Ls 5 SM ENG

SERVICE MANUAL
L213 / L215 / L218 / L220

L223 / L225 / L230
200 Series Skid Steer Loader
C227 / C232 / C238

200 Series Compact Track Loader
FRAME AND CAB - E

FRAME POSITIONING - F
TOOL POSITIONING - G
HITCH AND WORKING TOOL - H
EXCAVATING AND LANDSCAPING - J
Part number 84522921

1st edition English
July 2011
Printed in U.S.A.
Copyright © 2011 CNH America LLC. All Rights Reserved. New Holland is a registered trademark of CNH America LLC.
Racine Wisconsin 53404 U.S.A.
FRAME AND CAB - E
FRAME Primary frame - 10.B
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
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Contents
FRAME AND CAB - E
FUNCTIONAL DATA
FRAME Primary frame

Overview Model Frame Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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FRAME AND CAB - FRAME Primary frame
FRAME Primary frame - Overview Model Frame Identification

Model Frame Size Engine
L213 Small ISM 34 kW (46.2 Hp)
Radial boom architecture
L215 Small ISM 39 kW (53.0 Hp)

L218 Medium ISM 45 kW (61.2 Hp)

Vertical boom architecture
L220 Medium ISM 45 kW (61.2 Hp)

L223 Large F5C 55 kW (74.8 Hp)



C227 Medium F5C 55 kW (74.8 Hp)

C232 Large F5C 61 kW (82.9 Hp)

C238 Large F5C 67 kW (91.1 Hp)

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Index
FRAME AND CAB - E

FRAME Primary frame - Overview Model Frame Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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FRAME AND CAB - E
SHIELD - 20.A
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
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Contents
FRAME AND CAB - E
SHIELD - 20.A
SERVICE
Engine hood
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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FRAME AND CAB - SHIELD
Engine hood - Remove

1. Remove fuel lines (1) from support strap.
931001670 1
2. Remove hardware (2) from filter base and remove

from door
931001668 2
3. Disconnect back up alarm electrical connections (3).
931001672 3
4. If applicable, disconnect rear light electrical connec-

tions (4).
931001675 4
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5. Remove door hardware (5).
931001676 5
6. Remove rear door and grill assembly (6).
931001678 6
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Engine hood - Install

1. Install rear access door and grill assembly in mounts
931001678 1
2. Install door hardware, bolt (1) and nut (2) to the upper
and lower mounts.
931001676 2
3. Connect back up alarm electrical connection (3).
931001673 3
4. Mount fuel filter base to door using bolts (B) and nuts
(A).
931001671 4
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5. Support the fuel lines (5) to the back door using wire
ties (4).
931001670 5
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Index
FRAME AND CAB - E
SHIELD - 20.A
Engine hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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FRAME AND CAB - E
USER CONTROLS AND SEAT - 32.A
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
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Contents
FRAME AND CAB - E
SERVICE
Console
Left - Remove Left hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Left - Install Left hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Instrument panel
Digital instrument cluster - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Digital instrument cluster - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove Right hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install Right hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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FRAME AND CAB - USER CONTROLS AND SEAT
Console Left - Remove Left hand side console

1. Locate the left hand console (1), inside operator's
cab front left side cab frame post
93107448A 1
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2. Remove left console mounting hardware (1).
93109327Z 2
3. Remove connector from the switch (1).
20111506 3
4. Unclip the switch from the console.
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Console Left - Install Left hand side console

1. Insert switch into console. Connect the connector to
the switch (1).
20111506 1
2. Insert the mounting hardware into the left side (1) and
right side of the console (2).
93109327Z 2
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Instrument panel Digital instrument cluster - Remove

1. Locate instrument cluster (1) on the right hand frame
post inside operator's cab.
93107444 1
2. Remove hardware (1) retaining the instrument clus-

ter on to the right hand frame post.
93109330 2
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3. Disconnect connector X-C23 from the instrument

cluster (1).
93105890B 3
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Instrument panel Digital instrument cluster - Install

Prior operation:
Instrument panel Digital instrument cluster - Remove (E.32.A)
1. Connect connector X-C23 to the instrument cluster

(1).
93105890B 1
2. Place instrument cluster (1) into right hand frame

post. Place hardware (2) into instrument cluster to
secure to frame post.
93109330 2
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Instrument panel - Remove Right hand side console

1. Locate instrument cluster (1) on the right hand frame
post inside operator's cab.
93107444 1
2. Remove the mounting hardware from the left side (1)

and right side (2) of the right hand console.
93109330 2
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3. Disconnect connector from the switch. Remove

switch from the right hand console (1).
20111505 3
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Instrument panel - Install Right hand side console

1. Insert switch into the right hand console (1). Connect
the connector to the switch.
20111505 1
2. Insert the mounting hardware into the left side (1) and
right side (2) of the right hand console. Tighten to
proper torque.
93109330 2
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Index
FRAME AND CAB - E

Console Left - Install Left hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Console Left - Remove Left hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Instrument panel - Install Right hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Instrument panel - Remove Right hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Instrument panel Digital instrument cluster - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Instrument panel Digital instrument cluster - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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FRAME AND CAB - E
USER CONTROLS AND SEAT Operator seat - 32.C
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
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Contents
FRAME AND CAB - E
DIAGNOSTIC
Command
Testing Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Testing Operator Restraint Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Heater
Testing Seat Heat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
Command - Testing Seat Switch

