UCM has sent a signal to the Left Drive Pump Reverse Solenoid to energize, but no voltage detected. Diagnostic
Trouble Code 4372 has an error priority of Red.
Reverse Ground Drive is disabled while Diagnostic Trouble Code 4372 is active.
Cause:
The UCM has sent a signal to the Left Drive Pump Reverse Solenoid to energize, but no voltage detected. The fault
is active when the hydraulics are enabled and Aux Override is disabled and Parking Brake is off and solenoid output
pin, X-CN2A pin 14 current is high.

2. The Left Drive Pump Reverse Solenoid has failed.
Solution:

Inspect the UCM and the Left Drive Pump Reverse connections. All connections should be secure, tight, free of
Inspect the harness from the UCM to the Left Drive Pump Reverse solenoid. Verify that the harness is free of
Disconnect UCM connector X-CN2A, X-CN1A and the Left Drive Pump Reverse solenoid connector X-16.
47540694 28/04/2014
55.16 [55.DTC] / 545
4. Test the UCM.
Reconnect UCM connectors X-CN2A and X-CN1A. Leave the Left Drive Pump Reverse solenoid connector X-16
disconnected.
47540694 28/04/2014
55.16 [55.DTC] / 546
4381-Reverse Pump Control Valves (Directional) - Common

Solenoid Return Short to Power
Context:
The UCM has sensed higher than normal voltage on the Reverse Ground Drive Valve Solenoids ground line. Diag-
Cause:
The UCM has sensed higher than normal voltage on the Reverse Ground Drive Valve Solenoids ground line. The
fault is active while hydraulics are disabled and solenoid voltage feedback is greater than 5 V.

Solution:

Inspect the UCM, the Right Drive Pump Reverse and the Left Drive Pump Reverse connections. All connections
Inspect the harness from the UCM to the Right Drive Pump Reverse solenoid and Left Drive Pump Reverse sole-
3. Measure the voltage of the solenoid wires to chassis ground.
Disconnect solenoid connector X-18 and X-16. Disconnect UCM connector X-CN2A and X-CN1A.
47540694 28/04/2014
55.16 [55.DTC] / 547
A. All voltage measurement are less than 0.5 V. Go to step 4.
B. One or more voltage measurements is greater than 0.5 V. There is an short circuit to another voltage source.
4. Test the UCM.
Reconnect UCM connectors X-CN2A and X-CN1A. Leave connectors X-18 and X-16 disconnected.
47540694 28/04/2014
55.16 [55.DTC] / 548
4382-Reverse Pump Control Valves (Directional) - Pumps Reverse

Context:
The UCM has sensed that the solenoid return voltage is low. Diagnostic Trouble Code 4382 has an error priority of
Red.
Cause:
The UCM has sensed that the solenoid return voltage is low. The fault is active when the hydraulics are disabled and
solenoid return voltage feedback is low.

2. Failure of UCM.
Solution:

RAPH12SSL0385FA 1
47540694 28/04/2014
55.16 [55.DTC] / 549
Schematic legend
(1) Pump Right Reverse (6) Pump Right Forward
UCM Connector UCM Connector
X-CN2A pin 8 X-CN3B pin 32
(2) Pump Left Reverse (7) Pump Left Forward
(3) M-018 Right Drive Pump Reverse (8) M-017 Right Drive Pump Forward
(4) M-016 Left Drive Pump Reverse (9) M-013 Left Drive Pump Forward
(5) Drive Reverse Return (10) Drive Forward Return
(1) Inspect the UCM, Right Drive Pump Reverse and Left Drive Pump Reverse connections. All connections
(2) Inspect the harness from the UCM to the Right Drive Pump Reverse solenoid and Left Drive Pump Reverse
solenoid. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment.
3. Measure the resistance of the solenoid wires to chassis ground.
Disconnect solenoid connector X-18 and X-16. Disconnect UCM connector X-CN2A and X-CN1A.
4. Test the UCM.
Reconnect UCM connectors X-CN2A and X-CN1A. Leave connectors X-18 and X-16 disconnected.
47540694 28/04/2014
55.16 [55.DTC] / 550

47540694 28/04/2014
55.16 [55.DTC] / 551
4383-Reverse Pump Control Valves (Directional) - Common

Solenoid Return Open Circuit
Context:
The UCM has sensed improper Forward Pump Control Valve solenoid current. Diagnostic Trouble Code 4383 has
Reverse ground drive operating mode is disabled while Diagnostic Trouble Code 4383 is active.
Cause:
The UCM has sensed improper Forward Pump Control Valve solenoid current, X-CN1A pin 19. The fault is active
when the hydraulics are enabled and solenoid return current is incorrect.
1. Open wire in solenoid ground circuit.

Solution:

Inspect the UCM, the Right Drive Pump Reverse and the Left Drive Pump Reverse connections. All connections
Inspect the harness from the UCM to the Right Drive Pump Reverse solenoid and Left Drive Pump Reverse sole-
Fabricate a jumper wire that will connect between the Right Drive Pump Forward solenoid connector X-17 pin 1
and X-17 pin 2.
Disconnect connectors X-17 and X-13.
47540694 28/04/2014
55.16 [55.DTC] / 552
B. One or both resistance measurements is greater than 10 Ω. There is an open circuit in the solenoid signal or
solenoid ground line. Check splice SP-098. Repair or replace the harness as required. Return to step 1 to
4. Test the UCM.
Reconnect UCM connector X-CN3B and X-CN2B.
47540694 28/04/2014
55.16 [55.DTC] / 553
4401-Park Brake (Mechanical Machines) - Park Brake Solenoid

- Open Circuit
Context:
Cause:
The instrument cluster has sent a signal to the brake valve solenoid to energize, but the solenoid is off. The fault is
activate while the instrument cluster solenoid output, X-C23 pin 28 is off and brake commanded state, X-C23 pin 21
is high.

2. The brake valve solenoid has failed.
Solution:

RAPH12SSL0400FA 1
47540694 28/04/2014
55.16 [55.DTC] / 554
Schematic legend
(1) Instrument cluster (3) Cab to interface harness
Connector X-C23 Connector X-CC2A/2B pin 3
(2) Park brake switch signal to the instrument (4) Park brake solenoid
cluster. Connector X-BRK
(1) Inspect the instrument cluster and the park brake solenoid connections. All connections should be secure,
(2) Inspect the harness from the instrument cluster to the park brake solenoid. Verify that the harness is free of
(2) Disconnect instrument cluster connector X-C23 .
(3) Measure the resistance between X-C23 pin 28 and chassis ground. The resistance should be less than 100 Ω.
A. The resistance is less than 100 Ω. Temporarily replace the instrument cluster and retest. Return to Step 1 to
B. The resistance is greater than 100 Ω. There is an open circuit. Go to Step 4.

(1) Disconnect the brake valve solenoid connector X-BRK.
(2) Measure the resistance across the solenoid terminals. The resistance should be less than 100 Ω.
Return to Step 1 to confirm elimination of the fault.
5. Measure the resistance through the solenoid ground wire.
(1) Leave connector X-BRK disconnected.
(2) Measure the resistance between the solenoid ground wire, 960, BK and chassis ground. The resistance should
A. The resistance is less than 100 Ω. There is an open circuit between connector X-C23 and connector X-BRK .
Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault.
B. The resistance is greater than 100 Ω. There is an open circuit in the solenoid ground wire. Repair or replace
the harness as required. Return to Step 1 to confirm elimination of the fault.
F5H engine
Case machines ISM engine
47540694 28/04/2014
55.16 [55.DTC] / 555

New Holland machines ISM engine
47540694 28/04/2014
55.16 [55.DTC] / 556
4402-Park Brake (Mechanical Machines) - Park Brake Solenoid -

Short to Power
Context:
Vehicle is disabled while Diagnostic Trouble Code 4402 is active.
Cause:
The instrument cluster has sent a signal to the brake valve solenoid to de-energize, but the solenoid remains on. The
fault is activate while the instrument cluster solenoid output, X-C23 pin 28 is off, the brake commanded state, X-C23
pin 21 is low.
1. Signal wire is has a short circuit to another voltage source.

2. Instrument Cluster has an internal failure.
Solution:

RAPH12SSL0400FA 1
47540694 28/04/2014
55.16 [55.DTC] / 557
Schematic legend
(1) Instrument cluster (3) Cab to interface harness
Connector X-C23 Connector X-CC2A/2B pin 3
(2) Park brake switch signal to the instrument (4) Park brake solenoid
cluster. Connector X-BRK
(1) Inspect the instrument cluster and the park brake solenoid connections. All connections should be secure,
(2) Inspect the harness from the instrument cluster to the park brake solenoid. Verify that the harness is free of
3. Measure the voltage through the solenoid wire.
(3) Disconnect the park brake solenoid connector X-BRK .
(5) Measure the voltage between X-C23 pin 28 and chassis ground. The voltage should be less than 0.5 V. Wiggle
A. The voltage is less than 0.5 V. Temporarily replace the instrument cluster and retest. Return to Step 1 to confirm
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 558
4431-Park Brake Pressure Switch - Pressure Switch (Plausibility

Check With Solenoid Valve)
Context:
UCM has sensed disagreement between the park brake pressure switch and the park brake solenoid. Diagnostic
Trouble Code 4431 has an error priority of amber.
Cause:
UCM has sensed disagreement between the park brake pressure switch and the park brake solenoid. The fault is
active while engine is running and the park brake pressure switch input X-CN2B pin 13 is ON and the solenoid current
output X-CN3A pin 4 is less than 1 A or
The park brake pressure switch input X-CN2B pin 13 is OFF and the solenoid current output X-CN3A pin 4 is greater
than 1 A.
1. Low charge pressure.

2. Open or shorted wire in the circuit.
3. Failure of the park brake solenoid.
4. Failure of the park brake pressure switch.
Solution:

2. Verify the charge pressure.
Verify the charge pressure is approximately 2482 kPa (360 psi) at low idle.
Verify the charge pressure is approximately 2758 kPa (400 psi) at full throttle.
A. Charge pressure is in the correct range and fault code 4431 is still active. Go to step 3.
B. Charge pressure is not correct. Repair the cause of low charge pressure and retest. Return to step 1 to confirm
Inspect the UCM, the park brake solenoid and the park brake switch connections. All connections should be
Inspect the harness from the UCM to the park brake solenoid and the park brake switch. Verify that the harness
is free of damage, corrosion, abrasion and incorrect attachment.
47540694 28/04/2014
55.16 [55.DTC] / 559
4. Use EST to test the system.
Turn the park brake switch OFF.
Use the EST to access the status of the park brake pressure switch. The switch status should be OFF.
EST park brake parameters

Reference Data Description Source
534 Park Brake Button UCM
670 Park Brake Indicator Lamp Instrument Cluster
539 Park Brake Pressure Switch UCM
518 Park Brake Solenoid Output (EH machines only) UCM
502 Park Brake Status UCM
Enable the hydraulic system.
Use the EST to access the status of the park brake valve. The valve status should OFF.
A. The park brake switch status is ON. The solenoid status is OFF. Fault code 4309 will be come active after 30
minutes. Go to troubleshooting procedure 4309.
B. The park brake switch status is OFF. The solenoid status is ON. Fault code 4056 is active. Go to troubleshoot-
ing procedure 4056.
C. The park brake switch status is OFF and the solenoid status is OFF. Fault code 4431 is not active. Go to step
5 to confirm elimination of fault.
5. Use EST to test the system.
Turn the ignition switch ON and start the engine.
Turn the park brake switch ON.
Use the EST to access the status of the park brake pressure switch. The switch status should be ON.
Use the EST to access the status of the park brake valve. The valve status should ON.
A. The park brake switch status is OFF. The solenoid status is ON. Fault code 4431 is active. Go to step 6.
B. The park brake switch status is ON and the solenoid status is ON. Fault code 4431 is not active. There does
not appear to be a problem at this time. OK to return the machine to service.
Disconnect park brake switch connector X-BRKPRS.
Fabricate and install a jumper wire that will connect between X-BRKPRS pin 1 and pin 2.
Turn the ignition switch ON and start the engine.
Turn the park brake switch ON.
Use the EST to access the status of the park brake pressure switch. The switch status should be ON.
A. The park brake status is ON. Fault code 4431 is no longer active. Replace the pressure switch. Return to step
B. The park brake status is OFF. Fault code 4431 is still active. Go to step 7.
7. Measure the resistance through the wire.
47540694 28/04/2014
55.16 [55.DTC] / 560
Leave the jumper wire installed between X-BRKPRS pin 1 and pin 2.
Disconnect UCM connector X-CN2B.
Measure the resistance between X-CN2B pin 13 and chassis ground. The resistance should be less than 10 Ω.
B. The resistance is greater than 10 Ω. There is an open circuit in the wire. Go to step 8.
8. Measure the resistance of the solenoid ground wire.
Remove the jumper wire between X-BRKPRS pin 1 and pin 2.
Measure the resistance between X-BRKPRS pin 2 and chassis ground. The resistance should be less than 10 Ω.
A. The resistance is less than 10 Ω. There is an open circuit in the wiring between the UCM and the park brake
pressure switch. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault.
B. The resistance is greater than 10 Ω. There is an open circuit in the ground circuit. Verify the chassis ground
connections are tight and secure. Repair or replace the harness as required. Return to step 1 to confirm
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 561
4731-Right Swash Plate Sensor - Pin A Short to Ground/ Open

Circuit Right Hand Pump Angle #1
Context:
The UCM has sensed that the swash plate angle sensor signal has failed. Diagnostic Trouble Code 4731 has an error
priority of Amber.
Limp home ground drive operating mode is enabled while Diagnostic Trouble Code 4731 is active.
Cause:
The UCM has sensed that the swash plate angle sensor signal has failed low. The fault is active while the engine is
on and the Right Swash Plate Angle Sensor voltage, X-CN2B pin 32 is less than 0.2 V.
1. A short circuit to chassis ground.

2. An open circuit in the sensor signal wire.
3. Failure of the Swash Plate Angle Sensor.
Solution:

Inspect the UCM, the Left Hand Swash Plate sensor connection and the Right Hand Swash Plate sensor connec-
tion. All connections should be secure, tight, free of corrosion, abrasion and damage.
Inspect the harness from the UCM to the swash plate sensors. Verify that the harness is free of damage, corrosion,
Disconnect the Right Hand Swash Plate Sensor connector X-93.
Measure the voltage between X-93 pin 5 and X-93 pin 1. The voltage should be approximately 12 V. Wiggle the
47540694 28/04/2014
55.16 [55.DTC] / 562
A. The voltage measurement is approximately 12 V. Go to step 4.
B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to
the sensor. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination
of fault.
Disconnect UCM connector X-CN2B. Disconnect Right Hand Swash Plate Sensor connector X-93.
Measure the resistance from connector X-CN2B pin 32 to chassis ground. The resistance should be greater than
A. The resistance measurement is greater than 20,000 Ω. Go to step 5.
B. The resistance measurement is less than 20,000 Ω. There is a short circuit to chassis ground in the signal
wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault.
Fabricate a jumper wire that will connect between the UCM connector X-CN2B and chassis ground.
Disconnect connectors X-CN2B and X-93.
Use the jumper wire to connect X-CN2B pin 32 to chassis ground.
Measure the resistance between X-93 pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle
A. The resistance measurement is less than 10 Ω. Go to step 6.
B. The resistance measurement is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace
the harness or connectors as required. Return to step 1 to confirm elimination of fault.
6. Test the UCM.
Remove the jumper wire. Reconnect UCM connector X-CN2B.
Disconnect swash plate sensor connectors X-93 and X-94.
Connect the left hand swash plate sensor into the right hand swash plate sensor connector X-93.
Connect the right hand swash plate sensor into the left hand swash plate sensor connector X-94.
Monitor the active diagnostic screen. Fault code 4731 should no longer be active. Fault code 4744 is active.
A. Fault code 4731 is no longer active. Fault code 4744 is active. Replace the Swash Plate Angle sensor and
B. Fault code 4731 is still active. Fault code 4744 did not become active. Replace the UCM and retest. Return
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 563

47540694 28/04/2014
55.16 [55.DTC] / 564
4732-Right Swash Plate Sensor - Pin A Short to Power Right Hand

Pump Angle #1
Context:
he UCM has sensed a higher than normal voltage from the right hand swash plate sensor. Diagnostic Trouble Code
4732 has an error priority of Amber.
Cause:
The UCM has sensed a higher than normal voltage from the right hand swash plate sensor. The fault is active while
the engine is on and the swash plate angle sensor voltage, X-CN2B pin 32 is greater than 4.8 V.
1. The signal wire has a short circuit to another voltage source.

2. Failure of the swash plate sensor.
Solution:

Inspect the UCM, the left hand swash plate sensor connection and the right hand swash plate sensor connection.
All connections should be secure, tight, free of corrosion, abrasion and damage.
3. Measure the voltage on the sensor signal wire.
Disconnect the right hand swash plate sensor connector X-93. Disconnect UCM connector X-CN2B.
Measure the voltage between X-93 pin 4 and chassis ground. The voltage should be less than 0.5 V. Wiggle the
A. The voltage measurement is less than 0.5 V. Go to step 4.
B. The voltage measurement is greater than 0.5 V. There is a short circuit to another voltage source. Repair or
replace the harness or connectors as required. Return to step 1 to confirm elimination of fault.
47540694 28/04/2014
55.16 [55.DTC] / 565
4. Test the UCM.
Reconnect UCM connector X-CN2B.
Connect the left hand swash plate sensor harness on to the right hand swash plate sensor.
Connect the right hand swash plate sensor harness on to the left hand swash plate sensor.
A. Fault code 4732 is no longer active. Fault code 4745 is active. Replace the right hand swash plate angle
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 566
4734-Right Swash Plate Angle Sensor - Pin B Short to Ground/

Open Circuit Right Hand Pump Angle #2
Context:
The UCM has sensed that the swash plate angle sensor signal has failed. Diagnostic Trouble Code 4734 has an error
priority of Amber.
Cause:
on and the Right Swash Plate Angle Sensor voltage, X-CN2B pin 33 is less than 0.2 V.

Solution:

3. Measure the supply voltage to the sensor.
47540694 28/04/2014
55.16 [55.DTC] / 567
of fault.
Fabricate a jumper wire with alligator clips that can reach between the UCM connector X-CN2B and chassis
ground.
6. Test the UCM.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 568

47540694 28/04/2014
55.16 [55.DTC] / 569
4735-Right Swash Plate Angle Sensor - Pin B Short to Power Right

Hand Pump Angle #2
Context:
Limp Home Ground Drive operating mode is enabled while Diagnostic Trouble Code 4735 is active.
Cause:
The UCM has sensed a higher than normal voltage from the right hand swash plate sensor. The fault is active while
the engine is on and the swash plate angle sensor voltage, X-CN2B pin 33 is greater than 4.8 V.

Solution:

Disconnect the right hand swash plate sensor connector X-93. Disconnect UCM connector X-CN2B.
47540694 28/04/2014
55.16 [55.DTC] / 570
4. Test the UCM.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 571
4737-Right Swash Plate Angle Sensor - In Range Fault Right Hand

Pump Angle #1 and Right Hand Pump Angle #2
Context:
The UCM has sensed that the right swash plate angle sensor has failed. Diagnostic Trouble Code 4737 has an error
priority of Amber.
Cause:
The UCM has sensed that the right swash plate angle sensor has failed. The fault is active while of the swash plate
angle sensor inputs, X-CN2B pin 32 and X-CN2B pin 33 are less than 4.8 V or greater than 5.2 V.
1. An open circuit in the supply voltage to the sensor.

Solution:

Disconnect the right hand swash plate sensor connector X-93.
47540694 28/04/2014
55.16 [55.DTC] / 572
the sensor. Check splice SP-136. Repair or replace the harness or connectors as required. Return to step 1
to confirm elimination of fault.
A. Both resistance measurement are greater than 20,000 Ω. Go to step 5.
B. One or both resistance measurements are less than 20,000 Ω. There is a short circuit to chassis ground in the
signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination
of fault.
Fabricate a jumper wire with alligator clips that can reach between the UCM connector X-CN2B and chassis
ground.
Remove the jumper wire from X-CN2B pin 32.
B. One or both resistance measurements are greater than 10 Ω. There is an open circuit in the signal wire. Repair
6. Test the UCM.
47540694 28/04/2014
55.16 [55.DTC] / 573
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 574
4741-Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open

Circuit Left Hand Angle #1
Context:
The UCM has sensed that the swash plate angle sensor signal has failed low. Diagnostic Trouble Code 4741 has an
error priority of Amber.
Cause:
on and the Left Swash Plate Angle Sensor voltage, X-CN3A pin 9 is less than 0.2 V.

Solution:

Disconnect the Left Hand Swash Plate Sensor connector X-94.
47540694 28/04/2014
55.16 [55.DTC] / 575
of fault.
Disconnect UCM connector X-CN3A. Disconnect the Left Hand Swash Plate Sensor connector X-94.
Measure the resistance from connector X-CN3A pin 9 to chassis ground. The resistance should be greater than
Fabricate a jumper wire that will connect between the UCM connector X-CN3A and chassis ground.
Disconnect X-CN3A and X-94.
Use the jumper wire to connect X-CN3A pin 9 to chassis ground.
6. Test the UCM.
Remove the jumper wire. Reconnect UCM connector X-CN3A.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 576

47540694 28/04/2014
55.16 [55.DTC] / 577
4742-Left Swash Plate Angle Sensor - Pin A Short to Power Left

Hand Angle #1
Context:
The UCM has sensed a higher than normal voltage from the left hand swash plate sensor. Diagnostic Trouble Code
Cause:
The UCM has sensed a higher than normal voltage from the left hand swash plate sensor. The fault is active while
the engine is on and the swash plate angle sensor voltage, X-CN3A pin 9 is greater than 4.8 V.

Solution:

All connections should be secure, tight, free of corrosion, abrasion, and damage.
abrasion, and incorrect attachment.
Disconnect the left hand swash plate sensor connector X-94. Disconnect UCM connector X-CN3A.
47540694 28/04/2014
55.16 [55.DTC] / 578
4. Test the UCM.
Reconnect UCM connector X-CN3A.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 579
4744-Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open

Circuit Left Hand Pump Angle #2
Context:
The UCM has sensed that the swash plate angle sensor signal has failed low. Diagnostic Trouble Code 4744 has an
Cause:
on and the Left Swash Plate Angle Sensor voltage, X-CN3A pin 10 is less than 0.2 V.

Solution:

3. Measure the supply voltage to the sensor.
47540694 28/04/2014
55.16 [55.DTC] / 580
of fault.
Disconnect UCM connector X-CN3A. Disconnect Left Hand Swash Plate Sensor connector X-94.
Fabricate a jumper wire with alligator clips that can reach between the UCM connector X-CN3A and chassis
ground.
Disconnect connectors X-CN3A and X-94.
6. Test the UCM.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 581

47540694 28/04/2014
55.16 [55.DTC] / 582
4745-Left Swash Plate Angle Sensor - Pin B Short to Power Left

Hand Pump Angle #2
Context:
The UCM has sensed a higher than normal voltage from the left hand swash plate sensor. Diagnostic Trouble Code
Cause:
The UCM has sensed a higher than normal voltage from the left hand swash plate sensor. The fault is active while
the engine is on and the swash plate angle sensor voltage, X-CN3A pin 10 is greater than 4.8 V.

Solution:

Disconnect the right hand swash plate sensor connector X-94. Disconnect UCM connector X-CN3A.
47540694 28/04/2014
55.16 [55.DTC] / 583
4. Test the UCM.
Reconnect UCM connector X-CN3A.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 584
4747-Left Swash Plate Angle Sensor - In Range Fault Left Hand

Pump Angle #1 and Left Hand Pump Angle #2
Context:
The UCM has sensed that the left swash plate angle sensor has failed. Diagnostic Trouble Code 4747 has an error
priority of Amber.
Cause:
The UCM has sensed that the left swash plate angle sensor has failed. The fault is active while of the swash plate
angle sensor inputs, X-CN3A pin 9 and X-CN3A pin 10 are less than 4.8 V or greater than 5.2 V.
1. An open circuit in the supply voltage to the sensor.

Solution:

Disconnect the left hand swash plate sensor connector X-94.
47540694 28/04/2014
55.16 [55.DTC] / 585
of fault.
Disconnect UCM connector X-CN3A. Disconnect left hand swash plate sensor connector X-94.
A. Both resistance measurement are greater than 20,000 Ω. Go to step 5.
B. One or both resistance measurements are less than 20,000 Ω. There is a short circuit to chassis ground in the
signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination
of fault.
Fabricate a jumper wire that will connect between the UCM connector X-CN3A and chassis ground.
Disconnect connectors X-CN3A and X-94.
Remove the jumper wire from X-CN3A pin 9.
B. One or both resistance measurements are greater than 10 Ω. There is an open circuit in the signal wire. Repair
6. Test the UCM.
47540694 28/04/2014
55.16 [55.DTC] / 586
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 587
4752-Left Swash Plate Angle Sensor - Implausible Command,

Command Does Not Match With Swash Plate Angle Left Hand Pump
Angle #1 and Left Hand Pump Angle #2
Context:
The UCM has sensed that the swash plate sensor signal does not agree with the direction of vehicle travel. Diagnostic
Forward and reverse functions are disabled while Diagnostic Trouble Code 4752 is active.
Cause:
The UCM has sensed that the swash plate sensor signal does not agree with the direction of vehicle travel. The
fault active is when the swash plate sensor senses vehicle movement while the solenoids are not energized or while
vehicle movement is opposite of the energized solenoid.
1. Improper wiring in the circuit.