NOTE: Use schematics
Wiring harness - Electrical schematic frame 03 (A.30.A)
NOTE: The seat switch may become misaligned and not function properly, due to switch mounting or seat cushion
compression. Ensure proper switch mounting before replacing switch.
N° Test Point Expected Result Other Result (Possible Cause)
1 Condition Result Result
Disconnect connector X-58 from No circuit problems. No change in circuit response, re-
connector X-58A. Connect a jumper Action move jumper.
between connector X-58 pins 3 and The SEAT SWITCH S-002 or connect- Action
4. ing wiring has failed. Replace the Go to test 2
Check switch or failed wiring.
for circuit operation.
Use ELECTRICAL POWER SYS- No wire problems. Wire problems are found.
TEM - Testing General Wire Test- Action Action
ing (A.30.A) to Go to test 3 Locate and repair or replace broken
Check wire 315/317/313 (Red) or adjacent
wire condition between connector wiring.
X-C23 pin 3 and connector X-58 pin
3.
Check wire 323/328 (Yellow) (EH) 323 (Yel-
wire condition between connector low) (Mech) or adjacent wiring.
X-C23 pin 12 and connector X-58
pin 4.
Use Data bus - General specifica- No resistance problems. Resistance problems are found.
tion Instrument Cluster pin infor- Action Action
mation (A.50.A) to The SEAT SWITCH S-002 or connect- Replace the INSTRUMENT CLUSTER.
Check ing wiring has failed. Replace the
INSTRUMENT CLUSTER pins 3 and 12. switch or failed wiring.
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Command - Testing Operator Restraint Switch

NOTE: For EH machines follow steps 1-5. For Mechanical machines follow steps 6-8.
1 Condition Result Action
Disconnect connector X-104 from No circuit problems No change in circuit response, re-
the OPERATOR RESTRAINT SWITCH Action move jumper.
S-043. Connect a jumper between The OPERATOR RESTRAINT SWITCH Go to test 2
connector X-104 pins 1 and 2. has failed. Replace the switch.
Check
Disconnect connector X-99 from the Test satisfactory. Diode is faulty.
EH LAP BAR DIODE V-005. Action Action
Check Go to test 3 Replace the diode.
the diode using ELECTRICAL
POWER SYSTEM - Testing Diode
Testing (A.30.A).
Check wire 317/316 (Red) / 313 (Yellow) or
wire condition between X-104 pin 1 adjacent wiring.
and connector X-C23 pin 3.
Check wire 314 (Yellow) or adjacent wiring.
wire condition between X-99 pin A
and connector X-104 pin 2.
TEM - Testing General Wire Test-Action Action
ing (A.30.A) to The fault may be intermittent. Visu- Locate and repair or replace broken
Check ally inspect the relevant harnesses wire 524 (Yellow) or adjacent wiring.
and connectors for damage, bent or
wire condition between X-CN4A pin
10 and connector X-99 pin B. dislocated pins, corroded terminals
or broken wires. Verify that the con-
nectors are fully installed. Flex the
harnesses involved to reveal inter-
mittent breaks or shorts in the wiring
concerned. If no damage is found,
continue operation.
Disconnect connector X-104 from No circuit problems No change in circuit response, re-
the OPERATOR RESTRAINT SWITCH Action move jumper.
S-011. Connect a jumper between The OPERATOR RESTRAINT SWITCH Go to test 7
connector X-104 pins 1 and 2. has failed. Replace the switch.
Check
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Check wire 317/316 (Red) / 313 (Yellow) or
wire condition between X-104 pin 1 adjacent wiring.
and connector X-C23 pin 3.
ing (A.30.A) to The fault may be intermittent. Visu- Locate and repair or replace broken
Check ally inspect the relevant harnesses wire 314 (Yellow) or adjacent wiring.
wire condition between X-C23 pin 13 and connectors for damage, bent or
and connector X-104 pin 2. dislocated pins, corroded terminals
continue operation.
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Heater - Testing Seat Heat Switch

NOTE: See schematics
Place the SEAT HEAT SWITCH to the Bulb comes on. Bulb does not light.
on position. Action Action
Check The seat heat wiring has developed Go to test 2
for indicator bulb illumination. an open, or the SEAT HEAT ELEMENT
R-001 has failed. Replace the SEAT
HEAT ELEMENT or faulty wiring.
Remove ACCESSORY FUSE from the 0 Ω Fuse is blown.
MAIN POWER DISTRIBUTION FUSE Action Action
BLOCK 1 Z-2008 Go to test 3 Replace the fuse with same type and
Check amp rating.
for continuity across ACCESSORY
FUSE.
With the fuse removed, and ignition 12 V 0V
on, Action Action
Check Go to test 4 There is a problem in the DC distribu-
for voltage from MAIN POWER tion system upstream of ACCESSORY
DISTRIBUTION FUSE BLOCK 1 Z-2008 FUSE
pin C1 and ground.
Use ELECTRICAL POWER SYS- No wire problems Wire problems are found.
ing (A.30.A) to check wire condition Go to test 5 Locate and repair or replace broken
between MAIN POWER DISTRIBUTION wire 134/152/756 (Orange) or adja-
FUSE BLOCK 1 Z-2008 pin C2 and cent wiring.
connector X-58 pin 1.
ing (A.30.A) to check wire condition Go to test 6 Locate and repair or replace broken
between connector X-58 pin 2 and wire 933/1088/1093 (Black) or adja-
cab ground. cent wiring.
While cycling the SEAT HEAT Infinite resistance with switch in off Open in both positions.
SWITCH, position, low resistance with switch Action
Check in on position. The SEAT HEAT SWITCH S-003 has
resistance between connector X-58 Action failed. Replace the switch.
pin 1 and connector X-58 pin 2. The seat heat wiring has developed
an open, or the SEAT HEAT ELEMENT
R-001 has failed. Replace the SEAT
HEAT ELEMENT or faulty wiring.
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Index
FRAME AND CAB - E

Command - Testing Operator Restraint Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Command - Testing Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heater - Testing Seat Heat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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FRAME AND CAB - E
USER PLATFORM - 34.A
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
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E.34.A / 1
Contents
FRAME AND CAB - E
FUNCTIONAL DATA
Door, window and windscreen

Overview Door Switch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Tilt system
Tilt cab, secure the lift arm in the raised position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSTIC
Cigar lighter
Testing Accessory Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Door, window and windscreen
Testing Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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FRAME AND CAB - USER PLATFORM
Door, window and windscreen - Overview Door Switch - Overview