2. Mechanical pump adjustment.
Solution:

3. Verify that the pump harness is installed correctly.
Verify that connector X-18 is connected to the right drive pump reverse solenoid.
Verify that connector X-17 is connected to the right drive pump forward solenoid.
Verify that connector X-16 is connected to the left drive pump reverse solenoid.
Verify that connector X-13 is connected to the left drive pump forward solenoid.
A. The connectors are secure and installed in the proper location. Go to step 4.
47540694 28/04/2014
55.16 [55.DTC] / 588
B. The connectors are not secure or are not installed in the proper locations. Repair the harness or connectors
4. Verify that the swash plate sensors are connected properly.
Verify that connector X-93 is connected to the right hand pump swash plate sensor.
Verify that connector X-94 is connected to the left hand pump swash plate sensor.
A. The connectors are secure and installed in the proper location. Check the adjustment for mechanical neutral
in the left hand pump drive circuit. Return to step 1.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 589
4754-Right Swash Plate Angle Sensor - Implausible Command,

Command Does Not Match With Swash Plate Angle Right Hand
Pump Angle #1 and Right Hand Pump Angle #2
Context:
The UCM has sensed that the swash plate sensor signal does not agree with the direction of vehicle travel. Diagnostic
Forward and reverse functions are disabled while Diagnostic Trouble Code 4754 is active.
Cause:
The UCM has sensed that the swash plate sensor signal does not agree with the direction of vehicle travel. The
fault active is when the swash plate sensor senses vehicle movement while the solenoids are not energized or while
vehicle movement is opposite of the energized solenoid.
1. Improper wiring in circuit.

2. Mechanical pump adjustment.
Solution:

3. Verify that the pump harness is installed correctly.
Verify that connector X-18 is connected to the right drive pump reverse solenoid.
Verify that connector X-17 is connected to the right drive pump forward solenoid.
Verify that connector X-16 is connected to the left drive pump reverse solenoid.
Verify that connector X-13 is connected to the left drive pump forward solenoid.
A. The connectors are secure and installed in the proper location. Go to step 4.
47540694 28/04/2014
55.16 [55.DTC] / 590
4. Verify that the swash plate sensors are connected properly.
Verify that connector X-93 is connected to the right hand pump swash plate sensor.
Verify that connector X-94 is connected to the left hand pump swash plate sensor.
A. The connectors are secure and installed in the proper location. Check the adjustment for mechanical neutral
in the right hand pump drive circuit. Return to step 1.
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 591
4781-Solenoid Valve - Solenoid Supply Open Circuit Two Speed

Solenoid
Context:
The UCM has sent a signal to the Two Speed Solenoid to energize, but the UCM does not sense proper voltage.
codes.
Two Speed operating mode is disabled while Diagnostic Trouble Code 4781 is active.
Cause:
The UCM has sent a signal to the Two Speed Solenoid to energize, but the UCM does not sense proper voltage. The
fault is active when the Engine is on and solenoid output X-CN3A pin 25 is greater than 8 V or less than 1 V.

2. Two Speed solenoid has failed.
Solution:

Inspect the UCM and Two Speed solenoid connections. All connections should be secure, tight, free of corrosion,
Inspect the harness from the UCM to the Two Speed solenoid. Verify that the harness is free of damage, corrosion,
Fabricate a jumper wire that will connect between the Two Speed solenoid connector X-2SPD pin A and X-2SPD
pin B.
Disconnect UCM connectors X-CN3A.
Use the jumper wire to short X-2SPD pin A to X-SPD pin B.
47540694 28/04/2014
55.16 [55.DTC] / 592
4. Test the UCM.
Leave the jumper wire installed between X-2SPD pin A and X-2SPD pin B.
Reconnect UCM connectors X-CN3A.
Activate the two speed feature while monitoring the fault code screen. Fault code 4781 should no longer be active.
Fault code 4782 should become active.
Medium EH machines
Case models
New Holland models
47540694 28/04/2014
55.16 [55.DTC] / 593
4782-Solenoid Valve - Solenoid Supply Short to Ground Two Speed

Solenoid
Context:
The UCM has sent a signal to the Two Speed solenoid to energize, but no voltage detected. Diagnostic Trouble Code
4782 has an error priority of White.
Two Speed operating mode is disabled while Diagnostic Trouble Code 4782 is active.
Cause:
The UCM has sent a signal to the Two Speed solenoid to energize, but no voltage detected. The fault is active when
Two Speed is on and solenoid output, X-CN3A pin 25 current is high.

2. Two Speed Solenoid has failed.
Solution:

Inspect the UCM and Two Speed solenoid connections. All connections should be secure, tight, free of corrosion,
3. Measure the resistance of the solenoid wire to chassis ground.
Disconnect solenoid connector X-2SPD. Disconnect UCM connector X-CN3A.
Measure the resistance between X-2SPD pin A and chassis ground. The resistance should be greater than
B. The resistance measurement is less than 20,000 Ω. There is an short circuit to chassis ground. Repair or
replace the harness as required. Return to step 1 to confirm elimination of fault.
4. Test the UCM.
47540694 28/04/2014
55.16 [55.DTC] / 594
Reconnect UCM connector X-CN3A. Leave connector X-2SPD disconnected.
Activate the Two Speed function while monitoring the fault code screen. Fault code 4872 should no longer be
active. Fault code 4781 should become active.
Medium EH machines
Case models
New Holland models
47540694 28/04/2014
55.16 [55.DTC] / 595
4783-Solenoid Valve - Solenoid Supply Short to Power Two Speed

Solenoid
Context:
The UCM has sensed higher than normal voltage on the Two Speed Solenoid. Diagnostic Trouble Code 4783 has an
Ground Drive Limp Home operating mode is enabled while Diagnostic Trouble Code 4783 is active.
Cause:
The UCM has sensed higher than normal voltage on the Two Speed Solenoid. The fault is active when the Two Speed
function is off and the Two Speed Solenoid output voltage, X-CN3A pin 25 is greater than 8 V.

2. Failure of the Two Speed Solenoid.
Solution:

Inspect the UCM and the Two Speed solenoid connections. All connections should be secure, tight, free of corro-
3. Measure the voltage of the solenoid wire to chassis ground.
Disconnect solenoid connector X-2SPD. Disconnect UCM connector X-CN3A.
Measure the voltage between X-2SPD pin A and chassis ground. The voltage should be less than 0.5 V. Wiggle
replace the harness as required. Return to step 1 to confirm elimination of fault.
47540694 28/04/2014
55.16 [55.DTC] / 596
4. Test the UCM.
Reconnect UCM connector X-CN3A . Leave connector X-2SPD disconnected.
Activate the two speed function while monitoring the fault code screen. Fault code 4783 should no longer be
active. Fault code 4781 should become active.
A. Fault code 4781 is active. Fault code 4783 is no longer active. Temporarily replace the solenoid and retest.
Medium EH machines
Case models
New Holland models
47540694 28/04/2014
55.16 [55.DTC] / 597
4951-Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock

Solenoid, Short to Power
Context:
Cause:
Instrument Cluster has sensed a short to another voltage source in the Hydraulic Interlock circuit. The fault is active
when Ignition is On and Hydraulic Enable Commanded state is low and Hydraulic Enable solenoid is energized.

Solution:


(1) Inspect Instrument Cluster connector X-C23 and the Hydraulic Interlock Solenoid connections. All connections
should be secure, tight, free of corrosion, abrasion and/or damage.
(2) Inspect the harness from the Instrument Cluster to the Hydraulic Interlock Solenoid. Verify that the harness is
free of damage, corrosion, abrasion and incorrect attachment.
RAPH12SSL0267FA 1
47540694 28/04/2014
55.16 [55.DTC] / 598
Schematic Legend
(1) Port Lock Connector (3) Instrument Cluster Connector
X-PORT_LK PIN 1 X-C23 pin 30
(2) Vehicle Working Condition to Telematics (4) Chassis Ground
Wire 308, YE X-CNH_GND_RR
A. The voltage is less than 0.5 V, temporarily replace the Instrument Cluster and retest. Go to Step 1 to confirm
B. The voltage is greater than 0.5 V. The solenoid wire is shorted to another voltage. Repair or replace the har-
ness as required. Return to Step 1 to confirm elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 599
4952-Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock

Solenoid Open Circuit
NOTE: A machine with Loader Lock on will trigger trouble code 4952. This is normal.
Context:
Cause:
Instrument Cluster has sensed an open circuit condition in the Hydraulic Interlock circuit. The fault is active while
Ignition is On and Hydraulic Enable commanded state is high and Hydraulic Enable solenoid is not energized.

2. The Hydraulic Interlock Solenoid wiring has an open circuit.
3. Open circuit in the Hydraulic Interlock Solenoid.
Solution:


(1) Inspect Instrument Cluster connector X-C23 and the Hydraulic Interlock Solenoid connections. All connections
(2) Inspect the harness from the Instrument Cluster to the Hydraulic Interlock Solenoid. Verify that the harness is
free of damage, corrosion, abrasion and incorrect attachment.
RAPH12SSL0267FA 1
47540694 28/04/2014
55.16 [55.DTC] / 600
Schematic Legend
(1) Port Lock Connector (3) Instrument Cluster Connector
X-PORT_LK PIN 1 X-C23 pin 30
(2) Vehicle Working Condition to Telematics (4) Chassis Ground
Wire 308, YE X-CNH_GND_RR
(3) Measure the resistance between X-C23 pin 30 and chassis ground. The resistance should be less than 10 Ω.
A. The resistance is less than 10 Ω, temporarily replace the Instrument Cluster and retest. Go to Step 1 to confirm
the elimination of the fault. .
B. The resistance is greater than 10 Ω. There is a problem in the solenoid circuit. Go to Step 4.
4. Measure the resistance of the Hydraulic Interlock Solenoid.
(2) Disconnect connector X-PORT_LK from the Hydraulic Interlock Solenoid.
(3) Measure the resistance across the solenoid. The resistance should be approximately 7.25 Ω.
A. The resistance is between 6.5 Ω and 8 Ω. Go to Step 5.
B. The resistance is greater than 8 Ω. The Hydraulic Interlock Solenoid has an internal open circuit. Replace the
Hydraulic Interlock Solenoid and retest. Return to Step 1 to confirm elimination of fault.
(1) Disconnect X-C23 and the Hydraulic Interlock Solenoid connector, X-PORT_LK .
(2) Fabricate a 15 cm (6 in) jumper wire with pins on each end. Insert the jumper in connector X-PORT_LK pin 1
and X-PORT_LK pin 2.
(3) Measure the resistance between X-C23 pin 30 and X-C23 pin 34 (chassis ground). The resistance should be
A. The resistance is less than 10 Ω. Temporarily replace the Instrument Cluster and retest. Go to Step 1 to confirm
B. The resistance is greater than 10 Ω. There is an open circuit in the harness. Inspect connectors from the
Instrument Cluster to the Hydraulic Interlock Solenoid. Verify all connections are tight and secure and free of
damage. Repair or replace the wires as required. Return to Step 1 to confirm elimination of fault.
47540694 28/04/2014
55.16 [55.DTC] / 601
5051-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open

Circuit
Context:
Loader hydraulics are disabled while Diagnostic Trouble Code 5051 is active.
Cause:
The UCM has sensed an open circuit in the solenoid supply. The fault is active when the engine is ON and the UCM
pin voltage, X-CN2A pin 4 is less 1 V or greater than 8 V.
1. Open circuit in the solenoid wiring.

2. The loader pilot interlock valve has failed.
Solution:

Inspect the UCM and the loader pilot interlock connections. All connections should be secure, tight, free of corro-
Inspect the harness from the UCM to the loader pilot interlock. Verify that the harness is free of damage, corrosion,
3. Measure the resistance through the solenoid circuit.
A. The resistance measurement is less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to
B. The resistance measurement is greater than 100 Ω. There is an open circuit in the wiring. Go to step 4.
4. Measure the solenoid resistance.
47540694 28/04/2014
55.16 [55.DTC] / 602
Measure the resistance across the loader interlock solenoid terminals, pin 1 and pin 2. The resistance should be
less than 20 Ω.
5. Measure the resistance through the circuit.
Leave UCM connector X-CN2A disconnected.
Fabricate a jumper wire that will connect between X-PLTLK pin 1 and pin 2.
Connect the jumper wire between X-PLTLK pin 1 and pin 2.
47540694 28/04/2014
55.16 [55.DTC] / 603
5052-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short

to Ground
Context:
Cause:
The UCM has sent a signal to the Loader Pilot Interlock solenoid to energize, but there is no voltage detected. The
fault is active while hydraulics are enabled and the loader pilot interlock solenoid output, X-CN2A pin 4 is greater than
3 A.
1. Short circuit in the solenoid wiring.

2. The loader pilot interlock valve solenoid has failed.
Solution:

Disconnect solenoid connector X-PLTLK.
B. The resistance measurement is less than 20,000 Ω. There is a short circuit to chassis ground in the wiring.
47540694 28/04/2014
55.16 [55.DTC] / 604
greater than 5 Ω.
A. The resistance is greater than 5 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm
47540694 28/04/2014
55.16 [55.DTC] / 605
5053-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short

to Power
Context:
Cause:
The UCM has sent a signal to the Loader Pilot Interlock solenoid to energize, but there is no voltage detected. The
fault is active while hydraulics are enabled and the loader pilot interlock solenoid output, X-CN2A pin 4 is greater than
3 A.

2. The loader pilot interlock valve solenoid has failed.
Solution:

Disconnect solenoid connector X-PLTLK.
47540694 28/04/2014
55.16 [55.DTC] / 606
greater than 5 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 607
5061-Port Lock Valve (On/Off) - Solenoid Supply Open Circuit

Context:
Cause:
The UCM has sensed an open circuit in the solenoid supply. The fault is active when the engine is ON and the UCM
pin voltage, X-CN2A pin 5 is less 1 V or greater than 8 V.
1. An open circuit in the solenoid wiring.

2. The loader lock interlock valve has failed.
Solution:

Inspect the UCM and the loader port lock connections. All connections should be secure, tight, free of corrosion,
Inspect the harness from the UCM to the loader port lock. Verify that the harness is free of damage, corrosion,
Measure the resistance across the loader lock solenoid terminals, pin 1 and pin 2. The resistance should be less
than 20 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 608
Fabricate a jumper wire that will connect between X-PORT_LK pin 1 and pin 2.
Connect the jumper wire between X-PORT_LK pin 1 and pin 2.
47540694 28/04/2014
55.16 [55.DTC] / 609
5062-Port Lock Valve (On/Off) - Solenoid Supply Short to Ground

Context:
Cause:
The UCM has sent a signal to the Loader Port Lock solenoid to energize, but there is no voltage detected. The fault
is active while hydraulics are enabled and the loader port lock solenoid output, X-CN2A pin 5 is greater than 3 A.

2. The loader port lock valve solenoid has failed.
Solution:

Inspect the harness from the UCM to the loader port lock solenoid. Verify that the harness is free of damage,
Disconnect solenoid connector X-PORT_LK.
47540694 28/04/2014
55.16 [55.DTC] / 610
Measure the resistance across the loader port lock solenoid terminals, pin 1 and pin 2. The resistance should be
greater than 5 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 611
5063-Port Lock Valve (On/Off) - Solenoid Supply Short to Power

Context:
Cause:
The UCM has sent a signal to the loader port lock solenoid to de-energize, but the UCM detects a voltage on the
output. The fault is active when the hydraulics are disabled and the loader port lock solenoid output, X-CN2A pin 5
is greater than 8 V.
1. Signal wire is shorted to another voltage source.

Solution:

Inspect the harness from the UCM to the loader port lock solenoid. Verify that the harness is free of damage,
3. Measure the voltage on the solenoid circuit.
Disconnect solenoid connector X-PORT_LK.
A. The voltage is less than 0.5 V. Temporarily replace the UCM and retest. Return to step 1.
B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source in the wiring. Repair or
replace the harness as required. Return to step 1 to confirm elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 612

47540694 28/04/2014
55.16 [55.DTC] / 613
5121-Right Joystick F-B Axis - Pin A Short to Power/ Short to

Ground/ Open Circuit
Context:
Cause:
While in the H-Pattern, the UCM has sensed that the Right Joystick F-B signal has failed. The fault is active while the
voltage on X-CN4A pin 17 is less than 0.2 V or the voltage is greater than 4.8 V.
Normal operating voltage of the sensor output is 0.5 V to 4.5 V. Output of the sensor with the joystick in the neutral
position is approximately 2.5 V.
1. Short circuit in the signal wire.

2. Open circuit in the signal wire.
3. Failure of the Right Hand Control Handle.
Solution:

Inspect the UCM and the Right Joystick connections. All connections should be secure, tight, free of corrosion,
Inspect the harness from the UCM to the Right Joystick. Verify that the harness is free of damage, corrosion,
3. Measure the voltage on the signal wire to chassis ground.
Disconnect the UCM connector X-CN4A. Disconnect the Right Joystick connector X-UJMR.
Measure the voltage between X-UJMR pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle
47540694 28/04/2014
55.16 [55.DTC] / 614
Measure the resistance between X-UJMR pin 3 and chassis ground. The resistance should be greater than
Use a jumper wire with alligator clips on both ends to short connector X-CN4A pin 17 to chassis ground. The
chassis ground connection must be clean and free of rust, dirt oil and paint.
Measure the resistance between connector X-UJMR pin 3 and chassis ground. The resistance should be less
B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness
6. Measure the voltage to the sensor.
Disconnect the Right Joystick connector X-UJMR. Reconnect the UCM connector(s).
Measure the voltage between X-UJMR pin 1 and X-UJMR pin 4. The voltage should be approximately 5 V. Wiggle
RAPH12SSL0351FA 1
47540694 28/04/2014
55.16 [55.DTC] / 615
Schematic legend
(1) Connector X-UJMR (3) DVM set to measure voltage.
(2) Joystick X-Y Position Sensor (4) Right Joystick F-B
X-CN4A pin 17
Fault code 5121 or 5124
B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage
from the UCM. If the voltage from the UCM is correct, there is an open circuit in the voltage supply to the
sensor. Repair as required. Return to step 1 to confirm elimination of fault.
7. Measure the voltage output of the sensor.
Disconnect the Right Joystick connector X-UJMR.
Fabricate a breakout tee to measure the voltage output of the sensor.
RAPH12SSL0352GA 2
Schematic legend
(1) Dealer supplied breakout harness (2) DVM set to measure voltage.
Connect the breakout harness between the two mating connectors on X-UJMR.
47540694 28/04/2014
55.16 [55.DTC] / 616
Measure the voltage between pins 3 and 4 on the break out harness. The voltage should be approximately 2.5 V
while the joystick in the neutral position.
Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change
between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the
stop points.
A. The voltage is approximately 2.5 V in the neutral position and the voltage changes in a smooth fashion between
0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault.
B. The voltage was not 2.5 V in the neutral position or the voltage change was erratic. Temporarily replace the
Joystick and retest. Return to step 1 to confirm elimination of fault.
Small EH machines
Case machines
New Holland machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 617
5122-Right Joystick F-B Axis - Pin B Short to Power/ Short to

Context:
Cause:
While in the H-Pattern, the UCM has sensed that the Right Joystick F-B signal has failed. The fault is active while the
voltage on X-CN1B pin 13 is less than 0.2 V or the voltage is greater than 4.8 V.
1. Short circuit in signal wire.

2. Open circuit in signal wire.
Solution:

3. Measure the voltage on the signal wire to chassis ground, short circuit.
Disconnect the UCM connector X-CN1B. Disconnect the Right Joystick connector X-UJMR.
Measure the voltage of X-UJMR pin 9 to chassis ground. The voltage should be less than 0.5 V. Wiggle the
47540694 28/04/2014
55.16 [55.DTC] / 618
Disconnect the UCM connector X-CN1B. Disconnect the Right Joystick connector X-UJMR.
Use a jumper wire with alligator clips on both ends to short connector X-CN1B pin 13 to chassis ground. The
Measure the voltage between X-UJMR pin 7 and X-UJMR pin 10. The voltage should be approximately 5 V.
RAPH12SSL0353FA 1
47540694 28/04/2014
55.16 [55.DTC] / 619
Schematic legend
X-CN1B pin 13
RAPH12SSL0354GA 2
Schematic legend
47540694 28/04/2014
55.16 [55.DTC] / 620
stop points.
Small EH machines
Case machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 621
5124-Right Joystick F-B Axis - In Range Fault

Context:
Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 5124.
Cause:
The UCM has sensed that the Right Joystick F-B signal has failed. The fault is active while the voltage on X-CN4A
pin 17 and X-CN1B pin 13 is less than 0.2 V or the voltage is greater than 4.8 V.
Normal operating voltage of the sensor output is 0.5 V to 4.5 V. Output of the sensor in the neutral position is approx-
imately 2.5 V.
1. An open circuit in the signal wire.

2. A short circuit in the signal wire.
3. Failure of the Right Hand Control Module.
Solution:

3. Measure the voltage of the signal wire to chassis ground.
Disconnect UCM connectors X-CN4A and X-CN1B. Disconnect the Right Joystick connector X-UJMR.
47540694 28/04/2014
55.16 [55.DTC] / 622
Disconnect the UCM connector X-CN4A and X-CN1B. Disconnect the Right Joystick connector X-UJMR.
Connect one end of the jumper wire to connector X-CN1B pin 13 and the other end to chassis ground. The chassis
ground connection must be clean and free of rust, dirt oil and paint.
47540694 28/04/2014
55.16 [55.DTC] / 623
RAPH12SSL0355FA 1
Schematic legend
(1) Connector X-UJMR (4) Right Joystick F-B
X-CN4A pin 17
X-CN1B pin 13
(3) DVM set to measure voltage.
47540694 28/04/2014
55.16 [55.DTC] / 624
RAPH12SSL0356GA 2
Schematic legend
stop points.
stop points.
A. For both Joysticks, the voltage is approximately 2.5 V in the neutral position and the voltage changes at a
smooth rate between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm
47540694 28/04/2014
55.16 [55.DTC] / 625
B. On one or both Joysticks, the voltage was not 2.5 V in the neutral position or the voltage change was erratic.
Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault.
Small EH machines
Case machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 626
5131-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to

Context:
Limp home implement operating mode is enabled while Diagnostic Trouble Code 5131 is active.
Cause:
The UCM has sensed that the Right Joystick R-L signal has failed low. The fault is active while the engine is ON and
the voltage on X-CN4A pin 24 is less than 0.2 V.
Normal operating voltage of the sensor output is 0.5 V to 4.5 V.
Output of the sensor with the joystick in the neutral position is approximately 2.5 V.

Solution:

Measure the resistance of X-UJMR pin 2 to chassis ground. The resistance should be greater than 20,000 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 627
Measure the resistance of connector X-UJMR pin 2 to chassis ground. The resistance should be less than 10 Ω.
Turn the ignition switch OFF. Reconnect the UCM connector(s).
RAPH12SSL0351FA 1
Schematic legend
(2) Joystick X-Y Position Sensor (4) Right Joystick R-L
X-CN4A pin 24
Fault code 5131, 5132 or 5137
47540694 28/04/2014
55.16 [55.DTC] / 628
RAPH12SSL0373GA 2
Schematic legend
Turn the ignition switch ON. Connect the breakout harness between the two mating connectors on X-UJMR.
Continue measuring the voltage while slowly moving the throttle in the R-L position. The voltage should change
stop points.
Small EH machines
47540694 28/04/2014
55.16 [55.DTC] / 629

Case machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 630
5132-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power

Context:
Limp Home Implement operating mode is enabled with Diagnostic Trouble Code 5132.
Cause:
The UCM has sensed that the Right Joystick R-L signal has failed. The fault is active when the voltage on X-CN4A
pin 24 is greater than 4.8 V.
1. Signal wire short circuit to another voltage source.

2. Failure of the Right Joystick.
3. The UCM has and internal failure.
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 631
Turn the ignition switch OFF. Use a jumper wire with alligator clips on both ends to short connector X-CN4A pin
24 to chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint.
RAPH12SSL0351FA 1
Schematic legend
X-CN4A pin 24
Fault code 5131, 5132 or 5137
47540694 28/04/2014
55.16 [55.DTC] / 632
RAPH12SSL0373GA 2
Schematic legend
while the joystick is in the neutral position.
stop points.
Small EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 633

Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 634
5134-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to

Context:
Limp home implement operating mode is enabled with Diagnostic Trouble Code 5134.
Cause:
The UCM has sensed that the Right Joystick R-L signal has failed low. The fault is active while engine is ON and
voltage on X-CN3A pin 11 is less than 0.2 V.

Solution:

Inspect the UCM and Right Joystick connections. All connections should be secure, tight, free of corrosion, abra-
sion and damage.
47540694 28/04/2014
55.16 [55.DTC] / 635
chassis ground connection must be clean and free of rust, dirt, oil and paint.
RAPH12SSL0353FA 1
Schematic legend
X-CN3A pin 11
Fault code 5134, 5135 or 5137
47540694 28/04/2014
55.16 [55.DTC] / 636
RAPH12SSL0374GA 2
Schematic legend
stop points.
Small EH machines
47540694 28/04/2014
55.16 [55.DTC] / 637

Case machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 638
5135-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power

Context:
Limp Home Implement operating mode is enabled with Diagnostic Trouble Code 5135.
Cause:
UCM has sensed that the Right Joystick R-L signal has failed. The fault is active when the voltage on X-CN3A pin 11
is greater than 4.8 V.
1. Signal wire has a short circuit to another voltage source.

2. Failure of the Right Joystick.
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 639
RAPH12SSL0353FA 1
Schematic legend
X-CN3A pin 11
Fault code 5134, 5135 or 5137
47540694 28/04/2014
55.16 [55.DTC] / 640
RAPH12SSL0374GA 2
Schematic legend
while the joystick is in the neutral position.
stop points.
Small EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 641

Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 642
5137-Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault

Context:
The bucket is disabled while Diagnostic Trouble Code 5137 is active.
Cause:
The UCM has sensed that the Right Joystick R-L signal has failed. The fault is active while the engine is ON and the
voltage on X-CN4A pin 24 and X-CN3A pin 11 is less than 0.2 V or greater than 4.8 V.
imately 2.5 V.

3. Failure of the Right Hand Control Module.
Solution:

Disconnect the UCM connector X-CN4A and X-CN3A. Disconnect the Right Joystick connector X-UJMR.
47540694 28/04/2014
55.16 [55.DTC] / 643
Disconnect the UCM connector X-CN4A and X-CN3A. Disconnect the Right Joystick connector X-UJMR.
Measure the resistance between connector X-UJMR pin 2 to chassis ground. The resistance should be less than
Connect the jumper wire between connector X-CN3A pin 11 and chassis ground. The chassis ground connection
must be clean and free of rust, dirt, oil and paint.
Measure the resistance between connector X-UJMR pin 8 to chassis ground. The resistance should be less than
47540694 28/04/2014
55.16 [55.DTC] / 644
RAPH12SSL0355FA 1
Schematic legend
(1) Connector X-UJMR (4) Right Joystick R-L
X-CN4A pin 24
Fault code 5131, 5132 or 5137
X-CN3A pin 11
Fault code 5134, 5135 or 5137
47540694 28/04/2014
55.16 [55.DTC] / 645
RAPH12SSL0375GA 2
Schematic legend
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJMR. Turn
the ignition switch ON.
stop points.
stop points.
47540694 28/04/2014
55.16 [55.DTC] / 646
Small EH machines
Case machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 647
5141-Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit

Context:
codes.
The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5141 is active.
Cause:
The UCM has sensed that the auxiliary thumbwheel signal has failed low. The fault is active when the ignition is ON
and the aux thumbwheel axis input voltage, X-CN2B pin 28 is less than 0.2 V.

3. Failure of the right hand control handle.
Solution:

Inspect the UCM and the right hand joystick connections. All connections should be secure, tight, free of corrosion,
Inspect the harness from the UCM to the right hand joystick. Verify that the harness is free of damage, corrosion,
3. Measure the thumbwheel supply voltage.
Disconnect connector X-403 from the right hand joystick.
47540694 28/04/2014
55.16 [55.DTC] / 648
B. The voltage is less than 4 V. There is a problem in the voltage supply or ground to the sensor. Repair or replace
Disconnect connector X-403.
5. Check for an open circuit in the signal wire.
Fabricate a jumper that will connect between X-403 pin 2 and chassis ground.
Connect the jumper wire between X-403 pin 2 and chassis ground. The chassis ground connection must be clean
and free of paint, dirt, oil, and grease.
6. Test the UCM.
Disconnect the jumper wire.
Remove pin 2 and pin 1 from connector X-403.
Use a jumper wire with alligator clips to short X-403 pin 2 to X-403 pin 1.
Reconnect X-403 on to the joystick.
Use EST to access the fault code screen. Fault code 5141 should no longer be active. Fault code 5142 is now
active.
A. Fault code 5141 is no longer active. Fault code 5142 is now active. Replace the aux thumbwheel and retest.
B. Fault code 5141 is active. Fault code 5142 did not become active. Replace the UCM and retest. Return to
Small EH machines
Case machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 649

Case machines
47540694 28/04/2014
55.16 [55.DTC] / 650
5142-Aux Thumbwheel Axis - Pin A Short to Power

Context:
codes.
Cause:
The UCM has sensed that the auxiliary thumbwheel signal has failed high. The fault is active when the ignition is ON
and the aux thumbwheel axis input voltage, X-CN2B pin 28 is greater than 4.8 V.

2. The right hand control handle has an internal failure.
Solution:

Measure the voltage between X-CN2B pin 28 and chassis ground. The voltage should be less than 0.5 V. Wiggle
47540694 28/04/2014
55.16 [55.DTC] / 651
4. Test the UCM.
Reconnect joystick connector X-403.
active.
Small EH machines
Case machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 652
5144-Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit

Context:
codes.
Cause:
The UCM has sensed that the auxiliary thumbwheel signal has failed low. The fault is active when the ignition is ON
and the aux thumbwheel axis input voltage, X-CN4B pin 21 is less than 0.2 V.

3. Failure of the right hand control handle.
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 653
Fabricate a jumper that will connect between X-403 pin 11 and chassis ground.
Connect the jumper wire between X-403 pin 11 and chassis ground. The chassis ground connection must be clean
and free of paint, dirt, oil, and grease.
6. Test the UCM.
Disconnect the jumper wire.
Reconnect X-403 on to the joystick.
active.
Small EH machines
Case machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 654

Case machines
47540694 28/04/2014
55.16 [55.DTC] / 655
5145-Aux Thumbwheel Axis - Pin B Short to Power

Context:
codes.
Cause:
The UCM has sensed that the auxiliary thumbwheel signal has failed high. The fault is active when the ignition is ON
and the aux thumbwheel axis input voltage, X-CN4B pin 21 is greater than 4.8 V.

2. The right hand control handle has an internal failure.
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 656
4. Test the UCM.
Reconnect joystick connector X-403.
active.
Small EH machines
Case machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 657
5147-Aux Thumbwheel Axis - In Range Fault

Context:
codes.
Cause:
The UCM has sensed that the aux thumbwheel has failed. The fault is active while the engine is ON and the sum of
aux thumbwheel output voltages, XCN2B pin 28 and X-CN4B pin 21 is greater than 5.2 V or less than 4.8 V.

2. Failure of the Aux Thumbwheel
Solution:

Inspect the cab to chassis interface harness. Inspect the chassis ground and minus battery connections. Verify
that the connections is free of damage, corrosion, abrasion, and incorrect attachment.
47540694 28/04/2014
55.16 [55.DTC] / 658
A. Both voltage measurements are less than 0.5 V. Go to step 5.
B. One or both measurements are greater than 0.5 V. There is a short circuit to another voltage source. Repair
Leave UCM connectors X-CN2B and X-CN4B disconnected.
Fabricate a jumper that will connect between X-403 pin 2 and X-403 pin 11.
A. Both resistance measurements are less than 10 Ω. Temporarily replace the thumb wheel switch and retest.
47540694 28/04/2014
55.16 [55.DTC] / 659
B. One or both measurements are greater than 10 Ω. There is a short circuit to chassis ground. Repair or replace
Small EH machines
Case machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 660
5201-Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/

Open Circuit
Context:
Cause:
The UCM has sensed that the Left Joystick L-R signal has failed. The fault is active while Engine is On and voltage
on X-CN4A pin 25 is less than 0.2 V or greater than 4.8 V.
imately 2.5 V.

3. Failure of the Left Hand Control Module.
Solution:

Inspect the UCM and the Left Joystick connections. All connections should be secure, tight, free of corrosion,
Inspect the harness from the UCM to the Left Joystick. Verify that the harness is free of damage, corrosion,
Disconnect the UCM connector X-CN4A. Disconnect the Left Joystick connector X-UJML.
Measure the voltage between X-UJML pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle
47540694 28/04/2014
55.16 [55.DTC] / 661
Measure the resistance between X-UJML pin 2 and chassis ground. The resistance should be greater than
Measure the resistance between connector X-UJML pin 2 to chassis ground. The resistance should be less than
Disconnect the Left Joystick connector X-UJML. Reconnect the UCM connector(s).
Measure the voltage between X-UJML pin 1 and X-UJML pin 4. The voltage should be approximately 5 V. Wiggle
RAPH12SSL0339FA 1
47540694 28/04/2014
55.16 [55.DTC] / 662
Schematic legend
(1) Connector X-UJML (3) DVM set to measure voltage.
(2) Joystick X-Y Position Sensor (4) Left Joystick L-R
X-CN4A pin 25
Disconnect the Left Joystick connector X-UJML.
RAPH12SSL0363GA 2
Schematic legend
Connect the breakout harness between the two mating connectors on X-UJML.
47540694 28/04/2014
55.16 [55.DTC] / 663
Continue measuring the voltage while slowly moving the throttle in the L-R position. The voltage should change
stop points.
A. The voltage is approximately 2.5 V in the neutral position and the voltage changes at a smooth rate between
Small EH machines
Case machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 664
5202-Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/

Open Circuit
Context:
Limp Home Ground Drive operating mode is enabled while Diagnostic Trouble Code 5202 is active.
Cause:
The UCM has sensed that the Left Joystick L-R signal has failed. The fault is active while the voltage on X-CN2B pin
14 is less than 0.2 V or greater than 4.8 V.
imately 2.5 V.

Solution:

Disconnect the UCM connector X-CN2B. Disconnect the Left Joystick connector X-UJML.
47540694 28/04/2014
55.16 [55.DTC] / 665
Measure the resistance of X-UJML pin 8 to chassis ground. The resistance should be greater than 20,000 Ω.
RAPH12SSL0346FA 1
47540694 28/04/2014
55.16 [55.DTC] / 666
Schematic legend
X-CN2B pin 14
RAPH12SSL0370GA 2
Schematic legend
47540694 28/04/2014
55.16 [55.DTC] / 667
stop points.
A. The voltage is approximately 2.5 V in the neutral position and the voltage changes at a smooth rate between
Small EH machines
Case machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 668
5204-Left Joystick L-R Axis - In Range Fault

Context:
Cause:
The UCM has sensed that the Left Joystick L-R signal has failed. The fault is active while the voltage on X-CN4A pin
25 and X-CN2B pin 14 is less than 0.2 V or greater than 4.8 V.
imately 2.5 V.

Solution:

Disconnect the UCM connector X-CN4A and X-CN2B. Disconnect the Left Joystick connector X-UJML.
47540694 28/04/2014
55.16 [55.DTC] / 669
Connect the jumper wire between connector X-CN2B pin 14 and chassis ground. The chassis ground connection
must be clean and free of rust, dirt, oil and paint.
47540694 28/04/2014
55.16 [55.DTC] / 670
RAPH12SSL0348FA 1
Schematic legend
(1) Connector X-UJML (4) Left Joystick L-R
X-CN4A pin 25
X-CN2B pin 14
47540694 28/04/2014
55.16 [55.DTC] / 671
RAPH12SSL0371GA 2
Schematic legend
stop points.
stop points.
47540694 28/04/2014
55.16 [55.DTC] / 672
Small EH machines
Case machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 673
5211-Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit

Context:
Cause:
The UCM has sensed that the Left Joystick F-B 5 V signal has failed low. The fault is active while the engine is ON
and the voltage on X-CN4A pin 18 is less than 0.2 V.
1. A short circuit in the signal wire.

2. An open circuit in the signal wire.
3. Failure of the Left Hand Control Handle.
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 674
Measure the resistance of connector X-UJML pin 3 to chassis ground. The resistance should be less than 10 Ω.
RAPH12SSL0339FA 1
Schematic legend
(2) Joystick X-Y Position Sensor (4) Left Joystick F-B
X-CN4A pin 18
Fault code 5211, 5212 or 5217
47540694 28/04/2014
55.16 [55.DTC] / 675
RAPH12SSL0342GA 2
Schematic legend
Turn the ignition switch ON. Connect the breakout harness between the two mating connectors on X-UJML.
stop points.
Small EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 676

Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 677
5212-Left Joystick F-B Axis - Pin A Short to Power

Context:
Cause:
UCM has sensed that the 5 V signal has failed high. The fault is active while Ignition is On and Voltage is greater than
4.8 V.

2. Short circuit in signal wire to another voltage source.
3. Left Hand Control Module.
Solution:

Measure the voltage of X-UJML pin 3 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness
47540694 28/04/2014
55.16 [55.DTC] / 678
RAPH12SSL0339FA 1
Schematic legend
X-CN4A pin 18
Fault code 5211, 5212 or 5217
47540694 28/04/2014
55.16 [55.DTC] / 679
RAPH12SSL0342GA 2
Schematic legend
stop points.
Small EH machines
47540694 28/04/2014
55.16 [55.DTC] / 680

Case machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 681
5214-Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit

Context:
Cause:
The UCM has sensed that the Left Joystick F-B 5 V signal has failed low. The fault is active while the engine is ON
and the voltage on X-CN2B pin 31 is less than 0.2 V.
imately 2.5 V.

3. Failure of Left Hand Control Handle.
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 682
RAPH12SSL0346FA 1
Schematic legend
X-CN2B pin 31
Fault code 5214, 5215 or 5217
47540694 28/04/2014
55.16 [55.DTC] / 683
RAPH12SSL0347GA 2
Schematic legend
stop points.
Small EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 684

Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 685
5215-Left Joystick F-B Axis - Pin B Short to Power

Context:
Limp home ground drive operating mode is enabled with Diagnostic Trouble Code 5215.
Cause:
The UCM has sensed that the signal has failed high. The fault is active when the ignition is ON and the voltage is
greater than 4.8 V.

Solution:

Measure the voltage of X-UJML pin 9 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness
47540694 28/04/2014
55.16 [55.DTC] / 686
RAPH12SSL0346FA 1
Schematic legend
X-CN2B pin 31
Fault code 5214, 5215 or 5217
47540694 28/04/2014
55.16 [55.DTC] / 687
RAPH12SSL0347GA 2
Schematic legend
stop points.
Small EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 688

Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 689
5217-Left Joystick F-B Axis - In Range Fault

Context:
Cause:
The UCM has sensed that the Left Joystick F-B signal has failed. The fault is active while the engine is ON and
voltage on X-CN4A pin 18 and X-CN2B pin 31 is less than 0.2 V or greater than 4.8 V.
imately 2.5 V.

2. A short circuit to another voltage source.
Solution:

RAPH12SSL0335FA 1
47540694 28/04/2014
55.16 [55.DTC] / 690
Schematic legend
(1) Left Joystick F-B (5) Joystick X-Y Position Sensor
X-CN4A pin 18
Fault code 5211, 5212 or 5217
(2) Left Joystick F-B (6) Sensor supply voltage from UCM
X-CN2B pin 31
Fault code 5214, 5215 or 5217
(3) Connector X-UJML (7) Sensor supply ground from UCM
(4) Joystick X-Y Position Sensor
Disconnect the UCM connectors X-CN4A and X-CN2B. Disconnect the Left Joystick connector X-UJML.
47540694 28/04/2014
55.16 [55.DTC] / 691
RAPH12SSL0348FA 2
Schematic legend
(1) Connector X-UJML (4) Left Joystick F-B
X-CN4A pin 18
Fault code 5211, 5212 or 5217
X-CN2B pin 31
Fault code 5214, 5215 or 5217
47540694 28/04/2014
55.16 [55.DTC] / 692
RAPH12SSL0349GA 3
Schematic legend
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML. Turn
the ignition switch ON.
stop points.
47540694 28/04/2014
55.16 [55.DTC] / 693
stop points.
Small EH machines
Case machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 694
5221-Loader Arm Valve (Directional) - Solenoid Raise A Supply

Open Circuit
Context:
The loader arm functions are disabled while Diagnostic Trouble Code 5221 is active.
Cause:
The UCM has sensed an open circuit in the loader solenoid circuit, X-CN3B pin 6. The fault is active when the hy-
draulics are enabled and the calculated solenoid resistance has increased over 70 %.
1. Open wire or connection in the solenoid circuit.

2. The loader valve extend solenoid has failed.
Solution:

Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion,
abrasion, and damage.
Inspect the harness from the UCM to the loader solenoids. Verify that the harness is free of damage, corrosion,
47540694 28/04/2014
55.16 [55.DTC] / 695
Measure the resistance across the extend solenoid terminals, pin 1 and pin 2. The resistance should be less than
20 Ω.
Leave UCM connectors X-CN3B and X-CN2B disconnected.
B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Check splice SP-108. Repair or
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 696
5222-Loader Arm Valve (Directional) - Solenoid Raise A Supply

Short to Ground
Context:
Cause:
The UCM has sensed that the loader extend solenoid current is too high. The fault is active when hydraulics are
enabled and solenoid output current, X-CN3B pin 6 is greater than 3 A.

2. The loader valve solenoid has failed.
Solution:

3. Test the UCM.
Disconnect solenoid connector X-28.
Use the electronic service tool and access the fault code screen. Fault code 5222 should no longer be active.
Fault code 5221 is now active.
A. Fault code 5222 is no longer active. Fault code 5221 is now active. Replace the solenoid and retest. Return
B. Fault code 5222 is active. Fault code 5221 did not become active. Go to step 4.
47540694 28/04/2014
55.16 [55.DTC] / 697
B. The resistance is less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 698
5231-Loader Arm Valve (Directional) - Solenoid Lower B Supply

Open Circuit
Context:
Cause:
The UCM has sensed an open circuit in the loader solenoid circuit, X-CN3A pin 22. The fault is active when the
hydraulics are enabled and the calculated solenoid resistance has increased over 70 %.

2. The loader valve extend solenoid has failed.
Solution:

Disconnect UCM connectors X-CN3A and X-CN2B.
Measure the resistance between X-CN3A pin 22 and X-CN2B pin 7. The resistance should be less than 100 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 699
Measure the resistance across the retract solenoid terminals, pin 1 and pin 2. The resistance should be less than
20 Ω.
Leave UCM connectors X-CN3A and X-CN2B disconnected.
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 700
5232-Loader Arm Valve (Directional) - Solenoid Lower B Supply

Short to Ground
Context:
Cause:
The UCM has sensed that the loader retract solenoid current is too high. The fault is active when hydraulics are
enabled and solenoid output current, X-CN3A pin 22 is greater than 3 A.

2. The loader valve solenoid has failed.
Solution:

3. Test the UCM.
47540694 28/04/2014
55.16 [55.DTC] / 701
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 702
5241-Boom Valve (Directional) - Common Solenoid (C) Return Short

to Power
Context:
Fault code 5241 has an error priority of White. White errors are not displayed on the instrument cluster and are not
known to the Owner/Operator. They will appear in the EST when the technician checks for active trouble codes.
Loader arm functions are disabled while Diagnostic Trouble Code 5241 is active.
Cause:
The UCM has sensed higher than normal voltage on the loader solenoid lines, X-CN3A pin 22 or X-CN3B pin 6. The
fault is active when hydraulics are disabled and the solenoid voltage feedback is greater than 5 V.

Solution:

3. Measure the voltage on the signal wires.
Disconnect UCM connectors X-CN3A, X-CN2B, and X-CN3B.
the harness to reveal an intermittent condition.
47540694 28/04/2014
55.16 [55.DTC] / 703
A. All measured voltages are less than 0.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm
B. One or more of the voltage measurements are greater than 0.5 V. There is a short circuit to another voltage
source. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of
fault.
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 704
5242-Loader Arm Valve (Directional) - Loader Arm Solenoids Short

to Ground
Context:
Fault code 5242 has an error priority of White.
Loader arm functions are disabled while Diagnostic Trouble Code 5242 is active.
Cause:
The UCM has sensed that the solenoid voltages are too low. The fault is active when the hydraulics are disabled and
solenoid voltages on pin X-CN3A pin 22 and X-CN3B pin 6 are less than 2 V.

Solution:

3. Test the UCM.
Disconnect solenoid connectors X-27 and X-28.
Use the electronic service tool to access the fault code screen. Fault code 5242 should no longer be active. Fault
A. Fault code 5242 is no longer active. Fault code 5243 is now active. Replace both solenoids and retest. Return
47540694 28/04/2014
55.16 [55.DTC] / 705
Disconnect UCM connectors X-CN3A, X-CN2B, and both solenoid connectors, X-27 and X-28.
Measure the resistance between X-CN3A pin 22 and X-CN2B pin 7. The resistance should be greater than
Measure the resistance between X-CN3B pin 6 and X-CN2B pin 7. The resistance should be greater than
A. All resistance measurements are greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to
B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the wiring. Repair or
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 706
5243-Boom Valve (Directional) - Common Solenoid (C) Return Open

Circuit
Context:
Cause:
The UCM has sensed an open circuit in the loader solenoid return circuit, X-CN2B pin 7. The fault is active when the
ignition is ON and the calculated solenoid resistances have increased over 70 %.
1. An open circuit in the solenoid return wiring.

2. The loader solenoids have failed.
Solution:

Disconnect UCM connectors X-CN3A, X-CN2B and X-CN3B.
A. Both resistance measurements are less than 100 Ω. Temporarily replace the UCM and retest. Return to step
B. One or both resistance are greater than 100 Ω. There is an open circuit in the wiring. Go to step 4.
47540694 28/04/2014
55.16 [55.DTC] / 707
20 Ω.
20 Ω.
Leave UCM connectors X-CN3A, X-CN2B and X-CN3B disconnected.
Fabricate a jumper wire that will connect between X-27 pin 1 and pin 2.
Connect the jumper wire between X-27 pin 1 and pin 2.
Remove the jumper from X-27 and connect it between X-28 pin 1 and pin 2.
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 708
5251-Loader Bucket Valve (Directional) - Solenoid Rollback (A)

Supply Open Circuit
Context:
The bucket functions are disabled while Diagnostic Trouble Code 5251 is active.
Cause:
The UCM has sensed an open circuit in the bucket solenoid circuit, X-CN3B pin 17. The fault is active when the

2. The bucket valve retract solenoid has failed.
Solution:

Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion,
Inspect the harness from the UCM to the bucket solenoids. Verify that the harness is free of damage, corrosion,
Disconnect UCM connectors X-CN3B and X-CN1A.
Measure the resistance between X-CN3B pin 17 and X-CN1A pin 13. The resistance should be less than 100 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 709
20 Ω.
Leave UCM connectors X-CN3B and X-CN1A disconnected.
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 710
5252-Loader Bucket Valve (Directional) - Solenoid Rollback (A)

Context:
Cause:
The UCM has sensed that the bucket retract solenoid current is too high. The fault is active when hydraulics are
enabled and solenoid output current, X-CN3B pin 17 is greater than 3 A.

2. The bucket valve solenoid has failed.
Solution:

3. Test the UCM.
Turn the ignition switch ON, activate the hydraulics.
47540694 28/04/2014
55.16 [55.DTC] / 711
Leave solenoid connector X-25 disconnected.
Disconnect UCM connectors X-CN3B and X-CN1A.
Measure the resistance between X-CN3B pin 17 and X-CN1A pin 13. The resistance should be greater than
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 712
5261-Bucket Valve (Directional) - Solenoid Dump (B) Supply Open

Circuit
Context:
Cause:
The UCM has sensed an open circuit in the bucket solenoid circuit, X-CN4A pin 19. The fault is active when the
1. An open wire or connection in the solenoid circuit.

2. The bucket valve extend solenoid has failed.
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 713
20 Ω.
Leave UCM connectors X-CN4A and X-CN1A disconnected.
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 714
5262-Bucket Valve (Directional) - Solenoid Dump (B) Supply Short

to Ground
Context:
Cause:
The UCM has sensed that the bucket extend solenoid current is too high. The fault is active when hydraulics are
enabled and solenoid output current, X-CN4A pin 19 is greater than 3 A.

2. The bucket valve solenoid has failed.
Solution:

3. Test the UCM.
Turn the ignition switch ON, activate the hydraulics.
47540694 28/04/2014
55.16 [55.DTC] / 715
Leave solenoid connector X-26 disconnected.
Measure the resistance between X-CN4A pin 19 and X-CN1A pin 13. The resistance should be greater than
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 716
5271-Bucket Valve (Directional) - Common Solenoid (C) Return

Short to Power
Context:
Bucket functions are disabled while Diagnostic Trouble Code 5271 is active.
Cause:
The UCM has sensed higher than normal voltage on the bucket solenoid lines, X-CN3B pin 17 or X-CN4A pin 19.
The fault is active when hydraulics are disabled and the solenoid voltage feedback is greater than 5 V.

Solution:

Disconnect UCM connectors X-CN3B, X-CN1A, and X-CN4A.
47540694 28/04/2014
55.16 [55.DTC] / 717
fault.
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 718
5272-Loader Bucket Valve (Directional) - Loader Bucket Solenoids

Short to Ground
Context:
Bucket functions are disabled while Diagnostic Trouble Code 5272 is active.
Cause:
The UCM has sensed that the solenoid voltages are too low. The fault is active when the hydraulics are disabled and
solenoid voltages on pin X-CN3B pin 17 and X-CN4A pin 19 are less than 2 V.

Solution:

3. Test the UCM.
47540694 28/04/2014
55.16 [55.DTC] / 719
Disconnect UCM connectors X-CN3B, X-CN1A, and both solenoid connectors, X-25 and X-26.
Leave UCM connectors X-CN3B and X-CN1A disconnected.
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 720
5273-Bucket Valve (Directional) - Common Solenoid (C) Return

Open Circuit
Context:
Cause:
The UCM has sensed an open circuit in the loader solenoid return circuit, X-CN1A pin 13. The fault is active when
the ignition is ON and the calculated solenoid resistances have increased over 70 %.
1. An open circuit in the solenoid return wiring.

2. The loader solenoids have failed.
Solution:

Disconnect UCM connectors X-CN3B, X-CN1A and X-CN4A.
Measure the resistance between X-CN4A pin 19 and X-CN1AB pin 13. The resistance should be less than 100 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 721
20 Ω.
20 Ω.
Leave UCM connectors X-CN3B, X-CN1A and X-CN4A disconnected.
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 722
5281-Aux Valve (Directional) - Solenoid Forward (A) Supply Open

Circuit
Context:
Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5281 is active.
Cause:
The UCM has sensed an open circuit in the proportional aux extend solenoid circuit, X-CN1B pin 33 and X-CN1A pin
22. The fault is active when the ignition is ON and the calculated solenoid resistance has increased over 70 %.
1. An open circuit in the wiring.

2. The proportional aux extend solenoid has failed.
Solution:

Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of
Inspect the harness from the UCM to the proportional aux solenoids. Verify that the harness is free of damage,
47540694 28/04/2014
55.16 [55.DTC] / 723
Measure the resistance across the solenoid terminals pin 1 and pin 2. The resistance should be less than 100 Ω.
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 724
5282-Aux Valve (Directional) - Solenoid Forward (A) Supply Short

to Ground
Context:
Cause:
The UCM has sensed that the Proportional Aux Valve Extend solenoid current is too high. The fault is active when
hydraulics are enabled and solenoid output current, X-CN1B pin 33 is greater than 3 A.