If a unit has a door, the Door Switch Function will prevent the operator from operating the loader arm and bucket while
the door is open. This will prevent damage to the machine because when the door is open it is directly in the path of
the implement.
The operator can open the door at any time and the joystick control of loader and bucket will be shut off over software
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.
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Tilt system - Tilt cab, secure the lift arm in the raised position.
DANGER
Crushing hazard!
Loader lift arm is unsupported during support strut removal. Do not enter or exit the operator's com-
partment with an unsupported loader lift arm. Two persons are required during storage. One person
should remove and store the support strut while the operator remains in the operator's compartment.
Failure to comply will result in death or serious injury.
D0021A
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.
Failure to comply could result in death or serious injury.
W0230A
To secure the lift arms up and install the support lock pin on radial lift machines.
1. Remove any attachment.
2. Park the machine on firm and level surface.
3. See the instructional decal on the inside of the right
lift arm, just above the support strut. Read and un-
derstand these instructions before you perform this
procedure.
4. Remove the retaining clip (1) that secures the lift arm
support strut.
93106848A 1
5. Lay the support (1) down on the lift arm tubing and
cylinder, as shown.
6. Slowly raise the lift arms until the support strut drops
down onto the cylinder, as shown.
7. Install retaining clip (2) to secure support strut to the
lift arm cylinder. Gently, lower the lift arms down until
the support strut is in contact with the cylinder.
93106854A 2
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To secure the lift arms up and install the support lock pin on vertical lift machines.
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
1. Remove any attachment.

2. Park machine on firm level surface.
3. See instructional decal (2) located by the lift arm lever
lock.
4. Raise the loader arm until loader link is above the
lock pins.
5. Rotating mechanical lift arm lock lever (1) towards
the inside of the machine will extend the pins and
the lift arms will be LOCKED.
6. Slowly lower lift arm until it rests on the lock pins.
93109334 3
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Move operator protective structure to service position.

1. The operators compartment may be tilted forward,
for service access, only with the lift arms raised. Fol-
lowing instruction provided to access the engine, hy-
drostatic pumps, motors and control linkage.
2. To tilt the cab, confirm that the following steps have
been completed.
3. The machine is on firm, level ground.
4. The lift arms are up with the support strut or lock pin
in lock position.
5. Use a 24 mm (15/16 in) socket or wrench to remove
the two rear ROPS retaining nuts (1).
6. Use the cab entry hand holds and pivot the cab for-
ward as shown.
7. Confirm red lock tube (1) has lowered over pivot link-
age.
93107498 4
93105463 5
93107499A 6
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Tilt system - Lower

DANGER
Crushing hazard!
D0021A
WARNING
Crushing hazard!
W0230A
To lower the cab

1. To place the cab and loader lift arms back into the
work position raise the red lock tube over the cab
pivot linkage.
2. Confirm red lock tube (1) is raised over pivot linkage.
93107499A 1
3. Use the cab entry hand holds and pivot the cab down
onto frame.
4. Use a 24mm socket or wrench to install the two
rear ROPS retaining nuts (1) to a torque of 170 N·m
(125.4 lb ft) .
931001633 2
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To lower the working arms and disengage the support lock pin on vertical lift machines.
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
1. While sitting in the operator's seat with the seat belt

fastened and the engine running, Raise the lift arm
(4) high enough to clear the lift arm lock pins (3).
Rotate the mechanical lift arm lock lever away from
the seat (counter - clockwise) to retract the lock pins.
93107457 3
93109334 4
NOTICE: See the instructional decal (2) located by the mechanical lift arm lock lever.
2. Slowly lower the lift arm until the lift arms are on the
ground or floor.
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To lower the working arms and disengage the support bracket on radial lift machines.
WARNING
Crushing hazard!
W0230A
DANGER
Crushing hazard!
D0021A
1. See the instructional decal on the inside of the right

lift arm, just above the support strut. Read and un-
derstand these instructions before you perform this
procedure.
NOTE: Two people are required for this procedure.

2. One person should remove retaining clip (1) from
support strut while the operator remains in the op-
erator's compartment.
93106854A 5
3. Slowly raise the lift arms until the support strut sepa-
rates from the cylinder.
4. Have the person outside the unit raise support strut
and secure through tab with retaining clip (1), as
shown.
5. Once the second person has cleared the area, the
working arm can be lowered.
93106848A 6
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Cigar lighter - Testing Accessory Power Outlet

Remove ACCESSORY / BEACON FUSE 0Ω Fuse is blown.
from the MAIN POWER DISTRIBUTION Action Action
FUSE BLOCK 1 Z-2008. Go to test 2 Replace the fuse with same type and
Check amp rating.
for continuity across ACCESSORY /
BEACON FUSE.
With the fuse removed and Ignition 12 V 0V
on, Action Action
for voltage from MAIN POWER tion system upstream of ACCESSORY
DISTRIBUTION FUSE BLOCK 1 Z-2008 / BEACON FUSE.
pin D5 and ground.
Check wire 801/115/196 (Red) or adjacent
wire condition between connec- wiring.
tor X-ACC pin B and MAIN POWER
DISTRIBUTION FUSE BLOCK 1 Z-2008
pin D6.
ing (A.30.A) to The ACCESSORY POWER OUTLET Locate and repair or replace broken
Check Z-008 has failed. Replace the wire 952/842/1094 (Black) or adja-
wire condition between connector ACCESSORY POWER OUTLET. cent wiring.
X-ACC pin A and ground.
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Door, window and windscreen - Testing Door Switch

the DOOR SWITCH. Connect a jumper Action move jumper.
between connector X-505 pins 1 and The DOOR SWITCH has failed. Re- Action
2. place the switch. Go to test 2
Check
Check circuit operation.
ing (A.30.A) to Go to test 3 Repair or replace broken wire 1016/
Check 910/966 (Black).
wire condition between connector
X-505 pin 2 and ground.
Disconnect connector X-502 from No wire problems. Wire problems are found.
the DOOR WIPER MOTOR. Use ELEC- Action Action
TRICAL POWER SYSTEM - Test- Go to test 4 Repair or replace broken wire 250/
ing General Wire Testing (A.30.A) 251 (Yellow) or wire 220 (Yellow).
to
Check
X-505 pin 1 and connector X-C23
pin 17.
Use Data bus - General specifica- No resistance problems. Resistance problems are found.
tion Instrument Cluster pin infor- Action Action
mation (A.50.A) to The fault may be intermittent. Visu- Replace the INSTRUMENT CLUSTER.
Check ally inspect the relevant harnesses
INSTRUMENT CLUSTER pin 17. and connectors for damage, bent or
dislocated pins, corroded terminals
continue operation.
84423865 25/07/2011
E.34.A / 11
Index
FRAME AND CAB - E