2. Failure of the proportional aux extend solenoid.
Solution:

3. Test the UCM.
47540694 28/04/2014
55.16 [55.DTC] / 725
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 726
5291-Aux Valve (Directional) - Solenoid Reverse (B) Supply Open

Circuit
Context:
Cause:
The UCM has sensed an open circuit in the proportional aux retract solenoid circuit, X-CN1A pin 24 and X-CN1A pin
22. The fault is active when the ignition is ON and the calculated solenoid resistance has increased over 70 %.
1. An open circuit in the wiring.

2. The proportional aux retract solenoid has failed.
Solution:


47540694 28/04/2014
55.16 [55.DTC] / 727
Measure the resistance across the solenoid terminals pin 1 and pin 2. The resistance should be less than 100 Ω.
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 728
5292-Aux Valve (Directional) - Solenoid Reverse (B) Supply Short

to Ground
Context:
Cause:
The UCM has sensed that the Proportional Aux Valve Retract solenoid current is too high. The fault is active when
hydraulics are enabled and solenoid output current, X-CN1A pin 24 is greater than 3 A.

2. Failure of the proportional aux retract solenoid.
Solution:

3. Test the UCM.
47540694 28/04/2014
55.16 [55.DTC] / 729
Disconnect UCM connector X-CN1A and solenoid connector X-29.
F5H engine
47540694 28/04/2014
55.16 [55.DTC] / 730
5309-Float Button - Float Button Timeout (30 sec)

Context:
Loader Float is disabled with Diagnostic Trouble Code 5309.
Cause:
UCM has sensed that the Float Switch signal input, X-CN2B pin 27 has been high for more than 30 seconds.
1. Short circuit to another voltage source.

2. Failure of the Float Switch.
Solution:

Inspect the UCM and Float Switch connections on the Right Hand Joystick. All connections should be secure,
Inspect the harness from the UCM to the Float Switch on the Right Hand Joystick. Verify that the harness is free
3. Measure the resistance through the Float Switch.
Disconnect connector X-403 from the Right Hand Joystick.
Actuate the Float Switch while measuring the resistance between X-403 pin 13 and X-403 pin 14. The resistance
should be less than 10 Ω while the Float Switch is activated.
A. The resistance is greater than 20,000 Ω when the switch is in the open (not actuated) position and the resis-
tance is less than 10 Ω while the Float Switch is actuated. Go to step 4.
B. The resistance is less than 10 Ω when the switch is in the open (not actuated) position and the resistance
is less than 10 Ω while the Float Switch is actuated. There is a short circuit in the Float Switch, temporarily
replace the Float Switch and retest. Return to step 1 to confirm elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 731
Reconnect Right Hand Joystick connector X-403.
of the fault.
Small EH machines
Case machines
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 732
5371-EHF Pump Control PRV's (Directional) - Forward Solenoid

Context:
codes.
EHF Function is disabled while Diagnostic Trouble Code 5371 is active.
Cause:
UCM has sensed an open circuit condition for the EHF Extend solenoid, X-CN3A pin 19. The fault is active when
EHF setting is activated, Hydraulics are enabled, and solenoid current is below normal.

2. Failure of EHF Extend solenoid.
3. Faulty UCM.
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 733
RAPH12SSL0387FA 1
Schematic legend
(1) EHF Extend (4) EHF Extend
UCM Connector Connector X-19
X-CN3A pin 19
(2) EHF Return (5) EHF Retract
X-CN2B pin 8
(3) EHF Retract
UCM Connector
X-CN3A pin 6
(1) Inspect the UCM and EHF Extend solenoid connections. All connections should be secure, tight, free of cor-
rosion, abrasion and damage.
(2) Inspect the harness from the UCM to the EHF Extend solenoid. Verify that the harness is free of damage,
(1) Fabricate a jumper wire that will connect between the EHF Extend solenoid connector X-19 pin 1 and X-19 pin
2.
(3) Disconnect UCM connectors X-CN3A and X-CN2B.
(4) Use the jumper wire to short X-19 pin 1 to X-19 pin 2.
(5) Measure the resistance between X-CN3A pin 19 and X-CN2B pin 8. The resistance should be less than 10 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 734
Check splice SP-193. Repair or replace the harness as required. Return to Step 1 to confirm elimination of
the fault.
4. Test UCM
(1) Leave the jumper wire installed between X-19 pin 1 and X-19 pin 2
(2) Reconnect UCM connectors X-CN3A and X-CN2B.
(4) Activate the hydraulics while monitoring the fault code screen. Fault code 5371 should no longer be active.
47540694 28/04/2014
55.16 [55.DTC] / 735
5372-EHF Pump Control PRV's (Directional) - Forward Solenoid (A)

Context:
codes.
EHF Functions are disabled while Diagnostic Trouble Code 5372 is active.
Cause:
UCM has sensed a short circuit condition for the EHF Extend solenoid, XCN3A pin 19. The fault is active when EHF
setting is activated, Hydraulics are enabled, and solenoid current is greater than 3 A.

2. Failure of EHF Extend solenoid.
Solution:

RAPH12SSL0387FA 1
47540694 28/04/2014
55.16 [55.DTC] / 736
Schematic legend
X-CN3A pin 19
X-CN2B pin 8
(3) EHF Retract
UCM Connector
X-CN3A pin 6
(1) Inspect the UCM, EHF Extend solenoid and EHF Retract solenoid connections. All connections should be
(2) Inspect the harness from the UCM to the EHF Extend and Retract solenoids. Verify that the harness is free of
3. Measure the resistance of the solenoid wires to chassis ground
(2) Disconnect solenoid connector X-19. Disconnect UCM connector X-CN3A and X-CN2B.
(3) Measure the resistance between X-19 pin 1 and chassis ground. The resistance should be greater than
A. The resistance measurement is greater than 20,000 Ω. Go to Step 4.
4. Test the UCM
(2) Reconnect UCM connectors X-CN3A and X-CN2B. Leave connector X-19 disconnected.
(4) Activate EHF hydraulics while monitoring the fault code screen. Fault code 5372 should no longer be active.
47540694 28/04/2014
55.16 [55.DTC] / 737
5381-EHF Pump Control PRV's (Directional) - Reverse Solenoid

Context:
codes.
EHF Function is disabled while Diagnostic Trouble Code 5381 is active.
Cause:
UCM has sensed an open circuit condition for the EHF Retract solenoid, X-CN3A pin 6. The fault is active when EHF
setting is activated, Hydraulics are enabled, and solenoid current is below normal.

2. Failure of EHF Retract solenoid.
3. Faulty UCM.
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 738
RAPH12SSL0387FA 1
Schematic legend
X-CN3A pin 19
X-CN2B pin 8
(3) EHF Retract
UCM Connector
X-CN3A pin 6
(1) Inspect the UCM and EHF Retract solenoid connections. All connections should be secure, tight, free of cor-
rosion, abrasion and damage.
(2) Inspect the harness from the UCM to the EHF Retract solenoid. Verify that the harness is free of damage,
(1) Fabricate a jumper wire that will connect between the EHF Retract solenoid connector X-40 pin 1 and X-40 pin
2.
(3) Disconnect UCM connectors X-CN3A and X-CN2B.
47540694 28/04/2014
55.16 [55.DTC] / 739
Check splice SP-193. Repair or replace the harness as required. Return to Step 1 to confirm elimination of
the fault.
4. Test UCM
(1) Leave the jumper wire installed between X-40 pin 1 and X-40 pin 2
47540694 28/04/2014
55.16 [55.DTC] / 740
5382-EHF Pump Control PRV's (Directional) - Reverse Solenoid (B)

Context:
codes.
Cause:
UCM has sensed a short circuit condition for the EHF Retract solenoid, XCN3A pin 6. The fault is active when EHF
setting is activated, Hydraulics are enabled, and solenoid current is greater than 3 A.

2. Failure of EHF Retract solenoid.
Solution:

RAPH12SSL0387FA 1
47540694 28/04/2014
55.16 [55.DTC] / 741
Schematic legend
X-CN3A pin 19
X-CN2B pin 8
(3) EHF Retract
UCM Connector
X-CN3A pin 6
(2) Inspect the harness from the UCM to the EHF Extend and Retract solenoids. Verify that the harness is free of
(2) Disconnect solenoid connector X-40. Disconnect UCM connector X-CN3A and X-CN2B.
A. The resistance measurement is greater than 20,000 Ω. Go to Step 4.
4. Test the UCM
(2) Reconnect UCM connectors X-CN3A and X-CN2B. Leave connector X-40 disconnected.
(4) Activate EHF hydraulics while monitoring the fault code screen. Fault code 5382 should no longer be active.
47540694 28/04/2014
55.16 [55.DTC] / 742
5391-EHF Pump Control PRV's (Directional) - Solenoids Return

Open Circuit
Context:
codes.
Cause:
UCM has sensed an open circuit condition in the EHF Extend solenoid common line X-CN2B pin 8. The fault is active
while EHF setting is activated, Hydraulics are enabled and extend solenoid and retract solenoid current is correct.

2. Failure of EHF Extend and Retract solenoids.
3. Faulty UCM.
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 743
RAPH12SSL0387FA 1
Schematic legend
X-CN3A pin 19
X-CN2B pin 8
(3) EHF Retract
UCM Connector
X-CN3A pin 6
(2) Inspect the harness from the UCM to the EHF Extend solenoid and EHF Retract solenoid. Verify that the
(1) Fabricate two jumper wires, one that will connect between the EHF Extend solenoid connector X-19 pin 1 and
X-19 pin 2 and a second jumper wire for EHF Retract solenoid connector X-40 pin 1 and X-40 pin 2.
(3) Disconnect UCM connectors X-CN3A and X-CN2B. Disconnect solenoid connectors X-19 and X-40.
(6) Use the second jumper wire to short X-40 pin 1 to X-40 pin 2.
47540694 28/04/2014
55.16 [55.DTC] / 744
A. Both resistance measurements are less than 10 Ω. Go to Step 4.
B. One or both resistance measurement is greater than 10 Ω. There is an open circuit in the solenoid signal or
solenoid ground line. Check splice SP-193. Repair or replace the harness as required. Return to Step 1 to
4. Test UCM
(1) Leave the jumper wires installed in connectors X-19 and X-40.
47540694 28/04/2014
55.16 [55.DTC] / 745
5392-EHF Pump Control PRV's (Directional) - EHF Pumps Solenoids

Short to Ground
Context:
codes.
Cause:
UCM has sensed a short to ground condition for the EHF Pump solenoid. The fault is active when EHF setting is
activated, Hydraulics are disabled, and solenoid return voltage is low.

2. Failure of EHF Pump solenoid.
3. Faulty UCM
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 746
RAPH12SSL0387FA 1
Schematic legend
X-CN3A pin 19
X-CN2B pin 8
(3) EHF Retract
UCM Connector
X-CN3A pin 6
(2) Disconnect solenoid connector X-19 and X-40. Disconnect UCM connector X-CN3A and X-CN2B.
47540694 28/04/2014
55.16 [55.DTC] / 747
A. All resistance measurements are greater than 20,000 Ω. Go to Step 4.
Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
4. Test the UCM
(2) Reconnect UCM connectors X-CN3A and X-CN2B. Leave connectors X-19 and X-40 disconnected.
47540694 28/04/2014
55.16 [55.DTC] / 748
5393-EHF Pump Control PRV's (Directional) - EHF Pumps Solenoids

Short to Power
Context:
codes.
EHF Function is disabled with Diagnostic Trouble Code 5393.
Cause:
UCM has sensed a short to positive condition for the EHF Pump solenoid. The fault is active when EHF setting is
activated, Hydraulics are disabled, and either solenoid voltage feedback is greater than 5 V.

2. Faulty UCM
Solution:

RAPH12SSL0387FA 1
47540694 28/04/2014
55.16 [55.DTC] / 749
Schematic legend
X-CN3A pin 19
X-CN2B pin 8
(3) EHF Retract
UCM Connector
X-CN3A pin 6
3. Measure the voltage of the solenoid wires to chassis ground
(2) Disconnect solenoid connector X-19 and X-40. Disconnect UCM connector X-CN3A and X-CN2B.
(3) Turn the keyswitch ON.
(4) Measure the voltage between X-19 pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle
A. All voltage measurements are less than 0.5 V. Go to Step 4.
B. One or more voltage measurements is greater than 0.5 V. There is a short circuit to another voltage source.
Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
4. Test the UCM
(2) Reconnect UCM connectors X-CN3A and X-CN2B. Leave connectors X-19 and X-40 disconnected.
47540694 28/04/2014
55.16 [55.DTC] / 750
47540694 28/04/2014
55.16 [55.DTC] / 751
5409-CAN Message Error - Aux Override Disabled Due To Aux

Override Button Timeout (30 sec)
Context:
Aux Override is disabled while Diagnostic Trouble Code 5409 is active.
Cause:
The UCM has sensed an error with the Aux Override Button status. The fault is activate when ignition is on and CAN
message from AIC is high for more than 30 seconds.
1. Failure of the Instrument Cluster.
Solution:
1. Use the EST to verify fault code 5409 CAN Message Error - Aux Override Disabled Due To Aux Override Button
Timeout (30 sec) is active.
A. If the fault is active, erase it with the EST.

2. If the fault persists, it is an indication of an Instrument Cluster failure. Replace the Instrument Cluster.
47540694 28/04/2014
55.16 [55.DTC] / 752
5501-Loader Arm Spool Sensor - Sensor Short to Ground/ Open

Circuit
Context:
Limp home loader functions are enabled while Diagnostic Trouble Code 5501 is active.
Cause:
The UCM has sensed that the loader position sensor signal, X-CN3B pin 13 has failed low. The fault is active when
the engine is ON and loader position sensor signal is less than 0.2 V.

3. The loader valve spool sensor has failed.
Solution:

Inspect the UCM, the loader solenoid and loader position sensor connection. All connections should be secure,
tight, free of corrosion, abrasion, and damage.
Inspect the harness from the UCM to the loader solenoids and loader position sensor. Verify that the harness is
free of damage, corrosion, abrasion, and incorrect attachment.
Disconnect the loader position sensor.
B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector
X-CN1A pin 8. Verify the chassis ground connection from X-10 is secure. Repair or replace the harness as
47540694 28/04/2014
55.16 [55.DTC] / 753
Disconnect UCM connector X-CN3B. Disconnect the Loader Position Sensor from the harness.
chassis ground connection must be clean and free of rust, dirt, oil, and paint.
Measure the resistance of connector X-22 pin 4 to chassis ground. The resistance should be less than 10 Ω.
6. Test the UCM.
Reconnect UCM connector CN3B.
Fabricate a jumper wire 20 cm (8 in) that will connect between X-22 pin 1 and X-22 pin 4.
Turn the ignition switch ON and monitor the active fault screen.
Use the jumper wire to short the Loader Position Sensor connector X-22 pin 1 to X-22 pin 4. Fault code 5502
should become active. Fault code 5501 should no longer be active.
A. Fault code 5502 is active and fault code 5501 is no longer active. Temporarily replace the Loader Position
Sensor and retest. Return to step 1 to confirm elimination of the fault.
B. Fault code 5501 is still active. Fault code 5502 is not active. Temporarily replace the UCM and retest. Return
47540694 28/04/2014
55.16 [55.DTC] / 754
5502-Loader Arm Spool Sensor - Sensor Short to Power

Context:
Limp home loader functions are enabled while Diagnostic Trouble Code 5502 is active.
Cause:
The UCM has sensed a higher than normal voltage on the loader valve spool input, X-CN3B pin 13. The fault is active
while the ignition is ON and the loader position sensor voltage is greater than 4.8 V.
1. The signal wire is shorted to another voltage source.

Solution:

Inspect the UCM, the loader solenoid and loader position sensor connections. All connections should be secure,
Disconnect the Loader Position Sensor.
X-CN1A pin 8. Verify the chassis ground connection from connector X-10 is secure. Repair or replace the
4. Measure the voltage of the signal wire.
Disconnect UCM connector X-CN3B. Disconnect the Loader Spool Position Sensor from the harness.
47540694 28/04/2014
55.16 [55.DTC] / 755
chassis ground connection must be clean and free of rust, dirt, oil, and paint.
Measure the resistance between connector X-22 pin 4 and chassis ground. The resistance should be less than
6. Test the UCM.
Use the jumper wire to short the Loader Position Sensor connector X-22 pin 3 to X-22 pin 4.
Turn the ignition switch ON and monitor the active fault screen. Fault code 5501 should become active. Fault
code 5502 should no longer be active.
A. Fault code 5501 is active. Fault code 5502 is no longer active. Temporarily replace the Loader Position Sensor
47540694 28/04/2014
55.16 [55.DTC] / 756
5503-Hydraulic Enable (Mechanical Machines) - EH AUX Output,

Short to Power
Context:
Cause:
Instrument Cluster has sensed a short circuit to another voltage source in the EH Aux Output circuit. The fault is
active while Ignition is On, Aux Output Commanded state is low and EH Aux output is energized.

Solution:


(1) Inspect Instrument Cluster connector X-C23 and the EH AUX PWM Controller connections. All connections
(2) Inspect the harness from the Instrument Cluster to the EH AUX PWM Controller. Verify that the harness is free
47540694 28/04/2014
55.16 [55.DTC] / 757
RAPH12SSL0268FA 1
Schematic Legend
(1) Instrument Cluster Connector (2) EH Aux PWM Controller Connector
X-C23 pin 26 X-430 pin 1
3. Measure the voltage on the power wire.
A. The voltage is less than 0.5 V, temporarily replace the Instrument Cluster and retest. Go to Step 1 to confirm
B. The voltage is greater than 0.5 V. The EH AUX Power wire is shorted to another voltage. Repair or replace
the harness as required. Return to Step 1 to confirm elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 758
5504-Bucket Valve Spool Sensor - Sensor Short to Ground/ Open

Circuit
Context:
Cause:
The UCM has sensed that the loader arm position sensor does not agree with the direction of loader arm command.
The fault is active while the engine is ON and the loader arm position sensor senses loader arm movement but the
solenoids are not energized or loader arm movement is opposite of the energized solenoid.
1. Spool sticking inside the valve body.

2. Improper wiring in circuit, connector X-28 swapped with connector X-27.
3. Failure of the Loader Arm Spool Position Sensor.
4. Faulty UCM.
Solution:
1. Verify that the spool is not stuck in the valve.
Remove the loader arm spool position sensor from the valve body.
Access EST and monitor the spool position.
Move the pintle arm while monitoring the valve position sensor signal. The value should change linearly and not
become erratic.
A. The sensor values change in a linear fashion. The problem is in the valve body. Repair or replace the valve
or spool as required.
B. The fault sensor values did not change in a linear fashion. The problem is in the sensor circuit. Go to step 2.

47540694 28/04/2014
55.16 [55.DTC] / 759
Disconnect the Loader Spool Position Sensor.
X-CN1A pin 8. Verify the chassis ground connection from connector X-10 is tight and secure. Repair or replace
5. Test the UCM.
Disconnect the Loader Spool Position Sensor from the harness.
Turn the key switch ON. Monitor the EST fault code screen. Fault code 5504 should be active.
Use a jumper wire to short X-22 pin 1 to X-22 pin 4. Fault code 5505 should be active.
A. Fault code 5504 is active while the sensor is disconnected and fault code 5505 is active while the X-22 pin 1
is shorted to X-22 pin 4. Temporarily replace the Loader Spool Position Sensor and retest. Return to step 2 to
B. Fault code 5505 is not active while the X-22 pin 1 is shorted to X-22 pin 4. Temporarily replace the UCM and
47540694 28/04/2014
55.16 [55.DTC] / 760
5505-Bucket Valve Spool Sensor - Sensor Short to Power

Context:
Implement limp home operating mode is enabled while Diagnostic Trouble Code 5505 is active.
Cause:
The UCM has sensed a higher than normal voltage on the Bucket Valve Spool Sensor. The fault is active when the
ignition is ON and the Bucket Valve Spool Sensor voltage is high.

2. Failure of Bucket Valve Spool Sensor.
Solution:

Inspect the UCM and Bucket Spool Position Sensor connections. All connections should be secure, tight, free of
Inspect the harness from the UCM to the Bucket Spool Position Sensor. Verify that the harness is free of damage,
Disconnect the Bucket Spool Position Sensor.
X-CN1A pin 8. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.
Disconnect UCM connector X-CN3B. Disconnect the Bucket Spool Position Sensor from the harness.
47540694 28/04/2014
55.16 [55.DTC] / 761
Turn the ignition switch OFF. Use a jumper wire with alligator clips on both ends to short connector X-CN3B pin
(2) Measure the resistance of connector X-21 pin 4 to chassis ground. The resistance should be less than 10 Ω.
6. Test the UCM.
Use the jumper wire to short the Bucket Spool Position Sensor connector X-21 pin 3 to X-21 pin 4.
RAPH12SSL0414EA 1
Schematic Legend
(1) Jumper wire inserted between X-21 pin 3 (2) Bucket Spool Position Sensor
and X-21 pin 4
A. Fault code 5504 is active and fault code 5505 is no longer active. Temporarily replace the Bucket Spool Position
Sensor and retest. Return to step 1 to confirm elimination of the fault.
47540694 28/04/2014
55.16 [55.DTC] / 762

47540694 28/04/2014
55.16 [55.DTC] / 763
5507-Auxiliary Valve Spool Sensor - Sensor Short to Ground/ Open

Circuit
Context:
Cause:
The UCM has sensed that the aux position sensor signal, X-CN3B pin 14 has failed low. The fault is active while the
engine is ON and aux position sensor signal is less than 0.2 V.

3. The auxiliary valve spool sensor has failed.
Solution:

Inspect the UCM, the proportional aux solenoid connections, and the aux position sensor connections. All con-
nections should be secure, tight, free of corrosion, abrasion, and damage.
Inspect the harness from the UCM to the proportional aux solenoids, and the aux position sensor. Verify that the
harness is free of damage, corrosion, abrasion, and incorrect attachment.
Disconnect the Aux Position Sensor.
X-CN1A pin 8. Verify the chassis ground connection from X-10 is secure. Repair or replace the harness as
47540694 28/04/2014
55.16 [55.DTC] / 764
Disconnect UCM connector X-CN3B. Disconnect the Aux Position Sensor from the harness.
Use a jumper wire with alligator clips on both ends to connect X-CN3B pin 14 to chassis ground. The chassis
6. Test the UCM.
RAPH12SSL0412EA 1
Schematic Legend
(1) Jumper wire inserted between X-23 pin 1 (2) Aux Position Sensor
and X-23 pin 4
A. Fault code 5508 is active. Fault code 5507 is no longer active. Temporarily replace the Aux Position Sensor
47540694 28/04/2014
55.16 [55.DTC] / 765

47540694 28/04/2014
55.16 [55.DTC] / 766
5508-Auxiliary Valve Spool Sensor - Sensor Short to Power

Context:
Cause:
The UCM has sensed a higher than normal voltage on the auxiliary valve spool input, X-CN3B pin 14. The fault is
active while ignition is ON and the aux position sensor signal is greater than 4.8 V.

Solution:

Disconnect the Aux Position Sensor.
X-CN1A pin 8. Verify the chassis ground connection from connector X-10 is secure. Repair or replace the
Disconnect UCM connector X-CN3B. Disconnect the Aux Spool Position Sensor from the harness.
47540694 28/04/2014
55.16 [55.DTC] / 767
Fabricate a jumper wire that will connect between connector X-CN3B pin 14 and chassis ground. The chassis
ground connection must be clean and free of rust, dirt, oil and paint.
6. Test the UCM.
Use the jumper wire to short the Aux Position Sensor connector X-23 pin 3 to X-23 pin 4.
RAPH12SSL0413EA 1
Schematic Legend
(1) Jumper wire inserted between X-23 pin 3 (2) Aux Position Sensor
and X-23 pin 4
A. Fault code 5507 is active. Fault code 5508 is no longer active. Temporarily replace the Aux Position Sensor
47540694 28/04/2014
55.16 [55.DTC] / 768

47540694 28/04/2014
55.16 [55.DTC] / 769
5511-Loader Arm Spool Sensor - Implausible State Sensor vs.

Loader Arm Command, Stuck Spool/ PRV
Context:
Cause:
The UCM has sensed that the loader arm position sensor does not agree with the direction of loader arm the com-
mand. The fault is active while the engine is ON and the loader arm position sensor senses loader arm movement
while the solenoids are not energized or loader arm movement is opposite of the energized solenoid.
1. Improper wiring in the circuit, connector X-28 is swapped with connector X-27.
2. The spool is sticking inside the valve body.
3. Failure of the Loader Arm Spool Position Sensor.
4. Faulty UCM.
Solution:
Remove the loader arm spool position sensor from the valve body.
become erratic.
A. The sensor values change in a linear fashion. The problem is in the valve body. Repair or replace the valve or
spool as required. Return to step 2 to confirm elimination of the fault.
B. The sensor values did not change in a linear fashion. The problem is in the sensor circuit. Go to step 2.

47540694 28/04/2014
55.16 [55.DTC] / 770
20111502 1
Legend
(1) Boom / Loader Extend (3) Boom / Loader Position Sensor
(2) Boom / Loader Retract
Disconnect the Loader Spool Position Sensor.
5. Test the UCM.
Disconnect the Loader Spool Position Sensor from the harness.
Turn the ignition switch ON. Monitor the EST fault code screen. Fault code 5511 should be active.
Use a jumper wire to short X-22 pin 1 to X-22 pin 4. Fault code 5502 should be active. Fault code 5511 should
no longer be active.
is shorted to X-22 pin 4. Temporarily replace the Loader Spool Position Sensor and retest. Return to step 2 to
47540694 28/04/2014
55.16 [55.DTC] / 771
47540694 28/04/2014
55.16 [55.DTC] / 772
5512-Bucket Valve Spool Sensor - Implausible State Sensor vs.