Cigar lighter - Testing Accessory Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Door, window and windscreen - Overview Door Switch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Door, window and windscreen - Testing Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tilt system - Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tilt system - Tilt cab, secure the lift arm in the raised position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84423865 25/07/2011
E.34.A / 12
FRAME AND CAB - E
ENVIRONMENT CONTROL Heating system - 40.B
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
84423865 25/07/2011
E.40.B / 1
Contents
FRAME AND CAB - E
SERVICE
Heater
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
L213, L215
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
L223, L225, L230, C227, C232, C238
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
L218, L220
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
L213, L215
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
L223, L225, L230, C227, C232, C238
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
L218, L220
84423865 25/07/2011
E.40.B / 2
FRAME AND CAB - ENVIRONMENT CONTROL Heating system
Heater - Install
L213, L215
Prior operation:
Tilt system - Tilt (E.34.A)
1. Tip cab and remove seat; remove the cover plate

behind the seat, if equipped. If unit has EH controls
remove the control towers.
93104685 1
2. Remove HVAC switch blanking decal from left hand

side console. (No image available.)
3. Take left hand side console loose from the a-post.
Add heater control decal (1), fan switch (2), and tem-
perature control potentiometer (3) and knob (4).
93104687 2
4. The right hand side 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 side console and headliner
may be left in place.
5. If converting from an open cab without radio, remove
and replace the cab harness. Part not included. Or-
der deluxe harness separately.
6. [Optional] Clean and degrease underside of roof
panel and install roof foam (1) using firm even pres-
sure.
93104646 3
84423865 25/07/2011
E.40.B / 3
7. Remove the blocking plates that cover the fresh air

intake hole and plumbing holes in the firewall and cab
floor.
8. Install the heater box sealing foam (1) at the back of
the cab floor.
93104647 4
9. Using two M6x 30 carriage bolts (1), two M6 hex nuts

(2) and two washers (3) install the air intake duct (4)
to the firewall.
93104686 5
10. Using four M6 x 40 screws (1) and three washers

(2), install the heater (3) to the firewall. Be careful to
ensure that the plumbing ports are inserted properly
through the hole in the cab floor.
93104686 6
11. Connect heater box electrical connector to the cab

harness.
84423865 25/07/2011
E.40.B / 4
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 7
93104640 8
13. Install six directional louvers (1) in the ducts (2).
93104640 9
14. Reinstall headliner and consoles.

15. Remove silicone from bottom of J tubes (A) inside
the rear of the cab.
93104685 10
84423865 25/07/2011
E.40.B / 5
16. Install the rear trim panel (1) over the heater box and
washer bottle. Cap must be removed from washer
bottle to install, then replaced once the panel is se-
cure. 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. Secure the panel with fir
tree fasteners (2).
93104640 11
17. Apply silicone to bottom of J tubes (A) at back exte-

rior of cab and in the front corners of the upper chas-
sis. Fill drain hole (B) in tube with silicone.
93112374 12
18. Clean and degrease front surface of the chassis

crossmember behind the cab. Apply crossmember
foam (1) with firm even pressure.
93104643 13
19. Remove floorplate. Cab lift struts have to be re-

moved in order to remove floorplate. Do not remove
the cab tip safety lock!
20. Using four M6 x 25 flange bolts (1) and four M6 hex
nuts (2), install the water valve (3) to the water valve
bracket (4) and bolt the bracket under the floorboard.
Ensure that the water valve is facing with the outlet
rearward.
93104689 14
84423865 25/07/2011
E.40.B / 6
93112373 15
21. Connect the chassis harness electrical connector to

the water valve.
22. Drain the existing coolant from the engine and radi-
ator. Save for reuse.
23. Remove the plug from the thermostat housing on the
right side of the engine and install the 90 ° hose nip-
ple adapter (1). Use pipe thread compound on the
threads.
93104689 16
24. On naturally aspirated engines, remove the plug from

the top of the water pump and install the straight hose
nipple adapter (1). Use pipe thread compound on the
threads.
25. On turbocharged engine, cut the existing coolant re-
turn hose under the injector lines and route the two
halves over top of the injector lines.
26. Install the “Y” fitting (2) between two halves of return
hose.
93104688 17
84423865 25/07/2011
E.40.B / 7
27. Route the heater supply (1) and new return hoses
(2) from the engine to the front of the machine. Both
hoses route under the engine between the flywheel
side engine mounts. The cab side end of the return
hose has plastic spiral hose guard installed. The
cordura sleeve (3) must be installed over both hoses
where they pass under the engine and tandem pump.
93104689 18
93104688 19
28. Using ctb clamps (1), connect the supply hose (2) to
the hose nipple (3) on the thermostat housing and to
the inlet of the water valve (4).
93104689 20
29. If installing on turbocharged unit, cut return hose (1)

to a length of 2740 mm, where the Y hose fitting (2)
is located. Naturally aspirated units use the hose full
length.
93104688 21
84423865 25/07/2011
E.40.B / 8
30. Connect the return hose (1) to the straight nipple (2)
on the water pump (naturally aspirated) or to the “Y”
fitting (turbocharged).
93104688 22
31. Connect the other end of the return hose to the right
hand side hose stub (outlet hose) on the heater box
using one nylon hose elbow (1).
93104688 23
32. Connect the cab supply hose to the water valve outlet
and to the heater box inlet using the other nylon hose
elbow (1).
93104688 24
33. Install the carriage bolt (1) to the square hole in the
seat pan and hold in place with a flange nut.
34. Place a p-clamp (2) over both hoses and attach to the
carriage bolt on the seat pan. Order of installation is
washer, then p-clamp, then flange nut.
93104689 25
84423865 25/07/2011
E.40.B / 9
35. Install the spring mount brackets (1) to the second