Loader Bucket Command
Context:
Loader Hydraulics are disabled with Diagnostic Trouble Code 5512.
Cause:
The UCM has sensed that the Bucket Spool Position Sensor does not agree with the direction of Bucket travel. The
fault is active while the engine is ON and the Bucket Spool Position Sensor senses bucket movement when the
solenoids are not energized or bucket movement opposite of the energized solenoid.

3. Failure of Bucket Spool Position Sensor.
4. Faulty UCM.
Solution:
Remove the bucket spool position sensor from the valve body.
become erratic.
A. The sensor values change in a linear fashion. The problem is in the valve body. Repair or replace the valve or
spool as required. Return to step 2 to confirm elimination of the fault.
B. The sensor values did not change in a linear fashion. The problem is in the sensor circuit. Go to step 2.

Inspect the UCM and Bucket Spool Position Sensor connections. All connections should be secure, tight, free of
Inspect the harness from the UCM to the Bucket Spool Position Sensor. Verify that the harness is free of damage,
47540694 28/04/2014
55.16 [55.DTC] / 773
Inspect the Bucket Valve Retract Spool solenoid and the Bucket Valve Extend solenoid. Verify all connections are
20111502 1
Legend
(1) Bucket Position Sensor (3) Boom Position Sensor
(2) Bucket Valve Retract (4) Aux Position Sensor
A. The connectors are secure and the harness is free of damage. The Bucket Valve Spools are connected prop-
erly. Go to step 4.
Disconnect the Bucket Spool Position Sensor.
X-CN1A pin 8. Repair or replace the harness as required. Return to step 2 to confirm elimination of fault.
5. Test the UCM.
Disconnect the Bucket Spool Position Sensor from the harness.
Use a jumper wire to connect X-21 pin 1 to X-21 pin 4. Fault code 5505 should be active.
is shorted to X-21 pin 4. Temporarily replace the Bucket Spool Position Sensor and retest. Return to step 2 to
47540694 28/04/2014
55.16 [55.DTC] / 774

47540694 28/04/2014
55.16 [55.DTC] / 775
5513-Auxiliary Valve Spool Sensor - Implausible State Sensor vs.

Auxiliary Command
Context:
Cause:
The UCM has sensed that the aux position sensor does not agree with the direction of aux the command. The fault
is active when the engine is ON and the aux position sensor senses aux movement when the solenoids are not
energized or aux movement is opposite of the energized solenoid.

3. Failure of the Aux Position Sensor.
4. Faulty UCM.
Solution:
Remove the auxiliary spool position sensor from the valve body.
become erratic.
A. The fault sensor values change in a linear fashion. The problem is in the valve body. Repair or replace the
valve or spool as required. Return to step 2 to confirm elimination of the fault.
B. The fault sensor values did not change in a linear fashion. The problem is in the sensor circuit. Go to step 2.

47540694 28/04/2014
55.16 [55.DTC] / 776
Inspect the Aux Retract solenoid and the Aux Extend solenoid. Verify all connections are secure, tight, free of
20111502 1
Legend
(1) Aux Valve Retract (3) Bucket Position Sensor
(2) Aux Position Sensor (4) Boom Position Sensor
A. The connectors are secure and the harness is free of damage. The Aux Valve Spools are connected properly.
Go to step 4.
Disconnect the Aux Spool Position Sensor.
5. Test the UCM.
Disconnect the Aux Spool Position Sensor from the harness.
Use a jumper wire to short X-23 pin 1 to X-23 pin 4. Fault code 5508 should be active.
is shorted to X-23 pin 4. Temporarily replace the Aux Spool Position Sensor and retest. Return to step 2 to
47540694 28/04/2014
55.16 [55.DTC] / 777

47540694 28/04/2014
55.16 [55.DTC] / 778
5601-Aux Valve (Directional) - Common Solenoid Return Short to

Power
Context:
Cause:
The UCM has sensed higher than normal voltage on the proportional aux solenoid lines, X-CN1A pin 24 or X-CN1B
pin 33. The fault is active while the ignition is on, hydraulics are disabled, and the solenoid voltage feedback is greater
than 5 V.

Solution:

47540694 28/04/2014
55.16 [55.DTC] / 779
RAPH12SSL0411FA 1
Schematic legend
(1) Proportional Aux Retract Signal (6) Proportional Aux Extend Solenoid
UCM connector
X-CN1A pin 24
(2) Proportional Aux Return, Common (7) Control Valve Aux Position Sensor
Ground UCM Connector
X-CN1A pin 22
(3) Proportional Aux Extend Signal (8) Control Valve Sensor Ground
UCM Connector X-88 pin 9
X-CN1B pin 33 Chassis Ground
(4) Control Valve Aux Position Sensor Signal (9) Sensor Supply
UCM Connector X-88 pin 14
X-CN3B pin 14 UCM connector
X-CN1A pin 8
(5) Proportional Aux Retract Solenoid
47540694 28/04/2014
55.16 [55.DTC] / 780
fault.
47540694 28/04/2014
55.16 [55.DTC] / 781
5602-Loader Auxiliary Valve (Directional) - Loader Auxiliary

Context:
Cause:
The UCM has sensed that the solenoid voltages are too low. The fault is active while the hydraulics are disabled and
solenoid voltages on pin X-CN1A pin 33 and X-CN1B pin 24 are less than 2 V.

Solution:

3. Test the UCM.
47540694 28/04/2014
55.16 [55.DTC] / 782
Disconnect UCM connector X-CN1A and both solenoid connectors, X-29 and X-24.
47540694 28/04/2014
55.16 [55.DTC] / 783
5603-Loader Auxiliary Valve Solenoid Return Open Circuit

Context:
Cause:
The UCM has sensed an open circuit in the proportional aux solenoid return circuit, X-CN1A pin 22. The fault is active
while the ignition is ON and the calculated solenoid resistances have increased over 70 %.
1. An open circuit in the solenoid wiring.

2. The proportional aux solenoids have failed.
Solution:

47540694 28/04/2014
55.16 [55.DTC] / 784
20 Ω.
20 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 785
5701-Pattern Switch - Short to Ground/ Open Circuit

Context:
The selected joystick pattern is locked and cannot be changed while Diagnostic Trouble Code 5701 is active.
Cause:
The UCM has sensed the voltage at X-CN1B pin 15, X-CN2B pin 20 and X-CN2B pin 21 is less than 1.5 V.

3. Faulty Drive Pattern Select Switch.
Solution:

Inspect the UCM and Drive Pattern Selector Switch connections. All connections should be secure, tight, free of
Inspect the harness from the UCM to the Drive Pattern Selector Switch. Verify that the harness is free of damage,
3. Measure the voltage at the switch.
Remove the Drive Pattern Switch (ISO/ H Pattern) from the right hand post.
B. The voltage is less than 10 V. There is a problem in the battery supply to the switch. Repair as required. Return
47540694 28/04/2014
55.16 [55.DTC] / 786
Disconnect UCM connectors X-CN1B and X-CN2B. Disconnect the Drive Pattern (ISO/ H Pattern) Selector Switch.
Measure the resistance between connector X-95 pin 1 to chassis ground. The resistance should be less than
6. Test the Drive Pattern (ISO/ H Pattern) Switch.
Remove the Drive Pattern (ISO/ H Pattern) Switch from the right hand post.
Use a pair of jumper wires with alligator clips to connect the DVM to the switch.
Measure the resistance between pin 5 and pin 3 on the Drive Pattern (ISO/ H Pattern) Switch. The resistance
Actuate the switch to another function. The resistance should change to a value greater than 20,000 Ω.
A. The resistance is less than 10 Ω in the neutral state and the resistance changed to a value greater than
20,000 Ω when the switch was actuated. Go to step 7.
B. The resistance is not less than 10 Ω in the neutral state or the resistance did not change to a value greater
than 20,000 Ω when the switch was actuated. Temporarily replace the Drive Pattern (ISO/ H Pattern) Switch
47540694 28/04/2014
55.16 [55.DTC] / 787
Actuate the switch to the H Pattern. The resistance should change to a value less than 10 Ω.
Actuate the switch to the ISO Pattern. The resistance should change to a value less than 10 Ω.
A. The resistance is greater than 20,000 Ω when the switch is in the neutral state and the resistance changed to
a value less than 10 Ω when the switch was actuated. Temporarily replace the UCM and retest. Return to step
B. The resistance is less than 20,000 Ω while the switch is in the neutral state or the resistance did not change to
a value less than 10 Ω when the switch was actuated. Temporarily replace the Drive Pattern (ISO/ H Pattern)
Switch and retest. Return to step 1 to confirm elimination of fault.
47540694 28/04/2014
55.16 [55.DTC] / 788
5703-Pattern Switch - Short to Power

Context:
The selected joystick pattern is locked and cannot be changed while Diagnostic Trouble Code 5703 is active.
Cause:
The UCM has sensed the voltage at two or more Drive Pattern Selector (ISO/ H Pattern) Switch pins (X-CN1B pin
15, X-CN2B pin 20 or X-CN2B pin 21) is greater than 3.5 V.
1. A short circuit in the wiring.

2. A Faulty Drive Pattern Selector (ISO/ H Pattern) switch.
Solution:

Inspect the UCM and the Drive Pattern Selector Switch connections. All connections should be secure, tight, free
Inspect the harness from the UCM to the Drive Pattern Selector Switch. Verify that the harness is free of damage,
3. Measure the voltage at the switch inputs to the UCM.
Remove the Drive Pattern Switch (ISO/ H Pattern) from the right hand post.
Disconnect connector X-95 from the Drive Pattern Selector Switch.
Disconnect UCM connectors X-CN1B and X-CN2B from the UCM.
47540694 28/04/2014
55.16 [55.DTC] / 789
B. The voltage is greater than 0.5 V, there is a short circuit to another voltage source. Check for a short to battery
supply on X-95 pin 5. Repair as required. Return to step 1 to confirm elimination of fault.
Fabricate a jumper wire that will connect between connector X-CN2B pin 20 and chassis ground. The chassis
Connect one the jumper wire between connector X-CN1B pin 15 and chassis ground. The chassis ground con-
nection must be clean and free of rust, dirt oil and paint.
Remove the Drive Pattern (ISO/ H Pattern) Switch from the right hand post.
Actuate the switch to the other function. The resistance should change to a value greater than 20,000 Ω.
A. The resistance is less than 10 Ω in the neutral state and the resistance changed to a value greater than
20,000 Ω when the switch was actuated. Go to step 6.
B. The resistance is not less than 10 Ω in the neutral state or the resistance did not change to a value greater
than 20,000 Ω when the switch was actuated. Temporarily replace the Drive Pattern (ISO/ H Pattern) Switch
Actuate the switch to the H Pattern. The resistance should change to a value less than 10 Ω.
Actuate the switch to the ISO Pattern. The resistance should change to a value less than 10 Ω.
47540694 28/04/2014
55.16 [55.DTC] / 790
A. The resistance is greater than 20,000 Ω when the switch is in the neutral state and the resistance changed to
a value less than 10 Ω when the switch was actuated. Temporarily replace the UCM and retest. Return to step
B. The resistance is less than 20,000 Ω while the switch is in the neutral state or the resistance did not change to
a value less than 10 Ω when the switch was actuated. Temporarily replace the Drive Pattern (ISO/ H Pattern)
Switch and retest. Return to step 1 to confirm elimination of fault.
47540694 28/04/2014
55.16 [55.DTC] / 791
5811-Loader Lockout Switch - Implausible State

Context:
Cause:
The UCM has sensed an implausible state of the loader lockout switch. The fault is active when the engine is running
and both UCM inputs X-CN2B pin 26 and X-CN3B pin 19, are less than 1.5 V or greater than 3.5 V.

2. Faulty Loader Lockout switch.
3. Faulty UCM.
Solution:

Inspect the UCM and loader lockout switch connections. All connections should be secure, tight, free of corrosion,
Inspect the harness from the UCM to the loader lockout switch. Verify that the harness is free of damage, corrosion,
A. The wiring is free of corrosion, damage, abrasion and incorrect attachment. Go to step 3.
as required. Go to step 1 to confirm elimination of the fault.
Disconnect the loader lockout switch connector X-306.
Measure the voltage between X-306 pin B and chassis ground. The voltage should be approximately 12 V. Wiggle
B. The voltage is less than 10 V. There is a problem with the battery supply to the switch. Check fuses. Repair
or replace the harness as required. Go to step 1 to confirm elimination of the fault.
4. Test the UCM.
47540694 28/04/2014
55.16 [55.DTC] / 792
Disconnect and remove the loader lockout switch.
Fabricate a jumper with that will connect between X-306 pin B and X-306 pin A.
Connect the jumper between X-306 pin B and X-306 pin A.
Monitor the fault code screen. Fault code 5811 should no longer be active.
Use the EST to monitor the loader lockout switch status. The switch status should change from OFF to ON.
Connect the jumper between X-306 pin B and X-306 pin C.
Monitor the fault code screen. Fault code 5811 should no longer be active.
Use the EST to monitor the loader lockout switch status. The switch status should change from ON to OFF.
A. The switch status displayed ON when the jumper was connected between X-306 pin B and pin A. The switch
status displayed OFF when the jumper was not connected between X-306 pin B and pin C. Replace the loader
lockout switch. Return to step 1 to confirm elimination of the fault.
B. The switch status did not change or fault code 5811 remained active. Go to step 5.
5. Measure the resistance through the signal wires.
Use the jumper wire to short X-306 pin A to X-306 pin C.
A. The measured resistance is less than 10 Ω. Go to step 6.
B. The measured resistance is greater than 10 Ω. There is an open circuit in the wiring. Check connector
X-ECC4A/4B. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination
of the fault.
Remove the jumper wire connected between X-306 pin A and X-306 pin C.
A. Both measured voltages are less than 0.5 V. Temporarily replace the UCM and retest. Return to step 6.
B. One or both voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source.
Small EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 793
Medium EH machines
Case machines
47540694 28/04/2014
55.16 [55.DTC] / 794
9004-Memory Error - Triple Redundant: Hour Meter - Location 1

Corrupt
Context:
Cause:
The Instrument Cluster has sensed an internal memory corruption that has been automatically fixed.
1. Memory Fault of the Instrument Cluster.
Solution:
1. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will
appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another
fault. Use the EST to verify fault code 9004 Memory Error - Triple Redundant: Hour Meter - Location 1 is active.

2. If the fault persists, it may be an indication of a potential future Instrument Cluster failure. Continue normal oper-
ations of the machine.
47540694 28/04/2014
55.16 [55.DTC] / 795

Corrupt
Context:
Cause:
Solution:
fault. Use the EST to verify fault code 9005 Memory Error - Triple Redundant: Hour Meter - Location 2 Corrupt is
active.

47540694 28/04/2014
55.16 [55.DTC] / 796

Corrupt
Context:
Cause:
Solution:
fault. Use the EST to verify fault code 9006 Memory Error - Triple Redundant: Hour Meter - Location 3 is active.

47540694 28/04/2014
55.16 [55.DTC] / 797
9151-CAN Connection: CAN Communication Timed Out After 5

Seconds
Context:
Cause:

5. Faulty ECU.
Solution:
If three or more fault codes are active, such as 1051 through 1059 or 9151, 9152, 9153 or 9154 this is an indication
47540694 28/04/2014
55.16 [55.DTC] / 798
9152-CAN Connection - CAN Communication Timed Out After 5

Seconds
Context:
Cause:

5. Faulty ECU.
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 799
9153-CAN Connection - EEC1 Message Timed Out

Context:
Cause:

5. Faulty ECU.
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 800
9154-CAN Connection - TSC1 Message Timed Out

Context:
Cause:

5. Faulty ECU.
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 801
9156-Hyd Enable Switch - Hyd Enable Button Error from AIC

Context:
Diagnostic Trouble Code 9156 has an error priority of amber.
Loader limp home and ground drive limp home operating modes are enabled while Diagnostic Trouble Code 9156 is
active.
Cause:
The UCM is receiving conflicting information about the hydraulic enable button. The fault is active when the ignition
is on and hydraulic enable pin voltage is opposite of value transmitted from instrument cluster.

Solution:
B. Fault code 9156 is recorded again. Go to 1350-Hyd Enable Switch - Implausible State (Hardwire vs CAN)
(55.640).
47540694 28/04/2014
55.16 [55.DTC] / 802
9158-H-Pattern Indicator Short to Ground

Context:
ISO pattern will remain active while Diagnostic Trouble Code 9158 is active.
Cause:
The UCM has sensed that the H-Pattern indicator voltage signal has failed low. The fault is active while the H-Pattern
indicator voltage, X-CN2A pin 23 is less than 5 V.
1. Signal wire short circuit to chassis ground.

2. Faulty pattern select switch.
Solution:

Inspect the UCM and the drive pattern switch connections. All connections should be secure, tight, free of corro-
(2) Inspect the harness from the UCM to the drive pattern switch. Verify that the harness is free of damage,
Remove the switch from the right side column. Disconnect connector X-95.
Measure the voltage between X-95 pin 5 and chassis ground. The voltage should be approximately 12 V. Wiggle
47540694 28/04/2014
55.16 [55.DTC] / 803
A. All voltage measurements are approximately 12 V. Go to step 4.
B. One or more voltage measurements are less than 10 V. There is a problem with the voltage supply to the
switch. Check fuses and splices. Repair or replace the harness or connectors as required. Return to step 1 to
4. Measure the resistance of the indicator wire to other circuits.
Measure the resistance between connector X-95 pin 8 and chassis ground. The resistance should be greater than
Measure the resistance between connector X-95 pin 8 and X-95 pin 9. The resistance should be greater than
B. One or more resistance measurements are less than 20,000 Ω. The signal wire has a short circuit to chassis
ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.
5. Test the switch.
Leave the switch in the neutral position. Measure the resistance between pin 8 and pin 9. The resistance should
A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1.
B. The resistance is less than 20,000 Ω. There is a short circuit in the switch. Temporarily replace the switch and
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 804
9159-ISO-Pattern Indicator Short to Ground

Context:
H pattern will remain active while Diagnostic Trouble Code 9159 is active.
Cause:
The UCM has sensed that the ISO-Pattern indicator voltage signal has failed. The fault is active while the ISO-Pattern
indicator voltage, X-CN2B pin 2 is less than 5 V.
1. The signal wire is shorted to chassis ground.

Solution:

Inspect the harness from the UCM to the drive pattern switch. Verify that the harness is free of damage, corrosion,
47540694 28/04/2014
55.16 [55.DTC] / 805
A. All voltage measurements are approximately 12 V. Go to step 4.
B. One or more voltage measurements are less than 10 V. There is a problem with the voltage supply to the
switch. Check fuses and splices. Repair or replace the harness or connectors as required. Return to step 1 to
4. Measure the resistance of the indicator wire to other circuits.
Measure the resistance between connector X-95 pin 9 and chassis ground. The resistance should be greater than
B. One or more resistance measurements are less than 20,000 Ω. The signal wire has a short circuit to chassis
ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.
5. Test the switch.
A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1.
B. The resistance is less than 20,000 Ω. There is a short circuit in the switch. Temporarily replace the switch and
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 806
9160-H-Pattern Indicator Short to Power

Context:
ISO pattern will remain active while Diagnostic Trouble Code 9160 is active.
Cause:
The UCM has sensed that the H-Pattern indicator voltage signal has failed. The fault is active while the H-Pattern
indicator voltage, X-CN2A pin 23 is greater than 8 V.

Solution:

harness to reveal an intermittent condition.
47540694 28/04/2014
55.16 [55.DTC] / 807
4. Measure the resistance of the signal wire to other circuits.
Disconnect UCM connector X-CN2A and X-CN2B.
B. One or more resistance measurements are less than 20,000 Ω. The signal wire has a short circuit to another
circuit. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.
5. Test the switch.
be less than 10 Ω.
Measure the resistance between pin 8 and pin 10. The resistance should be greater than 20,000 Ω.
A. All resistance measurements are correct. Go to step 6.
B. One or more resistance measurements are incorrect. Temporarily replace the switch and retest. Return to step
6. Test the switch LED.
Set the digital voltmeter to measure diode voltage.
Place the red probe on pin 7 and place the black probe on pin 8. The forward bias voltage should be approximately
0.7 V.
A. The voltage is between 0.5 V and 0.8 V. Temporarily replace the UCM and retest. Return to step 1 to confirm
B. The voltage is less 0.5 V. The diode has an internal short circuit. Temporarily replace the switch and retest.
47540694 28/04/2014
55.16 [55.DTC] / 808
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 809
9161-ISO-Pattern Indicator Short to Power

Context:
H pattern will remain active while Diagnostic Trouble Code 9161 is active.
Cause:
The UCM has sensed that the ISO-Pattern indicator voltage signal has failed. The fault is active while the ISO-Pattern
indicator voltage, X-CN2B pin 2 is greater than 8 V.

Solution:

harness to reveal an intermittent condition.
47540694 28/04/2014
55.16 [55.DTC] / 810
4. Measure the resistance of the signal wire to other circuits.
Disconnect UCM connector X-CN2A and X-CN2B.
B. One or more resistance measurements are less than 20,000 Ω. The signal wire has a short circuit to another
circuit. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.
5. Test the switch.
be less than 10 Ω.
A. All resistance measurements are correct. Go to step 6.
B. One or more resistance measurements are incorrect. Temporarily replace the switch and retest. Return to step
6. Test the switch LED.
Set the digital voltmeter to measure diode voltage.
Place the red probe on pin 10 and place the black probe on pin 9. The forward bias voltage should be approxi-
mately 0.7 V.
A. The voltage is between 0.5 V and 0.8 V. Temporarily replace the UCM and retest. Return to step 1 to confirm
B. The voltage is less 0.5 V. The diode has an internal short circuit. Temporarily replace the switch and retest.
47540694 28/04/2014
55.16 [55.DTC] / 811
Small EH machines
Medium EH machines
47540694 28/04/2014
55.16 [55.DTC] / 812
9401-Memory Error - Double Redundant: Memory Corruption

Detected and Repaired
Context:
Cause:
1. Memory Fault in the Instrument Cluster.
Solution:
fault. Use the EST to verify fault code 9401 Memory Error - Double Redundant: Memory Corruption Detected and
Repaired is active.