from top front mounting bolt on the left drive motor
and bottom front mounting bolt on the right drive mo-
tor. Use thin nuts (2) to secure in place.
93104689 26
36. Slide one eyelet of each spring on the straight sec-

tion of the other p-clamp, and install the p-clamp (1)
over both hoses . There should be 350 mm between
p-clamps.
93104689 27
37. Connect the other end of each spring to a spring

mounting bracket (1) on each motor . On mechan-
ical units route the springs under the tandem pump
control rods so that the springs fall down away from
the control rods when the cab is lowered.
93104689 28
38. [OPTIONAL] Install the seat pan mat.

39. Reinstall the seat.
40. Refill the cooling system and run the engine to check
for leaks.
41. Reinstall the floor pan and re-connect the cab lift
strut.
42. [OPTIONAL] Install the heelplate mat followed by the
floormat.
84423865 25/07/2011
E.40.B / 10
43. Install the front cleanout hole blockoff plate (1).

44. Put 2 rows of seal strip (2) all around the edge of
blockoff plate (1).
45. Bolt to the front of the chassis using bolts (3).
93104642 29
23111106 30
46. Set the cab down and tip it up again to ensure that the
hoses are dropping into the chassis correctly without
kinking.
47. Close up and clean up.
84423865 25/07/2011
E.40.B / 11
Heater - Install
L223, L225, L230, C227, C232, C238
Prior operation:

from behind the seat, if equipped. If unit has EH
controls remove the control towers.
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 re-
moved 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.
and replace the cab harness with a deluxe cab har-
ness and remove the rear cover from behind the seat,
if equipped.
93104650 2
panel and install roof foam using firm even pressure.
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
84423865 25/07/2011
E.40.B / 12
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.
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.

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
replaced 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. Secure 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
84423865 25/07/2011
E.40.B / 13
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

21. Remove floorplate. Cab lift struts may have to be re-
93104643 8
84423865 25/07/2011
E.40.B / 14
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.
the water valve.
24. Connect the short guarded heater return hose (7)
between the front port of the water valve (1) and the
straight section of the "Y" fitting (8), securing with
constant 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.
27. Remove the EGR coolant return hose (C). Save the
p-clamp from the starter mount bolt (D) for reuse.
84423865 25/07/2011
E.40.B / 15
23112404A 10
28. Install the hose barb splice connector (11) on the

small end of the short formed heater supply hose
(12). Secure 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). Se-
cure 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).
84423865 25/07/2011
E.40.B / 16
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.
seat pan and hold in place with a flange nut (2).
carriage bolt on the seat pan. Order of installation is
washer (4), then p-clamp, then flange nut (2).
23112404C 12
84423865 25/07/2011
E.40.B / 17
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
control shield
46. Reinstall the seat.
for leaks.
48. Reinstall the floor pan.
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).
kinking.
93104642 15
84423865 25/07/2011
E.40.B / 18
Heater - Install
L218, L220
Prior operation:

from behind the seat, if equipped. If unit has EH
controls remove the control towers.
console.
93104685 1
3. Take left hand console loose from the a-post. Add

heater control decal (1), fan switch (2), and temper-
ature control potentiometer (3) and knob (4).
4. The right hand console and headliner must be re-
moved 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.
and replace the cab harness. Not included in kit.
Purchase separately.
93104664 2

panel and install roof foam (1) using firm even pres-
sure.
floor.
93104646 3
84423865 25/07/2011
E.40.B / 19
8. Install the heater box sealing foam (1) at the back of

the cab floor.
93104647 4
9. Using two of each, bolts (1), nuts (2), and washers

(3) install the air intake duct (4) to the firewall.
93104663 5
10. Using four of each, screws (1) and washers (2) install
the heater box (3) to the firewall. Be careful to ensure
that the plumbing ports are inserted properly through
the hole in the cab floor.
harness.
93104663 6
84423865 25/07/2011
E.40.B / 20
12. Install the left hand and right hand ducts (1) and (2)
to heater box using four bolts (3) and anchor to side
of cab using eight fir tree fasteners (4). Ensure that
wiring harness is not pinched between the ducts and
the cab side. Then install six directional louvers (5)
in the ducts.
93104691 7
93104640 8
14. Remove silicone from bottom of J tubes (A) inside

the rear of the cab.
93112374 9
15. Install the rear trim panel (1) over the heater box and
washer bottle. Cap must be removed from washer
bottle to install, then replaced once the panel is se-
cure. Seat belt is routed through the slot in the panel
and the upper lip of the panel is under the air filter ac-
cess cover. Secure the panel with fir tree fasteners.
16. Apply silicone to bottom of J tubes at back exterior
of cab and in the front corners of the upper chassis
(see figure 9).
93104640 10
84423865 25/07/2011
E.40.B / 21