47540694 28/04/2014
55.16 [55.DTC] / 813
9403-Memory Error - Double Redundant: Unrecoverable Memory

Corruption Operable
Context:
On EH controled machines, error code 9403 and/or 1207 displays after updating the earlier instrument cluster software
to version 1.3.0.0
Cause:
The Instrument Cluster expects the Enhanced High Flow (EHF) option is on the machine and displays the error codes
when the machine model configuration does not match the expectation of the Instrument Cluster.
Solution:
1. Use EST to reset the machine model configurations and clear the fault code(s).
(1) Connect the EST to the machine diagnostics connector per the Cable and Adapter Help icon.
(2) Sit in the seat to power the controllers.
(3) Click on the Controller Status icon. Verify that the Instrument Cluster (IC) and the Vehicle Control Module
(VCM) are both online.
(4) Click on the configuration icon.
(5) Double click on the Machine Configurations selection.
(6) Click on Set up Controller for Configuring. .
c) Select Model
d) Select Region
A. Error code 9403 and/or 1207 is no longer displayed. OK to return the machine to service.
B. Error code 9403 and/or 1207 are active,

For non-EHF machines continue with step 2
C. Error code 9403 and/or 1207 are active,

For EHF machines continue with step 3
2. Configure the machine to a model that offers EHF as an option and reconfigure to the original model.
Example: The SR150 or L215 are models that do not offer the EHF option and is displaying fault code 9403 after
configuring correctly and performing the power cycle.
c) Select a known EHF model such as SV300 or L230.
d) Select Region
e) Select available.
47540694 28/04/2014
55.16 [55.DTC] / 814
(5) Configure the machine to the correct settings of SR150 or L215 and EHF Not Available.
3. Ensure Enhanced High Flow is available and select a different model that offers EHF option.
Example: SV300 and L230 are models that offer EHF option and display 9403 after configuring correctly.
c) Select a different known model that is not the same model as the actual machine.
d) Select Region
(5) When fault code 9403 and/or 1207 are no longer displayed, follow steps 1 - 4 again to reconfigure the machine
back to the correct model.
47540694 28/04/2014
55.16 [55.DTC] / 815
9404-Memory Error - Triple Redundant: Hour Meter - Hour Meter

Failure
Context:
Cause:
The Instrument Cluster has sensed an internal failure.
Solution:
1. Use the machine to recreate conditions for error. Use the EST to verify fault code 9404 Memory Error - Triple
Redundant: Hour Meter - Hour Meter Failure is active.
2. Use the EST to reset the Instrument Cluster memory and clear the fault.
A. If the fault clears, Continue normal operation.
B. If the fault does not clear, the Instrument Cluster has failed. Replace the Instrument Cluster.
nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 816
9405-CAN - DM1 (EH Machines): Loss Of DM1 Message From UCM

Context:
Cause:

5. Faulty ECU.
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 817
9406-CAN - Can Communication Lost (EH Machines): Loss Of All

CAN Communication From UCM
Context:
Cause:

5. Faulty ECU.
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 818
9407-Memory Error - ID Errors: Unrecoverable Hardware ID

Context:
The vehicle is immediately disabled with Diagnostic Trouble Code 9407.
Cause:
Solution:
1. Use the machine to recreate conditions for error. Use the EST to verify fault code 9407 Memory Error - ID Errors:
Unrecoverable Hardware ID is active.
A. If the fault is active, the Instrument Cluster has failed. Replace the Instrument Cluster.
nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 819
9408-Memory Error - ID Errors: Unrecoverable Panel ID

Context:
The vehicle is immediately disabled with Diagnostic Trouble Code 9408.
Cause:
Solution:
1. Use the machine to recreate conditions for error. Use the EST to verify fault code Memory Error - ID Errors:
Unrecoverable Panel ID is active.
A. If the fault is active, the Instrument Cluster has failed. Replace the Instrument Cluster.
nearby wiring.
resolved.
continue operation.
47540694 28/04/2014
55.16 [55.DTC] / 820
9410-Loss of EGR inducement status message from EDC

Context:
Cause:

5. Faulty ECU.
Solution:
47540694 28/04/2014
55.16 [55.DTC] / 821
Index
FAULT CODES - DTC

1002-Engine Coolant Temperature Sender - Over Temperature >110° C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1004-Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1009-Hydraulic Oil Temperature Sender - Over Temperature >210° F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1014-Cluster Battery Monitor: Over Voltage > 16.5 volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1015-Cluster Battery Monitor: Under Voltage < 11.5 volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1025-Throttle Sensor - Out Of Range Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1026-Hand Throttle Signal Out Of Range - Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1030-Throttle Sensor - Out Of Range Short to Ground/ Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1031-Hand Throttle Sensor - Short To Ground/ Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1040-Engine overspeed warning, Engine speed greater than 2750 RPM for 5 seconds . . . . . . . . . . . . . . . . . . . . . 44
1041-RPM Monitoring - Over Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1045-Fuel Level Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1051-Timeout of CAN message EEC1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1053-Timeout of CAN message CM1BC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1054-Timeout of CAN message engine temperature, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . 55
1056-Timeout of CAN message DPFC1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1058-Timeout of CAN message EDC2BC, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1059-Timeout of CAN message DM1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1201-Hydraulic oil filter switch open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1202-RPM Monitoring - Over Speed (Max) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1203-RPM Monitoring - Open Circuit/ Short to Ground/ Short to Power EH Units (*) . . . . . . . . . . . . . . . . . . . . . . . . 65
1203-RPM Monitoring - Open Circuit/ Short to Ground/ Short to Power Mechanical Units (*) . . . . . . . . . . . . . . . . 62
1205-Hydraulic Enable (EH Machines) - Hydraulic Enable Output, Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . 67
1206-CAN Connection: Configuration Response Timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1207-Memory Parameters - Invalid Configuration Between IC and UCM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1208-Seat Switch - Plausibility Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1211-Calibration Functions - Joystick Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1212-Calibration Functions - Ground Drive Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1213-Calibration Functions - Loader Valve Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1214-Calibration Functions - Throttle Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1221-Health Monitor Functions - UCM - UCM Temperature / Current Draw Over Limit (*) . . . . . . . . . . . . . . . . . . . 79
1222-Health Monitor Functions - UCM - UCM Sustained Over Temperature Limit (*) . . . . . . . . . . . . . . . . . . . . . . . 80
47540694 28/04/2014
55.16 [55.DTC] / 822
1223-Health Monitor Functions - UCM - UCM Sustained Over Current Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1224-Health Monitor Functions - UCM - Internal Memory or Core Monitoring Fault (*) . . . . . . . . . . . . . . . . . . . . . . 82
1225-Health Monitor Functions - UCM - EEPROM Memory Checksum Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1350-Hyd Enable Switch - Implausible State (Hardwire vs CAN) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1511-Right Brake Lights Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1512-Right Brake Lights Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1513-Right Brake Lights Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1521-Left Brake Lights Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1522-Left Brake Lights Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1523-Left Brake Lights Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1532-Backup Alarm - Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1533-Backup Alarm - Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1900-UCM - UCM Ground Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1901-UCM - UCM Supply Voltage High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1902-UCM - UCM Supply Voltage Low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1903-UCM - UCM Supply Voltage Below Operational Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1904-UCM - Rail 12VB: 5V Regulators Supply Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1905-UCM - 5VREF1 Sensor Supply Voltage Out of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1906-UCM - 5VREF3 Sensor Supply Voltage Out of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1907-UCM - Rail 12VF1: Aux Retract Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1908-UCM - Rail 12VF2: Bucket Extend Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1909-UCM - Rail 12VF3: Boom Raise/Lower Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1910-UCM - Rail 12VH: Ldr Plt Interlk & Port Lock Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1911-UCM - Rail 12VH1: Left & Right Pump Reverse Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1912-UCM - Rail 12VM: Left & Right Brake Lights & Aux Extend Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . 123
1913-UCM - Rail 12VS1: Bucket Curl Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1914-UCM - Rail 12VS2: Backup Alarm Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1915-UCM - Rail 12VT1: Two Speed Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1916-UCM - Rail 12VU1: Right & Left Pumps Forward Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1917-UCM - Rail 12VU2: Park Brake Solenoid Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3007-Engine Coolant Temperature Sender - Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3008-Engine Coolant Temperature Sender - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3010-Air intake temperature sensor signal above maximum range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3011-Air intake temperature sensor signal below minimum range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3027-Oil pressure signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3051-Battery Voltage To Engine Controller - Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3052-Battery Voltage To Engine Controller - Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3059-ECM afterrun was interrupted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
47540694 28/04/2014
55.16 [55.DTC] / 823
3088-Crankshaft Sensor - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3089-Crankshaft Sensor - Invalid Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3090-Camshaft Sensor - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3091-Camshaft sensor - Invalid signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3093-Offset Between Camshaft And Crankshaft - Outside Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3096-ECM Busoff on vehicle CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3104-Rail Pressure Relief Valve - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3105-Rail Pressure Relief Valve - Pressure Shock Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3106-Rail Pressure Relief Valve - Did Not Open After Pressure Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3107-Fuel Metering Unit - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3108-Fuel Metering Unit - Short Circuit to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3137-Metering Unit - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3139-Metering Unit Signal Range Check - Signal Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
3140-Metering Unit Signal Range Check - Signal Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3141-Set point of fuel volume flow through metering unit is lower than calculated limit . . . . . . . . . . . . . . . . . . . . . 187
3146-Water detected in fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3157-CAN Engine Timeout SCH Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3158-Engine controller configuration error anti-tamper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3166-Fuel filter heater relay - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3167-Fuel Filter Heater Relay - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3168-Fuel filter heater relay - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3169-Fuel filter heater relay - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3176-Setpoint of metering unit not plausible in overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3177-Engine overspeed detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3179-Timeout of CAN Message BC2EDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
3180-Timeout of CAN Message VCM2EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3182-Timeout Of CAN Message RxCCVS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3188-Cylinder 1 Warning - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3210-Bank 1 - General Short Circuit To Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3218-Bank 2 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3230-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3235-Number of Injections Limited - by Charge Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3236-Number of Injections Limited - by Quantity Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
3237-Number of Injections Limited - by Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3238-Communication error of CJ940 processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
47540694 28/04/2014
55.16 [55.DTC] / 824
3239-Engine Controller EEPROM - Read Operation Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
3240-Engine controller EEPROM - Write operation failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3241-Engine controller EEPROM - Default value used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3242-Engine Controller (Locked) Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3243-Engine Controller Recovery (Suppressed) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3244-Engine Controller Recovery (Visible) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3245-Engine Controller - Watchdog Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3252-Controller Watchdog - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3253-ADC Monitoring - Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3255-ADC Monitoring Test Impulse Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
3256-ADC Monitoring Queue Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3260-Low side power - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
3261-Low side power - short circuit to battery or excess temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3262-Low side power - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
3265-Overrun Monitoring - Injection Time Too Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3266-Error in engine speed check, speed signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3283-Sensor Supply Voltage 2 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3285-Sensor Supply Voltage 3 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3293-Fuel Metering Unit: maximum positive deviation of rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . 246
3301-Fuel high pressure pump is at minimum delivery and the Rail pressure is not reducing . . . . . . . . . . . . . . . 247
3305-Cannot maintain rail pressure above the minimum pressure of 200 Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
3309-Maximum Fuel rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
3334-Timeout of CAN Message TSC1 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
3335-Timeout of CAN message TSC1-PE torque (when inactive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
3338-Timeout of CAN message TSC1-VE speed (when inactive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3339-Timeout of CAN message TSC1-VE speed (when active) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
3350-Terminal 50 - always on, starting circuit signal is active for an excessive time period . . . . . . . . . . . . . . . . . 257
3358-CAN transmit timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3361-ECM EEPROM - General Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
3362-Torque to Quantity Map - Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3368-Torque limitation due to performance limiter, may be triggered by inducement . . . . . . . . . . . . . . . . . . . . . . . 261
3369-Torque reduction due to smoke reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
3370-Torque limitation due to engine protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3371-Torque limitation due to Fuel quantity Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
3374-Unit injector NEMA codes are invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
3390-Engine Air Filter Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3390-Engine Air Filter Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
3402-Rail pressure sensor: maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
3403-ECU Power Stages: Starter relay HS power stage over temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3405-ECU Power stages: Open load temperature error on the Turbocharger PWM output power stage . . . . . . 273
3406-ECU Power stages: Over temperature error on the Turbocharger PWM output power stage . . . . . . . . . . . 275
3408-Lambda sensor: Oxygen concentration implausibly high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
47540694 28/04/2014
55.16 [55.DTC] / 825
3409-Oil pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
3410-Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
3414-Short circuit in cylinder 1 glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3418-ECU Power stages: SCB error on the Turbocharger PWM output power stage . . . . . . . . . . . . . . . . . . . . . . 291
3419-ECU Power stages: SCG error on the Turbocharger PWM output power stage . . . . . . . . . . . . . . . . . . . . . . 293
3420-CAN Bus Received frames: DFC of Auxiliary Engine Shutdown Switch Message . . . . . . . . . . . . . . . . . . . . 295
3425-Turbocharger: Over boost deviation at P2 too high in pressure charger regulator . . . . . . . . . . . . . . . . . . . . 296
3426-Low efficiency in DPF filter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
3427-Diesel particulate filter (DPF): Signal range check flow resistance of the particulate filter - low (*) . . . . . . 298
3428-Diesel Particulate Filter Pressure sensor: not plausibility error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
3429-Diesel Particulate filter Pressure sensor: hoseline plausibility error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
3430-EGR Inducement less severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3431-Exhaust Gas Recirculation (EGR) inducement most severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . 302
3432-Exhaust Gas Recirculation (EGR) inducement warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
3433-Diesel Particulate Filter (DPF) inducement less severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
3434-Diesel Particulate Filter (DPF) inducement most severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3435-Diesel Particulate Filter (DPF) inducement warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
3517-Ambient air temperature sensor failure (of humidity sensor) - signal too high . . . . . . . . . . . . . . . . . . . . . . . . 307
3518-Ambient air temperature sensor failure (of humidity sensor) - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . 308
3616-Torque limitation due to turbo charger protection high altitude operation related . . . . . . . . . . . . . . . . . . . . . 309
3648-EVGT Boost pressure monitoring for over boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3650-Battery voltage: SRC high for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
3651-Battery voltage: SRC low for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3652-CAN Bus: Bus off of CAN node A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3655-Torque limitation, Engine protection: General report of the event of torque limitations . . . . . . . . . . . . . . . . 317
3656-Torque limitation, Engine protection: Torque limitation caused by particulate filter . . . . . . . . . . . . . . . . . . . . 318
3657-Timeout Error of CAN-Receive-Frame CM1BC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3659-Battery voltage: Power stage diagnosis could be disabled due to high battery voltage . . . . . . . . . . . . . . . . 320
3660-Battery voltage: Power stage diagnosis could be disabled due to low Battery voltage . . . . . . . . . . . . . . . . 321
3663-EGR command saturation over higher threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3664-EGR command saturation over lower threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
3667-Open load error for power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3668-Over temperature error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
3669-Short circuit to battery on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
47540694 28/04/2014
55.16 [55.DTC] / 826
3671-Short circuit to ground on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3673-Short circuit over load error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3674-Under voltage error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
3675-DFC for long time valve drift at closed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
3676-DFC for valve position sensor voltage SRC high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
3677-DFC for valve position sensor voltage SRC low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
3680-Injection cut off: Injection cut off demand (ICO) for shut off coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
3688-Water sensor in the fuel filter: WIF sensor check is failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
3689-Faulty diagnostic data transmission or protocol error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
3691-No load error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
3692-Over temperature error on ECU power stage for glow plug low voltage system . . . . . . . . . . . . . . . . . . . . . . 349
3693-Short circuit to battery error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
3694-Short circuit to ground error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3695-Failure in glow plug cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
3699-EEPROM: Error in EEPROM block EEPData1, SD correction can not be calculated . . . . . . . . . . . . . . . . . 362
3702-Injection control: Detection of failed engine start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
3703-Injection control: check of minimum rail pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
3704-Injector adjustment programming: Check of missing injector adjustment value programming . . . . . . . . . . 365
3705-Injector adjustment programming: check of missing injector adjustment value programming . . . . . . . . . . . 366
3706-Injector adjustment programming: check of missing injector adjustment value programming . . . . . . . . . . . 367
3707-Lambda sensor: Open circuit at the lambda sensor Nernst cell pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
3708-Lambda sensor: Open circuit at the lambda sensor pump current pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
3709-Lambda sensor: Open circuit at the lambda sensor virtual ground pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
3710-Lambda sensor: Fault to indicate dynamics of the sensor signal too small . . . . . . . . . . . . . . . . . . . . . . . . . . 374
3711-SCB error of the LSU Heater Power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
3712-Lambda sensor: SCG error of the LSU heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
3713-Lambda sensor: Open Load error of the LSU Heater Power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
3714-Lambda sensor: Fault code to indicate SRC High error for O2 calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
3715-Lambda sensor: SRC Low error for O2 calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
3716-Lambda sensor: O2 value above the max threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
3720-Lambda sensor: Low battery voltage at the SPI chip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
3721-Lambda sensor: Fault check to indicate SPI chip error of lambda sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
3722-Lambda sensor: LSU sensor temperature Ri exceeds the maximum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
3723-Lambda sensor: LSU sensor temperature Ri is below the minimum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
3724-Lambda sensor: Short to battery at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
3725-Lambda sensor: Short to ground at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
3727-Low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
47540694 28/04/2014
55.16 [55.DTC] / 827
3728-Too low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
3735-Fuel Metering Unit: over temperature of device driver of metering unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
3736-O2 concentration is outside the predefined window during Heater coupling detection . . . . . . . . . . . . . . . . . 397
3737-Lambda sensor: Over temperature error of the LSU Heater Power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
3738-ECU Internal: Diagnostic fault check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
3739-Power stages, Injector: Loss of synchronization sending bytes to the MM from CPU . . . . . . . . . . . . . . . . . 400
3740-Power stages, Injector: DFC to set a torque limitation once an error is detected before MoCSOP's error re-
action is set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3741-Power stages, Injector: Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3742-Power stages, Injector: Too many SPI errors during MoCSOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3743-Power stages, Injector : Diagnostic fault check to report the error in under voltage monitoring . . . . . . . . . 404
3745-Power stages, Injector: Diagnostic fault check to report that WDA is not working . . . . . . . . . . . . . . . . . . . . 405
3746-Power stages, Injector: OS timeout in shutoff path test. Failure setting the alarm task period. . . . . . . . . . 406
3747-Power stages, Injector: Diagnostic fault check to report that the positive test failed . . . . . . . . . . . . . . . . . . . 407
3748-Power stages, Injector: Diagnostic fault check to report the timeout in the shutoff path test . . . . . . . . . . . . 408
3750-Injection control: Error in the plausibility of the injection energizing time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
3751-Injection control: Error in the plausibility of the start of energizing angles . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
3752-Zero Fuel Calibration (ZFC): Error in the plausibility of the energizing times of the zero fuel quantity calibration
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
3753-Level 2 Monitoring: Diagnostic fault check to report the error due to injection quantity correction . . . . . . . 412
3754-Level 2 Monitoring: Diagnostic fault check to report the plausibility error in rail pressure monitoring . . . . 413
3755-Level 2 Monitoring: Diagnostic fault check to report the error due to torque comparison . . . . . . . . . . . . . . 414
3756-Level 2 Monitoring: Diagnosis fault check to report the demand for normal mode due to an error in the post
injection 2 quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
3757-Level 2 Monitoring: Diagnosis fault check to report the error to demand for an ICO due to an error in the post
injection 2 shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
3758-Level 2 Monitoring: Diagnosis fault check to report the error to demand for an ICO due to an error in the post
injection 3 efficiency factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
3759-Level 2 Monitoring: Diagnosis of current path limitation forced by Engine Control Unit (ECU) monitoring level
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
3760-Level 2 Monitoring: Diagnosis air path limitation due to a functional control unit monitoring forced by Engine
Control Unit (ECU) monitoring level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
3761-Level 2 Monitoring: Diagnosis quantity path limitation due to a functional control unit monitoring (level 2) 420
3762-Level 2 monitoring: Reported overvoltage of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
3763-Level 2 monitoring: Reported under voltage of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
3764-Main Relay: Early opening defect of main relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
3766-Diesel particulate filter pressure sensor: Fault check for the pressure sensor plausibility (*) . . . . . . . . . . . 427
3767-ECU internal: Diagnostic fault check to report 'WDA active' due to errors in query-/response communication
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
3768-ECU Internal: Diagnostic fault check to report 'ABE active' due to under voltage detection . . . . . . . . . . . . 429
3769-ECU Internal: Diagnostic fault check to report 'ABE active' due to overvoltage detection . . . . . . . . . . . . . . 430
3770-ECU internal: Diagnostic fault check to report 'WDA/ABE active' due to unknown reason . . . . . . . . . . . . . 431
3771-Oxidation Catalyst: Up and down stream temperature sensors in Oxidation catalysts exchanged . . . . . . 432
47540694 28/04/2014
55.16 [55.DTC] / 828
3772-Turbocharger: Over boost deviation at P2 too high in pressure charge regulator . . . . . . . . . . . . . . . . . . . . . 434
3773-Turbocharger: Underboost detected in pressure charger regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
3786-Diesel particulate filter signal range check is high (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
3787-Diesel particulate filter (DPF) : Signal range check flow resistance of the particulate filter - very high (*) . 438
3789-Regeneration duration exceeds maximum allowed duration (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
3790-Diesel particulate filter: Signal range check flow resistance of the particulate filter - max (*) . . . . . . . . . . . 440
3794-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor . . . 442
3795-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor . . . 443
3796-Diesel particulate filter pressure sensor hose line error (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
3797-Diesel particulate filter pressure sensor: SRC high for differential pressure sensor (*) . . . . . . . . . . . . . . . . 445
3798-Diesel particulate filter pressure sensor: SRC low for differential pressure sensor (*) . . . . . . . . . . . . . . . . . 447
3799-Pressure Relief valve: pressure relief valve is forced to open, perform pressure shock . . . . . . . . . . . . . . . 449
3800-Pressure relief valve: Quantity balance check if a successful PRV opening is ensured . . . . . . . . . . . . . . . 450
3801-Turbine upstream pressure sensor: SRC high for turbine upstream pressure sensor . . . . . . . . . . . . . . . . . 451
3802-Turbine upstream pressure sensor: SRC low for turbine upstream pressure sensor . . . . . . . . . . . . . . . . . . 453
3803-ECU internal: Error R2S2 module (low level chip driver for the power stage chips) . . . . . . . . . . . . . . . . . . . 455
3808-Fuel Metering Unit: set point of metering unit in idle mode not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
3810-Fuel pressure sensor: Rail pressure raw value is intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
3811-ECU sensor supply monitor : ECU internal: Error sensor supplies 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
3812-Physical range check high for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
3813-Physical range check low for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
3814-ECU temperature sensor: SPI error ECU temperature sensor (LM71) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
3815-Low efficiency in DPF filter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
3818-Open load error for power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
3820-Over temperature error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
3825-Short circuit over load error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
3826-Temperature dependent over current error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
3827-Under voltage error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
3830-DFC for valve position sensor physical SRC high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
3831-DFC for valve position sensor physical SRC low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
3834-ECU Power stages: Throttle valve actuator power stage: SRC High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
3835-ECU Power stages: Throttle valve actuator power stage: SRC low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
3838-Oxidation catalyst upstream temperature shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
3839-Oxidation catalyst upstream temperature shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
47540694 28/04/2014
55.16 [55.DTC] / 829
3840-Diesel particulate filter upstream temperature sensor shorted to high source (*) . . . . . . . . . . . . . . . . . . . . . 489
3841-Diesel particulate filter upstream temperature sensor shorted to low source (*) . . . . . . . . . . . . . . . . . . . . . . 491
3842-Turbine upstream temperature sensor shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
3843-Turbine upstream temperature sensor shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
3844-Zero fuel calibration by lambda (ZFL) : DFC reporting error state on comparing energizing time to max value
injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
injector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
injector 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
injector 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
3848-Zero fuel calibration by lambda (ZFL) : DFC reporting error state on comparing energizing time to min value
injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
injector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
injector 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
injector 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
3852-Lambda sensor: The maximum allowed time for blow out is exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
3870-CAN message not received from Vehicle Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
3899-Info: Engine temperature exceeded pre-warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
3900-Info: Engine temperature exceeded warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
3906-Injector: Number of injections is limited by quantity balance of high pressure pump . . . . . . . . . . . . . . . . . . 509
3910-Fuel metering unit: Error check for loose contact between metering unit and ECU . . . . . . . . . . . . . . . . . . . 510
3915-Pressure Relief Valve: Averaged rail pressure is outside the expected range with open PRV . . . . . . . . . . 511
4043-Hydraulic Oil Temperature Sender Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
4044-Hydraulic Oil Temperature Sender Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
4055-Park Brake Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
4056-Park Brake Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
4057-Park Brake Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
4061-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . . . . . . . . . . . . . 523
4062-Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*) . . . . . . . . . . . 525
4071-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . 527
4072-Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) . . . . . . . . . . . . 529
4081-Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*) . . . . . . . . . . . . 531
4082-Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground (*) . . . . . . . . . . 533
4083-Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . . . . . . . . . . . . . . 535
4309-Park Brake Button - Park Brake Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
4361-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . . . . . . . . . . . . . 539
4362-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*) . . . . . . . . . . . 541
4371-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . 543
47540694 28/04/2014
55.16 [55.DTC] / 830
4372-Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) . . . . . . . . . . . . 545
4381-Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*) . . . . . . . . . . . . 547
4382-Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground (*) . . . . . . . . . . 549
4383-Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . . . . . . . . . . . . . . 552
4401-Park Brake (Mechanical Machines) - Park Brake Solenoid - Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . 554
4402-Park Brake (Mechanical Machines) - Park Brake Solenoid - Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . 557
4431-Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) (*) . . . . . . . . . . . 559
4731-Right Swash Plate Sensor - Pin A Short to Ground/ Open Circuit Right Hand Pump Angle #1 (*) . . . . . . . 562
4732-Right Swash Plate Sensor - Pin A Short to Power Right Hand Pump Angle #1 (*) . . . . . . . . . . . . . . . . . . . . 565
4734-Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit Right Hand Pump Angle #2 (*) . 567
4735-Right Swash Plate Angle Sensor - Pin B Short to Power Right Hand Pump Angle #2 (*) . . . . . . . . . . . . . . 570
4737-Right Swash Plate Angle Sensor - In Range Fault Right Hand Pump Angle #1 and Right Hand Pump Angle
#2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
4741-Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit Left Hand Angle #1 (*) . . . . . . . . . 575
4742-Left Swash Plate Angle Sensor - Pin A Short to Power Left Hand Angle #1 (*) . . . . . . . . . . . . . . . . . . . . . . . 578
4744-Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit Left Hand Pump Angle #2 (*) . . . . 580
4745-Left Swash Plate Angle Sensor - Pin B Short to Power Left Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . 583
4747-Left Swash Plate Angle Sensor - In Range Fault Left Hand Pump Angle #1 and Left Hand Pump Angle #2 (*)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
4752-Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle
Left Hand Pump Angle #1 and Left Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588
4754-Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate
Angle Right Hand Pump Angle #1 and Right Hand Pump Angle #2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
4781-Solenoid Valve - Solenoid Supply Open Circuit Two Speed Solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592
4782-Solenoid Valve - Solenoid Supply Short to Ground Two Speed Solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . 594
4783-Solenoid Valve - Solenoid Supply Short to Power Two Speed Solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 596
4951-Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid, Short to Power (*) . . . . . . . . . . . 598
4952-Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid Open Circuit (*) . . . . . . . . . . . . . . 600
5051-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
5052-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . 604
5053-Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 606
5061-Port Lock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
5062-Port Lock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
5063-Port Lock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
5121-Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 614
5122-Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 618
5124-Right Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
5131-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 627
5132-Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
5134-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 635
5135-Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
5137-Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
47540694 28/04/2014
55.16 [55.DTC] / 831
5141-Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648
5142-Aux Thumbwheel Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
5144-Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
5145-Aux Thumbwheel Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656
5147-Aux Thumbwheel Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
5201-Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . 661
5202-Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . 665
5204-Left Joystick L-R Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 669
5211-Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
5212-Left Joystick F-B Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
5214-Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 682
5215-Left Joystick F-B Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686
5217-Left Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 690
5221-Loader Arm Valve (Directional) - Solenoid Raise A Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 695
5222-Loader Arm Valve (Directional) - Solenoid Raise A Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . 697
5231-Loader Arm Valve (Directional) - Solenoid Lower B Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . 699
5232-Loader Arm Valve (Directional) - Solenoid Lower B Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . 701
5241-Boom Valve (Directional) - Common Solenoid (C) Return Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . 703
5242-Loader Arm Valve (Directional) - Loader Arm Solenoids Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . 705
5243-Boom Valve (Directional) - Common Solenoid (C) Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 707
5251-Loader Bucket Valve (Directional) - Solenoid Rollback (A) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . 709
5252-Loader Bucket Valve (Directional) - Solenoid Rollback (A) Supply Short to Ground (*) . . . . . . . . . . . . . . . . 711
5261-Bucket Valve (Directional) - Solenoid Dump (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
5262-Bucket Valve (Directional) - Solenoid Dump (B) Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . 715
5271-Bucket Valve (Directional) - Common Solenoid (C) Return Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . 717
5272-Loader Bucket Valve (Directional) - Loader Bucket Solenoids Short to Ground (*) . . . . . . . . . . . . . . . . . . . . 719
5273-Bucket Valve (Directional) - Common Solenoid (C) Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 721
5281-Aux Valve (Directional) - Solenoid Forward (A) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723
5282-Aux Valve (Directional) - Solenoid Forward (A) Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 725
5291-Aux Valve (Directional) - Solenoid Reverse (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727
5292-Aux Valve (Directional) - Solenoid Reverse (B) Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 729
5309-Float Button - Float Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731
5371-EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Open Circuit (*) . . . . . . . . . . . . . . . 733
5372-EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Short to Ground (*) . . . . . . . . . . . . 736
5381-EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . 738
5382-EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Short to Ground (*) . . . . . . . . . . . . 741
5391-EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . 743
5392-EHF Pump Control PRV's (Directional) - EHF Pumps Solenoids Short to Ground (*) . . . . . . . . . . . . . . . . . 746
5393-EHF Pump Control PRV's (Directional) - EHF Pumps Solenoids Short to Power (*) . . . . . . . . . . . . . . . . . . 749
5409-CAN Message Error - Aux Override Disabled Due To Aux Override Button Timeout (30 sec) (*) . . . . . . . . 752
47540694 28/04/2014
55.16 [55.DTC] / 832
5501-Loader Arm Spool Sensor - Sensor Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753
5502-Loader Arm Spool Sensor - Sensor Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755
5503-Hydraulic Enable (Mechanical Machines) - EH AUX Output, Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . 757
5504-Bucket Valve Spool Sensor - Sensor Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 759
5505-Bucket Valve Spool Sensor - Sensor Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761
5507-Auxiliary Valve Spool Sensor - Sensor Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764
5508-Auxiliary Valve Spool Sensor - Sensor Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 767
5511-Loader Arm Spool Sensor - Implausible State Sensor vs. Loader Arm Command, Stuck Spool/ PRV (*) 770
5512-Bucket Valve Spool Sensor - Implausible State Sensor vs. Loader Bucket Command (*) . . . . . . . . . . . . . . 773
5513-Auxiliary Valve Spool Sensor - Implausible State Sensor vs. Auxiliary Command (*) . . . . . . . . . . . . . . . . . 776
5601-Aux Valve (Directional) - Common Solenoid Return Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779
5602-Loader Auxiliary Valve (Directional) - Loader Auxiliary Solenoids Short to Ground (*) . . . . . . . . . . . . . . . . . 782
5603-Loader Auxiliary Valve Solenoid Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 784
5701-Pattern Switch - Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 786
5703-Pattern Switch - Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 789
5811-Loader Lockout Switch - Implausible State (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792
9004-Memory Error - Triple Redundant: Hour Meter - Location 1 Corrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 795
9151-CAN Connection: CAN Communication Timed Out After 5 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 798
9152-CAN Connection - CAN Communication Timed Out After 5 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 799
9153-CAN Connection - EEC1 Message Timed Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800
9154-CAN Connection - TSC1 Message Timed Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
9156-Hyd Enable Switch - Hyd Enable Button Error from AIC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
9158-H-Pattern Indicator Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
9159-ISO-Pattern Indicator Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
9160-H-Pattern Indicator Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
9161-ISO-Pattern Indicator Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
9401-Memory Error - Double Redundant: Memory Corruption Detected and Repaired . . . . . . . . . . . . . . . . . . . . . 813
9403-Memory Error - Double Redundant: Unrecoverable Memory Corruption Operable . . . . . . . . . . . . . . . . . . . 814
9404-Memory Error - Triple Redundant: Hour Meter - Hour Meter Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816
9405-CAN - DM1 (EH Machines): Loss Of DM1 Message From UCM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 817
9406-CAN - Can Communication Lost (EH Machines): Loss Of All CAN Communication From UCM (*) . . . . . 818
9407-Memory Error - ID Errors: Unrecoverable Hardware ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 819
9408-Memory Error - ID Errors: Unrecoverable Panel ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820
9410-Loss of EGR inducement status message from EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 821
47540694 28/04/2014
55.16 [55.DTC] / 833
PRINTED IN U.S.A.
47540694 28/04/2014
EN
SERVICE MANUAL
Front loader and bucket
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
82
Contents
Front loader and bucket - 82
[82.100] Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1
[82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2
47540694 28/04/2014
82
Arm - 100
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
82.1 [82.100] / 1
Contents
Arm - 100
SERVICE
Arm
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
47540694 28/04/2014
82.1 [82.100] / 2
Front loader and bucket - Arm
Arm - Remove
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
NOTE: The following steps show left side, loader arm components. Please repeat all steps to right side, loader arm
components.
1. Raise the loader arm, and engage the loader arm lock
pins. Lower the loader arm down on the pins.
2. Remove the engine area body panels (1).
RAPH12SSL0312AA 1
3. Remove the auxiliary hoses hold-down clamp (1) lo-