18. Remove floorplate. Cab lift struts have to be re-
93104643 11
19. Install the water valve (1) to the water valve bracket
(2) with bolts (3) and nuts (4) and bolt the bracket un-
der the floorboard using bolts (5) and nuts (6). En-
sure that the water valve is facing with the outlet rear-
ward.
the water valve.
23112387C 12
22. Remove the plug from the thermostat housing on the

right side of the engine and install the 90 ° hose nip-
ple adapter (1). Use pipe thread compound on the
threads.
23112385A 13
23. Cut the existing coolant return hose (1) under the
injector lines and route the two halves over top of the
injector lines.
23112382D 14
84423865 25/07/2011
E.40.B / 22
24. Using ctb clamps (1), install the “Y” fitting (2) between
the two halves of return hose (3).
23112382E 15
25. Route the heater supply (1) and new return hoses
(2) from the engine to the front of the machine. Both
hoses route under the engine between the flywheel
side engine mounts. The cab side end of the return
hose has plastic spiral hose guard installed. The
hose guard (3) must be installed over both hoses
where they pass under the engine and tandem pump.
26. Using two ctb clamps (4), connect the supply hose
(1) to the hose nipple (5) on the thermostat housing
and to the inlet of the water valve (6).
23112387D 16
27. Using a ctb clamp (1), connect the new return hose
(2) to the “Y” fitting (3).
23112382F 17
28. Using a ctb clamp (1), connect the other end of the
return hose (2) to the right hand hose stub (outlet
hose) on the heater box using a nylon hose elbow
(3).
29. Using ctb clamps (1), connect the cab supply hose
(2) to the water valve (5) outlet and to the heater box
inlet using a nylon hose elbow (3).
23112387E 18
84423865 25/07/2011
E.40.B / 23
seat pan and hold in place with a flange nut (2).
carriage bolt (1) on the seat pan. Order of installation
is washer (4), then p-clamp, then flange nut (2).
23112384 19
32. Install the small spring mount bracket (1) to the top
front mounting bolt on the right drive motor. Use a
thin nut (2) to secure in place.
33. Install the large spring mount bracket (3) between the
brake control valve and the chassis nut cages that
the valve mounts to.
23112384A 20
34. Slide one eyelet of the spring (2) on the straight sec-
tion of the other p-clamp (4), and install the p-clamp
over both hoses. There should be 350 mm (14 in)
between p-clamps.
35. Connect each end of spring to the spring mounting
brackets (1) and (3) on the right side motor and the
brake valve. On mechanical units route the springs
under the tandem pump control rods so that the
springs fall down away from the control rods when
the cab is lowered.
37. Reinstall the seat. 23112384B 21
for leaks.
39. Reinstall the floor plate and lift struts.
floormat.
84423865 25/07/2011
E.40.B / 24
a. Place 2 rows of seal strip (1) around the outside edge of

plate (2).
23111106 22
41. Install the front cleanout hole blockoff plate (2) using
4 bolts (3).
93104642 23
kinking.
84423865 25/07/2011
E.40.B / 25
Heater - Remove
L213, L215
Prior operation:
Tilt system - Tilt (E.34.A).
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 re-
move the cab tip safety lock!
5. Remove heater hoses (1), from the back exterior of
the cab and the front corners of the upper chassis,
and silicone fittings.
93112374 3
84423865 25/07/2011
E.40.B / 26
6. Disconnect the cab supply hose (1),from the heater

box.
93104688 4
7. Disconnect the cab return hose (1), from the heater

box.
93104688 5
8. Disconnect heater supply hose (1), from the thermo-

stat housing and install a plug fitting.
93104688 6
9. Disconnect the heater return hose (1), from the water

pump.
93104688 7
84423865 25/07/2011
E.40.B / 27
10. Remove the heater hoses (1), and heater hose hard-
ware from the machine. The hoses are mounted
under the engine, between the flywheel side engine
mounts.
93104689 8
11. Disconnect the chassis harness electrical connector

from the water valve.
12. Remove the headliner and left hand and right hand
consoles.
13. 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 9
14. Remove the six directional louvers (1), in the ducts

(2).
93104640 10
84423865 25/07/2011
E.40.B / 28
15. 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 11
93104640 12
16. Disconnect heater box electrical connector from the

cab harness.
17. Remove the heater box (1), from firewall.
93104686 13
18. Remove air intake duct (1), from firewall.
93104686 14
84423865 25/07/2011
E.40.B / 29
Heater - Remove
L223, L225, L230, C227, C232, C238
Prior operation:

93104685 1

bolts (2).
93104642 2
4. Remove spring (3), from the hole on left hand side
control shield. Remove shields (1), and (2), from
below the heel plate.
23112407 3

84423865 25/07/2011
E.40.B / 30

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

hardware from the machine. The hoses are mounted
mounts.
23112404 7

consoles.
84423865 25/07/2011
E.40.B / 31

93104640 8

(2).
93104640 9
93104691 10
93104640 11

cab harness.
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16. Remove the heater box (1), from the firewall.
93104649 12
93104649 13
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Heater - Remove
L218, L220
Prior operation:

93104685 1

bolts (2).
93104642 2
the cab and the front corners of the upper chassis.
Silicone open ports.
93112374 3
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6. Disconnect the cab supply hose (1), and cab return

hose (2) from the heater box (3).
23112382 4
7. Disconnect the heater supply hose (1), from the ther-

mostat housing and install plug fitting.
23112385 5
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8. Disconnect the heater return hose (2), from water

pump housing.
23112382 6
9. Remove the heater hoses (1), and all heater hose

hardware from the machine. The hoses are mounted
mounts.
23112387D 7
consoles.
93104640 8
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(2).
93104640 9
93104691 10
93104640 11

cab harness.
16. Remove the heater box (1), from the firewall.
93104663 12
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93104663 13
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Index
FRAME AND CAB - E

Heater - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
L213, L215
Heater - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
L223, L225, L230, C227, C232, C238
Heater - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
L218, L220
Heater - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
L213, L215
Heater - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
L223, L225, L230, C227, C232, C238
Heater - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
L218, L220
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FRAME AND CAB - E
ENVIRONMENT CONTROL Air-conditioning system - 40.C
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
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Contents
FRAME AND CAB - E
TECHNICAL DATA
ENVIRONMENT CONTROL Air-conditioning system

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA

Overview HVAC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview HVAC Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview HVAC Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electronic A/C control
Overview HVAC Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Evacuate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressor
Belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
L223, L225, L230, C227, C232, C238
Belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