cated on the loader arm link.
RAPH12SSL0326AA 2
4. Remove the bucket cylinder hoses hold-down clamp

(1) located on the loader arm link.
RAPH12SSL0325AA 3
47540694 28/04/2014
82.1 [82.100] / 3
5. Raise the loader arm, and release loader arm lock pins.
Carefully lower the loader arms.
6. Place a suitable lifting device on the bucket end of the
loader arm.
RAPH12SSL0314AA 4
7. Disconnect, label, and cap off the auxiliary hoses (2).

8. Remove the horn (1).
9. Disconnect and cap off the hydraulic coupler hoses (3)
(if applicable).
RAPH12SSL0323AA 5
10. Pull the hydraulic coupler hoses through the loader

arm (if applicable).
RAPH12SSL0316AA 6
47540694 28/04/2014
82.1 [82.100] / 4
11. Disconnect, label, and cap off the bucket cylinder

hoses (1).
RAPH12SSL0313AA 7
12. Remove the loader arm cylinder hardware (1), and

disconnect the loader arm cylinders from the loader
arm.
RAPH12SSL0320AA 8
13. Support the loader arm link with a suitable lifting de-
vice.
RAPH12SSL0315AA 9
47540694 28/04/2014
82.1 [82.100] / 5
14. Support the loader arm with a suitable lifting device ,

and remove the loader arm link hardware (1).
RAPH12SSL0324AA 10
15. Remove the loader arm link hardware (1).
RAPH12SSL0322AA 11
16. Carefully remove the loader arm link.
RAPH12SSL0321AA 12
47540694 28/04/2014
82.1 [82.100] / 6
17. Support the loader arm with a suitable lifting device.
RAPH12SSL0319AA 13
18. Remove the loader arm hardware (1) , and lower the
loader arm links (2).
RAPH12SSL0318AA 14
19. Carefully remove the loader arm.
RAPH12SSL0317AA 15
47540694 28/04/2014
82.1 [82.100] / 7
Arm - Install
C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
NOTE: The following steps show left side, loader arm components. Please repeat all steps to right side, loader arm
components.
1. Carefully move the loader arm into installation position.
RAPH12SSL0317AA 1
2. Apply LOCTITE® SILVER GRADE ANTI-SEIZE 767 to the

tapered area of the pins and bosses. Carefully place
the loader arm link into installation position. Install the
loader arm link hardware (1).
RAPH12SSL0318AA 2
3. Carefully place the loader arm link into installation po-

sition.
RAPH12SSL0321AA 3
47540694 28/04/2014
82.1 [82.100] / 8
4. Apply LOCTITE® SILVER GRADE ANTI-SEIZE 767 to the

tapered area of the pins and bosses. Install the loader
arm hardware (1). Tighten the link bolt (1) to a torque
of 645 - 873 N·m (476 - 644 lb ft).
RAPH12SSL0324AA 4
5. Install the loader arm link hardware (1).
RAPH12SSL0322AA 5
6. Connect the loader arm cylinders to the loader arm.

Install the loader arm cylinder hardware (1).
RAPH12SSL0320AA 6
47540694 28/04/2014
82.1 [82.100] / 9
7. Push the hydraulic coupler hoses through the loader

arm (if applicable).
RAPH12SSL0316AA 7
8. Connect the auxiliary hoses (2).

9. Install the horn (1).
10. Connect the hydraulic coupler hoses (3) (if applica-
ble).
RAPH12SSL0323AA 8
11. Connect the bucket cylinder hoses (1).
RAPH12SSL0313AA 9
12. Remove the lifting device.

13. Raise the loader arm, and engage the loader arm lock
pins.
47540694 28/04/2014
82.1 [82.100] / 10
14. Install the bucket cylinder hoses hold-down clamp (1)

located on the loader arm link.
RAPH12SSL0325AA 10
15. Install the auxiliary hoses hold-down clamp (1) located

on the loader arm link.
RAPH12SSL0326AA 11
16. Install the engine area body panels (1).
RAPH12SSL0312AA 12
17. Raise the loader arm, and release loader arm lock
pins. Carefully lower the loader arms.
18. Grease all grease points on the loader arm.
47540694 28/04/2014
82.1 [82.100] / 11
Index
Arm - 100
Arm - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Arm - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
82.1 [82.100] / 12
Bucket - 300
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
82.2 [82.300] / 1
Contents
Bucket - 300
TECHNICAL DATA
Bucket
FUNCTIONAL DATA
Bucket release device

Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Bucket
Cutting edge - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bucket release device
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Quick coupler
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
47540694 28/04/2014
82.2 [82.300] / 2
Front loader and bucket - Bucket
Bucket - General specification

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
BT97G325 1
1. 10 mm ( 3/8 in) fillet (weld twice 1 root pass 1 cover 3. 6 mm ( 1/4 in) groove 6 mm ( 1/4 in) fillet (weld
pass) twice-wrap ends)
2. 6 mm ( 1/4 in) fillet (weld 4 times)
47540694 28/04/2014
82.2 [82.300] / 3
Bucket release device - Exploded view

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
BS04E150 1
Mechanical coupling mounting plate assembly
47540694 28/04/2014
82.2 [82.300] / 4
(1) Mounting Plate (7) Latch Pin (13) Pin

(2) Left Hand Handle (8) Plug (14) Bolt
(3) Dust Cap (9) Clip (15) Right Hand Handle
(4) Grease Zerk (10) Pin (16) Pin
(5) Plate (11) Compression Spring (17) Bushing
(6) Spring Pin (12) Guide
47540694 28/04/2014
82.2 [82.300] / 5
Bucket Cutting edge - Replace

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Cut or grind the old cutting edge from the bucket floor
and sides. Remove all old weld and foreign material
from the welding area.
SH88030 1
2. Straighten the bucket floor and sides if required.

3. Thoroughly clean the area where the new cutting edge
will be welded.
4. Use dry AWS-E7018 low hydrogen electrodes or ei-
ther of the following equivalent low hydrogen wire feed
electrodes: Gas metal arc welding (C0² or argon C0²)
AWS-E70S6 or flux cored arc welding AWS-E70T1.
5. Preheat the parts to be welded (both tack and final
welds) to a minimum of 204 °C (400 °F). The preheat
temperature must be throughout the entire thickness of
the parts joined, and at least 51 mm ( 2 in) back from
the joint. Maintain preheat throughout the entire weld-
ing operation.
NOTE: This is a hardened steel edge. If not preheated, the
cutting edge may later crack during use.
6. Tack weld the preheated parts starting at the center of
the bucket and working toward the outside ends.
7. Finish welding the preheated parts starting at the center
of the front edge of the bucket floor and working toward
the outside ends. Repeat this operation at the back
side of the cutting edge to bucket floor.
8. Do not remove the bucket from the welding environ-
ment until the weld and metal temperature drops to the
ambient temperature. Do not force the cooling rate of
the welds and material.
9. Follow the same welding procedure for welding the side
cutting edges and bottom wear plates to the bucket.
Bolt On Cutting Edge Replacement

10. Loosen and remove the bolts from the cutting edge.
11. Remove the cutting edge from the bucket.
12. Install new cutting edge on the bucket. Install new
bolts and tighten the bolts.
47540694 28/04/2014
82.2 [82.300] / 6
Dirt Tooth Kit Installation/Bucket Dirt Tooth Kit

13. The dirt tooth kit consists of six teeth that are welded to
the bucket cutting edge as indicated in image 4. The
teeth are used to break up the material when rough
digging conditions are experienced. This will make it
easier to fill the bucket. The teeth are intended to be
used only on dirt and foundry or low-profile buckets.
SH88032 2
Tooth Point Replacement

14. The points of the teeth are a replaceable "pin-on" de-
sign and can be obtained from Parts.
15. To replace the "pin-on" points, use a punch that just
fits into the pin hole, (1), and drive the old retaining
pin from the shank.
16. Place the new point over the shank and insert the re-
taining pin into the hole, (1). With a punch that con-
tacts both sides of the metal part of the retaining pin,
drive the pin until it is centered in the shank.
NOTE: If the punch or driver is too small and just contacts
the rubber center of the retaining pin, the pin will be dam-
aged and will not retain the point.
SH88033 3
Tooth Location and Installation

17. The bucket should be flat on the floor when placing
and welding the teeth to maintain good weld points,
(1).
NOTICE: Remove the bucket from the loader while welding
teeth to prevent damage to the loader electrical system.
18. Slide the replaceable points in place but do not attach
with the steel/rubber pins as the rubber may be dam-
aged during the welding process.
SH88034 4
19. Locate the teeth on the bucket edge as indicated (see

image 5). Please see table below for spacing values.
47540694 28/04/2014
82.2 [82.300] / 7
BS04E165 5
Bucket Tooth Spacing

NOTE: Position the teeth at these spacings, then re-center if necessary for equal spacing.
Bucket width From end (2) 2nd tooth (3) 3rd tooth (4) 4th tooth (5) 5th tooth (6) 6th tooth (7)
(1)
152.4 cm 4.6 cm (1 27.7 cm (10 54.1 cm (21 81.3 cm (32 in) 108.2 cm (42 135.4 cm (53
(60 in) 13/16 in) 15/16 in) 5/16 in) 5/8 in) 5/16 in)
167.6 cm 4.6 cm (1 35.1 cm (13 66.4 cm (25 98.2 cm (37 127.5 cm (50 158.1 cm (62
(66 in) 13/16 in) 27/32 in) 27/32 in) 29/32 in) 7/32 in) 1/4 in)
182.8 cm 4.6 cm (1 33 cm (13 in) 66 cm (26 in) 98.9 cm (38 131.7 cm (51 164.7 cm (64
(72 in) 13/16 in) 15/16 in) 7/8 in) 7/8 in)
198.1 cm 4.6 cm (1 36 cm (14 73.2 cm (28 107.9 cm (42 143.9 cm (56 180 cm (70
(78 in) 13/16 in) 3/16 in) 5/6 in) 1/2 in) 11/16 in) 7/8 in)
213.3 cm 4.6 cm (1 39 cm (15 78.1 cm (30 117.1 cm (46 156.2 cm (61 195.1 cm (76
(84 in) 13/16 in) 3/8 in) 3/4 in) 1/8 in) 1/2 in) 13/16 in)
20. Welds are high carbon steel (tooth) to high carbon

steel (bucket). Use welding rods marked 7018 or
some comparable rod. Weld on both sides of the tooth
from the back of the tooth towards the replaceable
point at (1). Stop welding 13 mm ( 1/2 in) from the
cutting edge as noted at (2). Weld along the back of
the tooth at (3). A minimum 5 mm ( 3/16 in) fillet weld
is required for this application.
SH88036 6
21. Weld in the direction shown at (1).
47540694 28/04/2014
82.2 [82.300] / 8
22. Weld a 5 mm ( 3/16 in) fillet weld along both sides

and rear of the tooth at (2), high carbon steel to high
carbon steel.
BS04E166 7
47540694 28/04/2014
82.2 [82.300] / 9
Bucket release device - Remove

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. WARNING
Avoid injury! Always do the following before
lubricating, maintaining, or servicing the ma-
chine.
3. Lower all attachments to the ground, or raise
and engage all safety locks.
4. Shut off engine.
ous injury.
W0047A
Before removing the coupler, remove any attachment

from the machine.
2. Tilt the coupler forward until the face of the plate is
resting on the ground. At this point you can relieve
the pressure in the system. See Hydraulic systems
- Depressurising (35.000).
3. On the left hand side of the coupler, remove the hard-
ware (1) securing the pin (2) attached to the tilt cylinder.
4. Remove the pin (2) from the coupler. This will remove
the tilt cylinder from the coupler.
5. Repeat steps three and four for the right hand side.
931002056 1
6. Remove the hardware (1) from the pivot pin (2) secur-
ing the coupler to the machine.
7. Repeat step six for the left hand side.
8. Coupler is now unattached from the machine.
20115831 2
47540694 28/04/2014
82.2 [82.300] / 10
Bucket release device - Disassemble

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
Prior operation:
Remove the bucket release device. See Bucket release device - Remove (82.300)
NOTE: Remove all attachments from working arm prior to removal of the mechanical coupler
1. Release locking pins by placing coupler handles (1) in
up position.
931002056 1
2. Using a hammer and punch remove the spring pin (1),

dropping the latch pin out of the bottom of the coupler
(2).
86092923 2
3. Remove clip (1) from handle pivot pin.
931001791 3
47540694 28/04/2014
82.2 [82.300] / 11
4. While supporting coupler handle, remove handle pivot

pin (1).
931001788 4
5. Remove handle and locking pin assembly from coupler.
20115824 5
6. To disassemble the locking pin assembly carefully un-

thread pin (1), from bolt (2) and check parts for wear.
20115823 6
47540694 28/04/2014
82.2 [82.300] / 12
Bucket release device - Assemble

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
1. Assemble the handle and locking pin assembly by in-

serting pin (1) through hole (2) in the handle. Install bolt
(3) through pin (2). Install bushing spacer (4), compres-
sion spring (5), and thread pin (6) onto bolt (3) holding
assembly together.
20115823 1
2. Install the assembled unit (1) through the inside of the

coupler (2).
20115824 2
86092923 3
47540694 28/04/2014
82.2 [82.300] / 13
3. While supporting the coupler handle in place, install

pivot pin (1).
931001788 4
4. Install clip (1) on backside of pivot pin.
931001790 5
5. Insert the latch pin (1) through the bottom of the cou-
pler, and secure to the locking pin assembly with a
spring pin (2).
86092922 6
47540694 28/04/2014
82.2 [82.300] / 14
Bucket release device - Install

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
NOTE: The images in these instructions may not be the actual model being worked on. All models have the same
concept.
1. Move the machine into position and align the holes to
insert the pivot pins (2).
2. On the right hand side of machine, insert the pivot pin
and install the hardware (1) to secure the pin in place.
Tighten hardware.
3. Repeat step two for the left hand side of the machine.
931002057 1
4. Extend the tilt cylinders (3) until they align with the top
holes of the coupler.
5. On the left hand side of machine, insert the pin (2) into
the coupler as shown, through the cylinder end and out
the other side of the coupler.
6. Install the hardware (1) to the pin locking plate, secur-
ing the pin to the coupler.
7. Repeat steps five and six for the right hand side of the
machine.
931002056 2
8. Start the machine and cycle through the positions of

the coupler to bleed the system of air.
47540694 28/04/2014
82.2 [82.300] / 15
Quick coupler - Remove

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
WARNING
Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the
engine off, turn the key on, and move the hydraulic control lever through all movements several times
to relieve residual pressure in the system.
W0161A
WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Burn hazard!
W0241A
WARNING
4. Shut off engine.
W0047A
concept.
1. Before removing the coupler, remove any attachment
from the machine.
2. Tilt the coupler forward until the face of the plate is
resting on the ground. At this point you can relieve
the pressure in the system. See Hydraulic systems
- Depressurising (35.000).
47540694 28/04/2014
82.2 [82.300] / 16
3. On the right hand side of the coupler, remove the hard-

ware (1) securing the pin (2) attached to the tilt cylinder.
4. Remove the pin (2) from the couple. This will remove
the tilt cylinder from the coupler.
20111348 1
5. Repeat steps three and four for the left hand side.
6. Mark the hoses and ports on the valve accordingly.
This will help in reinstalling the hoses to the proper
ports. Remove the two hoses (1) from the hydraulic
valve (2). Plug or cap the valve ports and the hose
ends. This will keep the hydraulic system from getting
contaminated.
20111349 2
7. Remove the hardware (1) from the pivot pin (2) secur-
ing the coupler to the machine. Remove the pivot pin
from the machine.
8. Repeat step seven for the left hand side.
9. Coupler is now unattached from the machine.
931002057 3
47540694 28/04/2014
82.2 [82.300] / 17
Quick coupler - Install

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
concept.
1. Move the machine into position and align the holes to
insert the pivot pins (2).
2. On the right hand side of machine, insert the pivot pin
and install the hardware (1) to secure the pin in place.
Tighten hardware.
3. Repeat step two for the left hand side of the machine.
931002057 1
4. Extend the tilt cylinders until they align with the top
holes of the coupler.
5. On the right hand side of machine, insert the pin (2) into
the coupler as shown, through the cylinder end and out
the other side of the coupler.
6. Install the hardware (1) to the pin locking plate, secur-
ing the pin to the coupler.
7. Repeat steps five and six for the left hand side of the
machine.
20111348 2
8. Remove the caps or plugs from the hydraulic valve (2)

and the hoses (1) and install the two hoses into their
correct ports. Tighten hoses to standard torque.
20111349 3
9. Start the machine and cycle through the positions of

the coupler to bleed the system of air.
47540694 28/04/2014
82.2 [82.300] / 18
Index
Bucket - 300
Bucket - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bucket Cutting edge - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bucket release device - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bucket release device - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bucket release device - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bucket release device - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Bucket release device - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Quick coupler - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Quick coupler - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
47540694 28/04/2014
82.2 [82.300] / 19
PRINTED IN U.S.A.
47540694 28/04/2014
EN
SERVICE MANUAL
Platform, cab, bodywork, and decals
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
90
Contents
Platform, cab, bodywork, and decals - 90
[90.154] Cab doors and hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
47540694 28/04/2014
90
Cab doors and hatches - 154
C232 TIER 4 [NDM451672 - ]

C238 TIER 4 [NCM425510 - ]
L223 TIER 4 [NDM474381 - ]
L225 TIER 4 [NDM461085 - ]
L230 TIER 4 [NCM449907 - ]
47540694 28/04/2014
90.1 [90.154] / 1
Contents
FUNCTIONAL DATA
Cab doors and hatches

Overview – Door switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
90.1 [90.154] / 2
Platform, cab, bodywork, and decals - Cab doors and hatches
Cab doors and hatches - Overview – Door switch

C232 NA
C238 NA
L223 NA
L225 NA
L230 NA
If a unit has a door, the door switch will prevent the operator from operating the loader arm and bucket while the door
is open. This safety switch prevents damage to the machine and to the operator.
If the operator opens the door, the joystick control of loader and bucket will be shut off and the port locks will engage.
Once the door is closed, the operator will regain control of the attachment.
The door switch is a magnetic reed switch. The switch operates on low current, and closes in the presence of metal.
The switch mush be adjusted properly to function correctly.
The door switch function is active when Ignition is ON.