L213, L215, L218, L220
DIAGNOSTIC

Problem solving HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Compressor
Testing A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Condenser
Testing HVAC Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electronic A/C control
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Testing Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Testing A/C Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Testing HVAC Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Testing HVAC Heat Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Sensing system
Testing HVAC High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
ENVIRONMENT CONTROL Air-conditioning system - General

specification
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.
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ENVIRONMENT CONTROL Air-conditioning system - Overview

HVAC System
NOTE: For more information on the mechanical operation of the HVAC system see: ENVIRONMENT CONTROL Air-
conditioning system - Overview HVAC Mechanical (E.40.C) and for more information on the electrical operation of
the HVAC system see: ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Electrical (E.40.C).
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 S-020 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 AC SWITCH S-017 on, and an Electric Fan speed selected, the HVAC CONDENSER FAN and A/C
COMP are energized, starting the refrigeration cycle and providing cool air to the cab.
In heat mode, with AC Switch off and the TEMPCONTROL Z-017 potentiometer to “hot”, the potentiometer provides a
control signal to the WATER VALVE Z-019 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 Tempcontrol potentiometer is turned to "hot", both the Water Valve and AC components
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 Tempcontrol 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 HVAC 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.
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HVAC Mechanical
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 HVAC 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.
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HVAC Electrical
NOTE: See schematic Wiring harness - Electrical schematic frame 17 (A.30.A)
The HVAC system has several power inputs. One line of source power comes from the ACCESSORY RELAY K-018 to
the HVAC BOX A-003 on pin 11. This energizes the Auxiliary Relay for 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 Electronic A/C control - Overview HVAC Box (E.40.C)
The Auxiliary Relay for Electric Fan main power comes directly from the BATTERY via HVAC FUSE F-001 through
HVAC Box pin 14. The Auxiliary Relay for Electric Fan is shut anytime the ignition is on, allowing power to WATER
VALVE Z-019 and TEMPCONTROL Z-017 potentiometer, also allowing power to BLOWER SWITCH S-020 from HVAC Box
pin 10. Power is provided to the AC SWITCH S-017, from the Blower Switch, anytime a fan speed is selected. The
Blower Switch, AC Switch, and Tempcontrol potentiometer are all located on the Left Console.
Since the Water Valve and Tempcontrol 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 Box pin 6, through Single-Level Pressure Switch (internal to HVAC Box), through Ther-
mostat (internal to HVAC Box), out HVAC Box pin 7 to HVAC HIGH PRESSURE SWITCH back into HVAC Box pin 8 to
the Compressor Relay coil (internal to HVAC Box), shutting the Compressor Relay (internal to HVAC Box). When
Compressor Relay is shut, this allows
battery power via COMPRESSOR FUSE F-002 through HVAC Box pin 2 to the Compressor Relay, out HVAC box pin 12,
to the A/C COMP.
When the AC 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 fuse
F-002 to the CONDENSER FAN.
The Blower Switch, since energized, can provide 4 speed levels (off, low, medium, high) through HVAC box pins 3,
4, and 5 (low, medium, and high) to the Electric Fan Motor (internal to HVAC Box). This is done through a Resistor
(internal to HVAC Box).
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Electronic A/C control - Overview HVAC Box

NOTE: See X-HVC1 and X-HVC2 for connector information
NOTE: See ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Electrical (E.40.C)for electri-
cal 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
10 Power to BLOWER SWITCH S-020, TEMPCONTROL Z-017
potentiometer, and WATER VALVE Z-019 from Auxiliary
Relay for Electric Fan
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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
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ENVIRONMENT CONTROL Air-conditioning system - Install

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 hard-

ware (2).
931001769 3
4. Install left hand side and right hand side duct work
and secure with hardware (3).
931001763 4
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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
8. Install cover and mounting screws (7).
931001752 8
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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
12. Connect heater hoses (3).
931001757 12
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13. Connect air condition hoses (4).
931001757 13
14. After the heater/air conditioning assembly has been

installed refer to Radiator - Filling (B.50.A) and refill
the cooling system.
15. Refer to ENVIRONMENT CONTROL Air-condition-
ing system - Evacuate (E.40.C). Connect the Re-
frigerant Recovery, Recycling and Charging Station
to the high and low charge ports in the hose fitting on
the compressor. Evacuate the system to remove all
moisture from the system.
16. Refer to ENVIRONMENT CONTROL Air-condition-
ing system - Charging (E.40.C) and charge the sys-
tem with reclaimed or new refrigerant. Start the en-
gine and test the air conditioning system for proper
operation.
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ENVIRONMENT CONTROL Air-conditioning system - Remove

Prior operation:
Bucket - Remove (J.20.B)
1. Raise cab to disconnect air conditioning system

hoses (1) and cap open ports.
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
4. Disconnect seat safety switch electrical connection

(4).
931001793 4
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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
8. Remove window wash bottle lid (8).
931001775 8
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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
12. Disconnect air condition electrical connector (11).
931001771 12
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13. Remove air condition unit.
931001773 13
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ENVIRONMENT CONTROL Air-conditioning system - Discharging

1. Recovered refrigerant passes through an oil separa-
tor and filter-drier before entering the refrigerant tank.
The moisture indicator will turn green when dry refrig-
erant passes over it.
2. If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system 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.
4. 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 suc-
tion 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.
5. Open the high and low valves.
6. Make certain the refrigerant tank gas and liquid
valves are open.
7. Connect the main power plug to a 115 volt AC outlet.
Move the main power switch to the ON position and
depress the recovery start switch. The compressor
will shut OFF automatically when recovery is com-
plete. Wait for five minutes and observe the mani-
fold 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
compressor discharge pressure back into the sepa-
rator.
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.
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ENVIRONMENT CONTROL Air-conditioning system - Charging

1. The correct system refrigerant charge capacity is
828.5 ml (28.0 US fl oz).
Press the charge key to begin refrigerant charging.
Automatic and Charge will appear on the display.
The display shows the programmed amount and
counts down to zero as charging proceeds. When
charging is completed, 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
system. See chart on ENVIRONMENT CONTROL
Air-conditioning system - General specification
(E.40.C) for temperature and pressure variations.
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.
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ENVIRONMENT CONTROL Air-conditioning system - Leakage test

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
1. Shut off the engine.