ATTENTION: Usage of the override connector (1) will bypass all safety features associated with the door switch. Use
the override connector with extreme caution. Failure to comply will result in serious injury or death. Failure to comply
can result in machine damage.
The operator can bypass the door switch by using the
override connector (1). To use, unplug the washer nozzle
tube (2) and remove the override connector (1), discon-
nect the door switch harness (3), and plug the override
connector (1) into the door switch harness (3).
RAPH12SSL0300BA 1
47540694 28/04/2014
90.1 [90.154] / 3
Index

Cab doors and hatches - Overview – Door switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47540694 28/04/2014
90.1 [90.154] / 4
47540694 28/04/2014
90.1 [90.154] / 5
PRINTED IN U.S.A.
47540694 28/04/2014
EN
SPECIAL TOOL INDEX
Genuine Reference PAGE

CAS10162A [Portable Filter Hydraulic systems - Cleaning 35.1 / 31
Caddy]
CAS1871 [Seal Press] Hydraulic systems - Cleaning 35.1 / 31
CAS10192 [Vacuum Pump] Hydraulic systems - Cleaning 35.1 / 31
CAS10508 [Fitting Kit For Hydraulic systems - Cleaning 35.1 / 32
Unions]
CAS1871 [Seal Press] Oil reservoir - Apply vacuum 35.4 / 3
CAS10193 [ Kit For Vacuum Oil reservoir - Apply vacuum 35.4 / 3
Pump]
Kit Reference PAGE
CAS10899 [Nitrogen Charging Accumulator - Discharging 35.8 / 34
Kit Complete]
47540694 28/04/2014
PRINTED IN U.S.A.
47540694 28/04/2014
EN
SUB SYSTEM DESCRIPTION
MAIN POWER DISTRIBUTION 1
SYMBOLS COLOR ABBREVIATION ACCESSORY POWER DISTRIBUTION 2
BLACK BK IGNITION/CHARGING SYSTEM 3
BLUE BL BATTERY AND GROUNDS 4
LIGHT BLUE LB ENGINE F5C T4 (VEHICLE) 5
PRESSURE SWITCH DIOD E
LAMP MOTOR BLACK/WHITE BK/WH ENGINE F5C T4 (ENGINE) 6
GREEN GN ENGINE POWER DISTRIBUTION
LIGHT GREEN LG & FUEL PUMP 7
ORANGE OR THROTTLE SENSORS 8
LIGHT EMITTING EH PUMP/HYDRAULICS 9
DIODE (LED) PINK PK
PRESSURE TEMPERATURE SPEAKER HYDRAULIC INTERLOCKS 10
VIOLET VT
LOADER VALVE AND SENSORS 11
RED RD CAB TO CHASSIS INTERFACE 12
GREY GY CAB TO CHASSIS INTERFACE 13
TAN TN CAB TO CHASSIS INTERFACE 14
COIL
VARIABLE RESISTOR RESISTOR WHITE WH CAB CONSOLE SWITCHES 15
YELLOW YE LEFT HAND CONTROL HANDLE 16
RIGHT HAND CONTROL HANDLE 17
SEAT 18
WIRE SIZE CHART UNIT CONTROL MODULE 19
S.P. S.T. S.P. D.T. D.P. S.T. D.P. D.T.
Sq. mm AWG UNIT CONTROL MODULE 20
0.5 20 LAMPS 21
0.8 18 INDICATORS 22
TURN SIGNALS AND WORK LIGHTS 23
1.0 16
FUSE ROADING LIGHTS 24
RELAY GROUND BATTERY
2.0 14 WIPERS/WASHERS 25
3.0 12 INSTRUMENT CLUSTER 26
5.0 10 HVAC 27
CIRCUIT DIAGRAM LEGENDS 8.0 8 RADIO 28
CASE FRONT LIGHTS 29
WIRE BREAKOUT WIRE ID MULTIFUNCTION LOADER ARM 30
TELEMATICS 31
WB-255 SP-107 WB-254 ENHANCED HIGH FLOW 32
Sheet 255 Y 0. 8 Sheet
Number
254 Y 0. 8
Number MULTIFUNCTION ON/OFF 33
2ND AUX 34
SPLICE WB - WIRE BREAKOUT DIAGNOSTIC CONNECTOR 35
COLOR
WIRE SIZE FB - FUSE BREAKOUT FUEL FILTER JUMPER 36
GB - GROUND BREAKOUT NH FRONT LIGHTS 37 MAIN POWER DISTRIBUTION 1 ACCESSORY POWER DISTRIBUTION 2
IGNITION / CHARGING SYSTEM 3 BATTERY AND GROUNDS 4 ENGINE F5C T4 (VEHICLE) 5
L221/ L223/ L225/ L230/ C227/ C232/ C238

TIER 4 SSL EH MACHINES
ELECTRICAL SCHEMATIC
RAC 47686152
LEGEND
UNSWITCHED BATTERY POWER

SWITCHED BATTERY POWER
STARTING CIRCUIT
ENGINE F5C T4 (ENGINE) 6 ENGINE POWER DISTRIBUTION & FUEL PUMP 7 RAC47686152S1S1
THROTTLE SENSORS 8 EH PUMP / HYDRAULICS 9 HYDRAULIC INTERLOCKS 10
LOADER VALVE AND SENSORS 11 CAB TO CHASSIS INTERFACE 12 CAB TO CHASSIS INTERFACE 13
CAB TO CHASSIS INTERFACE 14 CAB CONSOLE SWITCHES 15 LEFT HAND CONTROL HANDLE 16
DIODE (LED) PINK PK
VIOLET VT
COIL
SEAT 18
0.5 20 LAMPS 21
1.0 16
5.0 10 HVAC 27
TELEMATICS 31
Number
254 Y 0. 8
2ND AUX 34
COLOR
GB - GROUND BREAKOUT NH FRONT LIGHTS 37 RIGHT CONTROL HANDLE 17 SEAT 18
UNIT CONTROL MODULE 19 UNIT CONTROL MODULE 20 LAMPS 21
L221/ L223/ L225/ L230/ C227/ C232/ C238

RAC 47686152
LEGEND

STARTING CIRCUIT
INDICATORS 22 TURN SIGNAL & WORK LIGHTS 23 RAC47686152S2S1

ROADING LIGHTS 24 WIPERS / WASHERS 25 INSTRUMENT CLUSTER 26
HVAC 27 RADIO 28 CASE FRONT LIGHTS 29
MULTIFUNCTION LOADER ARM 30 TELEMATICS 31 ENHANCED HIGH FLOW 32

DIODE (LED) PINK PK
VIOLET VT
COIL
SEAT 18
0.5 20 LAMPS 21
1.0 16
5.0 10 HVAC 27
TELEMATICS 31
Number
254 Y 0. 8
2ND AUX 34
COLOR
GB - GROUND BREAKOUT NH FRONT LIGHTS 37 MULTIFUNCTION ON/OFF 33 2ND AUX 34
DIAGNOSTIC CONNECTOR 35 FUEL FILTER JUMPER 36 NH FRONT LIGHTS 37
L221/ L223/ L225/ L230/ C227/ C232/ C238

RAC 47686152
LEGEND

STARTING CIRCUIT
RAC47686152S3S1
SYMBOLS COLOR ABBREVIATION MAIN POWER DISTRIBUTION 1
BLACK BK ACCESSORY POWER DISTRIBUTION 2
BLUE BL IGNITION/CHARGING SYSTEM 3
LIGHT BLUE LB BATTERY AND GROUNDS 4
LAMP MOTOR BLACK/WHITE BK/WH ENGINE POWER DISTRIBUTION
GREEN GN & FUEL PUMP 5
LIGHT GREEN LG ENGINE F5C T4 (ENGINE) 6
ORANGE OR ENGINE F5C T4 (ENGINE) 7
LIGHT EMITTING
PINK PK
PRESSURE TEMPERATURE SPEAKER DIODE (LED) THROTTLE SENSORS 8
VIOLET VT
CONTROL VALVE INTERLOCK
RED RD
& 2ND AUX HYDRAULICS 9
GREY GY
TAN TN CAB TO CHASSIS HARNESS 10
VARIABLE RESISTOR RESISTOR
COIL
WHITE WH CAB CONSOLE SWITCHES 11
SEAT 14
WIRE SIZE CHART STD AUX HYDRAULICS 15
Sq. mm AWG LAMPS 16
0.8 18 TURN SIGNALS AND WORK LIGHTS 18
FUSE
1.0 16 ROADING LIGHTS 19
5.0 10 HVAC 22
MULTIFUNCTION ARM 24
WIRE BREAKOUT WIRE ID TELEMATICS 25
WB-255 SP-107 WB-254
Sheet 255 Y 0. 8 254 Y 0. 8 Sheet DIAGNOSTIC CONNECTOR 27
Number Number
FUEL FILTER JUMPER 28
COLOR
SPLICE WB - WIRE BREAKOUT NH FRONT LIGHTS 29
WIRE SIZE FB - FUSE BREAKOUT BOOM LOCK VALVE 30
GB - GROUND BREAKOUT
MAIN POWER DISTRIBUTION 1 ACCESSORY POWER DISTRIBUTION 2
IGNITION/CHARGING SYSTEM 3 BATTERY AND GROUNDS 4 ENGINE POWER DISTRIBUTION & FUEL PUMP 5
L221/ L223/ L225/ L230

TIER 4 SSL MECH MACHINES
RAC 47686156
LEGEND

STARTING CIRCUIT
ENGINE F5C T4 (ENGINE) 6 ENGINE F5C T4 (ENGINE) 7 RAC47686156S1S1

THROTTLE SENSOR 8 CONTROL VALVE INTERLOCK & 2ND AUX HYDRAULICS 9 CAB TO CHASSIS INTERFACE 10
CAB CONSOLE SWITCHES 11 LEFT HAND CONTROL HANDLE 12 RIGHT HAND CONTROL HANDLE 13
SEAT 14 STD AUX HYDRAULICS 15 LAMPS 16

SYMBOLS COLOR ABBREVIATION MAIN POWER DISTRIBUTION 1
BLACK BK ACCESSORY POWER DISTRIBUTION 2
BLUE BL IGNITION/CHARGING SYSTEM 3
LIGHT BLUE LB BATTERY AND GROUNDS 4
LAMP MOTOR BLACK/WHITE BK/WH ENGINE POWER DISTRIBUTION
GREEN GN & FUEL PUMP 5
LIGHT GREEN LG ENGINE F5C T4 (ENGINE) 6
ORANGE OR ENGINE F5C T4 (ENGINE) 7
LIGHT EMITTING
PINK PK
PRESSURE TEMPERATURE SPEAKER DIODE (LED) THROTTLE SENSORS 8
VIOLET VT
CONTROL VALVE INTERLOCK
RED RD
& 2ND AUX HYDRAULICS 9
GREY GY
TAN TN CAB TO CHASSIS HARNESS 10
VARIABLE RESISTOR RESISTOR
COIL
WHITE WH CAB CONSOLE SWITCHES 11
SEAT 14
WIRE SIZE CHART STD AUX HYDRAULICS 15
Sq. mm AWG LAMPS 16
0.8 18 TURN SIGNALS AND WORK LIGHTS 18
FUSE
1.0 16 ROADING LIGHTS 19
5.0 10 HVAC 22
MULTIFUNCTION ARM 24
WIRE BREAKOUT WIRE ID TELEMATICS 25
WB-255 SP-107 WB-254
Sheet 255 Y 0. 8 254 Y 0. 8 Sheet DIAGNOSTIC CONNECTOR 27
Number Number
FUEL FILTER JUMPER 28
COLOR
SPLICE WB - WIRE BREAKOUT NH FRONT LIGHTS 29
WIRE SIZE FB - FUSE BREAKOUT BOOM LOCK VALVE 30
GB - GROUND BREAKOUT
INDICATORS 17 TURN SIGNAL AND WORK LIGHTS 18
ROADING LIGHTS 19 WIPERS/WASHERS 20 INSTRUMENT CLUSTER 21
L221/ L223/ L225/ L230

TIER 4 SSL MECH MACHINES
RAC 47686156
LEGEND

STARTING CIRCUIT
HVAC 22 RADIO 23 RAC47686156S2S1

MULTIFUNCTION LOADER ARM 24 TELEMATICS 25 CASE FRONT LIGHTS 26
DIAGNOSTIC CONNECTOR 27 FUEL FILTER JUMPER 28 NH FRONT LIGHTS 29
BOOM LOCK VALVE 30

L213 / L215 / L216 / L218 / L220 Hydraulic Coupler Lift Cylinders 4 Tip Cylinders
L221 / L223 / L225 / L230

C227 / C232 / C238
SINGLE SPEED AND TWO SPEED Auxiliary
MECHANICAL VALVE ASSEMBLY
A1 A2 B1 B2
Quick Disconnects
Self Level
RAC 47551846
Hydraulic Coupler Option

Boom Down Option
Valve
B A
V1 V2 D
NOTES:
C
FLUSHING VALVE C2 C1
-10 BAR SPRINGS

1 -2 mm FLUSHING ORIFICE A
-290 PSI (20BAR) CUTOFF RELIEF

2 4
2 LOAD CHECK REMOVED IF HIGH FLOW INSTALLED. CPLRV
3 IN-LINE ORIFICE AT MANIFOLD BLOCK FOR VERTICAL C

Charge Pressure
MACHINES ONLY.
for Port Lock 3
4 LIFT CYLINDERS ARE CUSHIONED FOR VERTICAL T P
B
FRAME MACHINES ONLY. 3 1
Vertical Only
Main Control Valve Pressure Relief Case Drain From A1 A2 CONNECT

Pumps and Motors Ride Control UNDER
MR- 3046 PSI +/-72.5 (210 BAR)
Option 0 cm3
PRESSURE
A1 (PR1) - 3263 PSI +145/-73 (225 BAR) VALVE
A2 (PR2) - 3771 PSI +145/-73 (260 BAR)
B2 (PR3) - 3336 PSI +145/-73 (230 BAR) A3
B2 (PR3- OPTIONAL) 1160 PSI +174/0 (80 BAR) PLV
HFV - 3250 PSI (224 BAR)
CPLRV - 2500 PSI (172 BAR) Pressure from PLV Drain
Charge Pump
Auxiliary Pump Secondary PR1 PR2 PR3
Tier 4 Tier 3 Auxiliary Quick Loader
36.6cc -F5C 34.1cc -F5C Disc Valve
27.8cc -ISM Med Frm 24.9cc -ISM Med Frm Secondary Auxiliary
Option
23.7cc -ISM Sml Frm 20.4cc -ISM Sml Frm
Case POUT MR
High Flow Pump (optional) (not available on Sml Frm) B A

Tier 4 Tier 3
20.4cc -F5C 61-67kW 18.3cc -F5C 61-67kW
13.7cc -F5C 55kW 12.5cc -F5C 55kW A
13.7cc -ISM Med Frm 12.5cc -ISM Med Frm P TANK
B
B3
.6mm
P2
PIN
L HFV T
PIN
L V
Gear Pump interface B1 B2
to Tandem Pump
High Flow Option
Crossover Pump
Suction Line 0 bar
HYDROSTATIC PUMP
CHARGE PRESSURE Charge Pump
Suction Line
RETURN TO TANK/SUMP
Oil Cooler
QUICK DISCONNECTS w/ 75psi Bypass
Hyd Oil Filter
w/ 50psi Bypass
MECHANICAL SINGLE SPEED DRIVE ASSEMBLY MECHANICAL TWO SPEED DRIVE ASSEMBLY
(L213, L215, L216, L218, L220, L221) (L218, L220, L221)
Right Hand Left Hand Right Hand Left Hand
MCR03 Mtr MCR03 Mtr MCR03 Mtr MCR03 Mtr
FWD FWD
Z
F
F
L
L
X
X
B
B
A
A
1 1
1 1
To Case Drain Tube

To Case Drain Tube
B1&B2
To Case Drain Tube

2SPD B1&B2
Brake T
P Charge Pressure
to Port Lock
Brake/Shift Manifold
To Case Drain Tube
Shift Brake
T
P Charge Pressure
to Port Lock
A B B A
A B B A
GEAR PUMP
INTERFACE TO
Charge TANDEM PUMP GEAR PUMP
Pump
INTERFACE TO
Charge TANDEM PUMP
Pump
To Case Drain Tube
Crossover Pump To Case Drain Tube

Sauer M35 - Manual Displacement Suction Line
Crossover Pump
Main Relief (all ports) - 345 bar (5000 psi) Sauer M35 - Manual Displacement Suction Line
Charge Relief - 25 bar (360 psi) Charge Pump
Suction Line Main Relief (all ports) - 345 bar (5000 psi) Charge Pump
Charge Relief - 25 bar (360 psi) Suction Line
MECHANICAL TWO SPEED TRACK DRIVE
Sauer M46 - Servo Displacement
(C227, C232, C238)
Main Relief (all ports) - 362 bar(5250 psi) FWD
FWD
FWD
Charge Relief - 25 bar (360 psi)

FWD
Right Hand Mtr Left Hand Mtr
NOTES:
FLUSHING VALVE
-10 BAR SPRINGS
PB
PB
1
-2 mm FLUSHING ORIFICE
-290 PSI (20 BAR) CUTOFF RELIEF
DR
DR
2 LOAD CHECK REMOVED IF HIGH FLOW INSTALLED.
STANDARD PUMP STACK NOT USED ON EHF OPTION
3
SEE PAGE 3 OF DRAWING FOR EHF.
4 IN-LINE ORIFICE AT MANIFOLD BLOCK FOR VERTICAL

MACHINES ONLY. 1 1
PS
PS
5 LIFT CYLINDERS ARE CUSHIONED FOR VERTICAL
FRAME MACHINES ONLY.
P2
P2
P1
P1
To Case Drain Tube
B1&B2
2SPD
To Case Drain Tube

Shift Brake
T
Charge Pressure
P
to Port Lock
Crossover Pump
B A Suction Line
A B
Charge Pump
Suction Line
Charge Pump
Gear Pump interface

RAC 47551846 to Tandem Pump
HYDROSTATIC PUMP
CHARGE PRESSURE
RETURN TO TANK/SUMP
QUICK DISCONNECTS To Case Drain Tube
MECHANICAL SINGLE SPEED DRIVE ASSEMBLY MECHANICAL TWO SPEED DRIVE ASSEMBLY
(L223, L225, L230) (L223, L225, L230)
Right Hand FWD FWD Left Hand Right Hand Left Hand
MCR05 Mtr
FWD
MCR05 Mtr MCR05 Mtr MCR05 Mtr
Z
F
F
L
L
X
X
B
B
1 1
A
1 1
To Case Drain Tube
To Case Drain Tube

B1&B2
2SPD B1&B2
To Case Drain Tube

Brake
T
P Charge Pressure To Case Drain Tube

to Port Lock
Shift Brake
Brake/Shift Manifold T
P Charge Pressure
to Port Lock
A B B A A B B A
Charge Pump
Charge Pump
GEAR PUMP GEAR PUMP
INTERFACE TO INTERFACE TO
TANDEM TANDEM
PUMP PUMP
Crossover Pump
Suction Line
To Case Drain Tube

To Case Drain Tube
Crossover Pump
Suction Line Charge Pump
Sauer M46 - Servo Displacement Suction Line
Main Relief (all ports) 362 bar (5250 psi) Sauer M46 - Servo Displacement
Charge Relief - 25 bar (360 psi) Charge Pump Main Relief (all ports) 362 bar (5250 psi)
Suction Line Charge Relief - 25 bar (360 psi)
ELECTRO-HYDRAULIC (EH) VALVE ASSEMBLY
L213 / L215 / L216 / L218 / L220
L221 / L223 / L225 / L230 Hydraulic Coupler Lift Cylinders 4 Tip Cylinders
C227 / C232 / C238

SINGLE SPEED AND TWO SPEED
ELECTRO-HYDRAULIC (EH) VALVE ASSEMBLY Auxiliary
RAC 47551846
A1 A2 B1 B2
Quick Disconnects
Self Level
Hydraulic Coupler Option

Boom Down Option
Valve
B A
V1 V2
D
C
C2 C1
NOTES: A
FLUSHING VALVE
-10 BAR SPRINGS
1 -2 mm FLUSHING ORIFICE
2 4
CPLRV
-290 PSI (20BAR) CUTOFF RELIEF CONNECT
C UNDER
Charge Pressure
2 LOAD CHECK REMOVED IF HIGH FLOW INSTALLED. 3
PRESSURE
forPort Lock
VALVE
3 IN-LINE ORIFICE AT MANIFOLD BLOCK FOR VERTICAL T P

Orifice - B
MACHINES ONLY. 3 1
Vertical Only

FRAME MACHINES ONLY. Case Drain From
A1 A2
Pumps and Motors Ride Control
Option 0 cm3
Main Control Valve Pressure Relief

MR- 3046 PSI +/-72.5 (210 BAR) A3
A1 (PR1) - 3263 PSI +145/-73 (225 BAR) PLV
A2 (PR2) - 3771 PSI +145/-73 (260 BAR)
B2 (PR3) - 3336 PSI +145/-73 (230 BAR) Pressure from PLV Drain
Brk/Shft/EH Valve
B2 (PR3- OPTIONAL) 1160 PSI +174/0 (80 BAR)
HFV - 3250 PSI (224 BAR) Secondary
CPLRV - 2500 PSI (172 BAR)
Loader PR1 PR2 PR3
Auxiliary Quick
Disc Valve
Auxiliary Pump Secondary Auxiliary
Option L
Tier 4 Tier 3
36.6cc -F5C 34.1cc -F5C Case POUT V MR
27.8cc -ISM Med Frm 24.9cc -ISM Med Frm
23.7cc -ISM Sml Frm 20.4cc -ISM Sml Frm B A
High Flow Pump (optional) (not available on Sml Frm) A
Tier 4 Tier 3 P TANK

20.4cc -F5C 61-67kW 18.3cc -F5C 61-67kW
13.7cc -F5C 55kW 12.5cc -F5C 55kW B B3
13.7cc -ISM Med Frm 12.5cc -ISM Med Frm .6mm
P2
PIN
Gear Pump interface

to Tandem Pump L HFV T
B1 B2
High Flow Option
Crossover Pump
Suction Line 0 bar
HYDROSTATIC PUMP
CHARGE PRESSURE Charge Pump
Suction Line
RETURN TO TANK/SUMP
QUICK DISCONNECTS Hyd Oil Filter
Oil Cooler
w/ 75psi Bypass
w/ 50psi Bypass
EH SINGLE SPEED DRIVE ASSEMBLY EH TWO SPEED DRIVE ASSEMBLY
(ALL MODELS EXCEPT L213, L215, L216)
Right Hand Rexroth - A20VG - ET (EH) Left Hand Right Hand Rexroth - A20VG - ET (EH) Left Hand
MCR03 Mtr Main Relief (all ports) - 362 bar (5250 psi) MCR03 Mtr MCR03 Mtr Main Relief (all ports) - 362 bar (5250 psi) MCR03 Mtr
Charge Relief - 25 bar (360 psi) FWD
Charge Relief - 25 bar (360 psi)
FWD
Z
F
F
L
L
X
X
B
B
1 1
A
1 1
To Case Drain Tube
LV B1&B2
15b
(225psi) To Case Drain Tube
Brake
LV 2SPD B1&B2 Pilot Control
To Case Drain Tube 15b Pressure from
Brake (225psi) Brk/Shft/ EH Valve
EH Intrlk
T
P Charge Pressure
Brake
to Port Lock
To Case Drain Tube

EH Intrlk Shift Brake
Brake/Shift Manifold T Charge Pressure to
P Port Lock
G1
YST A B B A G1
YST A B B A
Charge Pump
Charge Pump
Gear Pump interface

to Tandem Pump
Gear Pump interface
to Tandem Pump
Charge Pump
Suction Line
Charge Pump
Suction Line
To Case Drain Tube Crossover Pump

Suction Line
Crossover Pump
Suction Line To Case Drain Tube
ELECTRO-HYDRAULIC (EH) TWO SPEED TRACK DRIVE ASSEMBLY
Rexroth - A20VG - ET (EH) (C227, C232, C238)
Main Relief (all ports) - 362 bar (5250 psi) FWD
FWD
FWD
FWD
Charge Relief - 25 bar (360 psi) Right Hand Mtr

Left Hand Mtr
PB
PB
DR
DR
NOTES:
FLUSHING VALVE
1 -10 BAR SPRINGS
-2 mm FLUSHING ORIFICE 1 1
PS
PS
STANDARD PUMP STACK NOT USED ON EHF OPTION
3
SEE PAGE 3 OF DRAWING FOR EHF.
IN-LINE ORIFICE AT MANIFOLD BLOCK FOR VERTICAL
P2
P1
P2
P1
4
MACHINES ONLY.

FRAME MACHINES ONLY. To Case Drain Tube
LV 2SPD B1&B2
15.5b
(225psi)
Pilot Control
Pressure from
Brake
Brk/Shft/EH Valve
To Case Drain Tube

EH Intrlk Shift Brake
T Charge Pressure
P
to Port Lock
G1
YST A B B A
Charge Pump
RAC 47551846 Gear Pump interface

to Tandem Pump
HYDROSTATIC PUMP
CHARGE PUMP Charge Pump
Suction Line
RETURN TO TANK/SUMP
QUICK DISCONNECTS
To Case Drain Tube
Crossover Pump
Suction Line
ENHANCED HIGH FLOW OPTION ENHANCED HIGH FLOW (EHF) OPTION PUMP ASSEMBLY
L230 / C238
RAC 47551846 EHF QUICK DISCONNECT
Right Hand Loader Arm
A B C
NOTES: A E C
FLUSHING VALVE
1 -10 BAR SPRINGS
-2 mm FLUSHING ORIFICE
LOOP FLUSHING VALVE

3 Auxiliary Pump
Non-Reg Tier 4 B F D
34.1cc 36.6cc -F5C
To Case Drain Tube
High Flow Pump (as applicable)
Non-Reg Tier 4
18.3cc 20.4cc -F5C 61-67kW
4 IN-LINE ORIFICE AT MANIFOLD BLOCK FOR VERTICAL

MACHINES ONLY. TO RESPECTIVE
CONTROL PRESSURE MOTOR PORTS TO BRAKE/SHIFT
FROM BRAKE/SHIFT VALVE
5 LIFT CYLINDERS ARE CUSHIONED FOR VERTICAL VALVE
FRAME MACHINES ONLY.
G1
YST A B B A
Flow to EH Loader
Valve - PIN Main
Charge Pump
Suction Line
Reservoir Suction
Line
To Case Drain Tube
Auxiliary Pump Charge Pump

A10VG - EP Rexroth - A20VG - ET (EH)
HYDROSTATIC PUMP 34.1cc- Non Reg 23.7cc- Non Reg
A port - 275bar(4kpsi) Main Relief(all ports) - 362bar(5250psi) 23.7cc- Tier 4
36.6cc- Tier 4
B port - 210bar(3kpsi) Charge Relief - 25bar(360psi)
CHARGE PRESSURE
RETURN TO TANK/SUMP
QUICK DISCONNECTS

l230 Service Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

l230 Service Manual

Uploaded by

Copyright:

Available Formats

SERVICE MANUAL

L223 / L225 / L230

Part number 47540694

Product Market Product Engine

[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

Front axle system ....................................................................... 25

Rear axle system........................................................................ 27

[29.134] Two-speed assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2

[29.200] Mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.3

[29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.4

Brakes and controls .................................................................... 33

[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2

[35.128] Auxiliary hydraulic function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

[35.350] Safety and main relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

[35.600] High flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7

[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8

[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9

[35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10

[35.734] Tool quick coupler hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11

Frames and ballasting ................................................................. 39

[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Tracks and track suspension ........................................................ 48

[48.130] Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2

[48.134] Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.3

[48.138] Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.4

Cab climate control ..................................................................... 50

[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2

Electrical systems ....................................................................... 55

[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

[55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3

[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4

[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5

[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

[55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7

[55.031] Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8

[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . 55.10

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11

[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12

[55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13

[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14

[55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15

[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16

Front loader and bucket............................................................... 82

[82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2

Platform, cab, bodywork, and decals ............................................. 90

Foreword - Important notice regarding equipment servicing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models

Foreword - Important notice regarding equipment servicing

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

Safety rules - Personal safety

• Disengage all clutching levers or switches.

6. Always keep the machine in gear while travelling downhill.

Safety rules - Ecology and the environment

Torque - Minimum tightening torques for normal assembly

METRIC NON-FLANGED HARDWARE

METRIC FLANGED HARDWARE

Metric Hex head and carriage bolts, classes 5.6 and up

Metric Hex nuts and locknuts, classes 05 and up

INCH NON-FLANGED HARDWARE

INCH FLANGED HARDWARE