2. Use an electronic leak detector to inspect all con-
nections. Use instructions from manufacturer of leak
finding 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.
3. Repair all leaks and recharge the system.
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ENVIRONMENT CONTROL Air-conditioning system - Evacuate

1. Recovered refrigerant passes through an oil separa-
tor and filter-drier before entering the refrigerant tank.
The moisture indicator will turn green when dry refrig-
erant passes over it.
2. If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system 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.
tion hose . Connect the hose from the high pressure
gauge to the port on the discharge hose . Turn in
5. Open the high and low valves.
6. Make certain the refrigerant tank gas and liquid
valves are open.
Move the main power switch to the ON position and
depress the recovery start switch. The compressor
will shut OFF automatically when recovery is com-
plete. Wait for five minutes and observe the mani-
fold 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
compressor discharge pressure back into the sepa-
rator.
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.
12. Replace the receiver-drier if one or more of the fol-
lowing 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 parti-
cles of moisture removing material (gold or brown
particles).
(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.
84423865 25/07/2011
E.40.C / 21

tion hose. Connect the hose from the high pressure
gauge to the port on the discharge hose. Turn in
14. Removal of air and moisture from the system is nec-
essary after the refrigerant has been removed from
the system after the system has been opened for
maintenance. 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.
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 828.5 mL( 28 oz) and press the enter
key. The display will flash once indicating the pro-
grammed 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
programmed and begin a countdown to zero.
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 - 291/2 inof
mercury (Hg). The low pressure gauge must not in-
crease faster than one inch of mercury (Hg) in 15
minutes. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See ENVIRONMENT CONTROL Air-condi-
tioning system - Leakage test (E.40.C) for a leak
test.
84423865 25/07/2011
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Compressor Belt - Tension adjust

L223, L225, L230, C227, C232, C238
Check the alternator 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. Check alternator belt tension every 50 hours. Measure deflection and adjust as necessary. Inspect
for cracks and damage.
1. Use the following procedure to adjust the poly V/ser-

pentine belt tension for F5C engines.
1. Loosen the upper and lower mounting
bolts on the alternator (1).
2. Loosen the adjusting bolt jam nut (2).
3. Rotate the adjusting bolt (3) until the belt
has a deflection equal to the width of the
belt when a 1 kg (2.2 lb) force is applied
perpendicular to the belt.
4. Tighten the adjusting bolt jam nut.
5. Tighten the alternator mounting bolts.
73092896 1
84423865 25/07/2011
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Compressor Belt - Tension adjust

L213, L215, L218, L220
Check the alternator 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. Check alternator belt tension every 50 hours. Measure deflection and adjust as necessary. Inspect
for cracks and damage.
1. Use the following procedure to adjust the V Belt ten-

sion for ISM engines.
1. Loosen the adjusting bracket bolt (2).
2. Pull the alternator toward the outside of
the machine to tighten belt (1) . The belt
is tightened properly 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
(0.118 in) deflection.
3. Tighten the adjusting bracket bolt (2)
93109316 1
84423865 25/07/2011
E.40.C / 24
ENVIRONMENT CONTROL Air-conditioning system - Problem

solving HVAC
OPERATION
To understand the electrical flowpaths and help narrow down the troubleshooting efforts, refer to HVAC System Elec-
trical overview ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Electrical (E.40.C).
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 POWER SYSTEM - Component identification Relay
Index (A.30.A).
4. Switches are operated in accordance with Operator's Manual.
Problem Possible Cause Correction
No heat Faulty TEMPCONTROL Z-017 potentiometer Electronic A/C control - Testing HVAC
Heat Components (E.40.C)
Faulty WATER VALVE Z-019 Electronic A/C control - Testing HVAC
Faulty Fan Relay (internal to HVAC Box) Electronic A/C control - Testing HVAC
Box (E.40.C)
Poor Heat Faulty TEMPCONTROL Z-017 potentiometer Electronic A/C control - Testing HVAC
Faulty WATER VALVE Z-019 Electronic A/C control - Testing HVAC
Poor cooling No voltage at connector X-74 pin B. Faulty CONDENSER RELAY or associated
wiring. See Fuse and relay box - Testing
Relay Testing (A.50.A) and Fuse and
relay box - Testing Condenser Relay
Control (A.30.A)
Faulty HVAC CONDENSER FAN Condenser - Testing HVAC Condenser
Fan (E.40.C)
Thermostat (internal to HVAC Box) not cy- Electronic A/C control - Testing HVAC
cling correctly Box (E.40.C)
Poor cooling after engine Faulty WATER VALVE Z-019 Electronic A/C control - Testing HVAC
is at normal temperature Heat Components (E.40.C)
Faulty TEMPCONTROL Z-017 potentiometer Electronic A/C control - Testing HVAC
No cooling Faulty Fan Relay (internal to HVAC Box) Electronic A/C control - Testing HVAC
Box (E.40.C)
Faulty BLOWER SWITCH S-020 Electronic A/C control - Testing Blower
Switch (E.40.C)
Faulty AC SWITCH S-017 Electronic A/C control - Testing A/C
Switch (E.40.C)
Faulty Single-Level Pressure Switch (inter- Electronic A/C control - Testing HVAC
nal to HVAC Box) Box (E.40.C)
Faulty Thermostat (internal to HVAC Box) Electronic A/C control - Testing HVAC
Box (E.40.C)
Faulty HVAC HIGH PRESSURE SWITCH Sensing system - Testing HVAC High
Pressure Switch (E.40.C)
Faulty Compressor Relay (internal to HVAC Electronic A/C control - Testing HVAC
Box) Box (E.40.C)
Faulty A/C COMPRESSOR Compressor - Testing A/C Compressor
(E.40.C)
No fan speeds available No voltage at HVAC Box pin 14 Faulty HVAC FUSE F-001 or associated
wiring
84423865 25/07/2011
E.40.C / 25

No voltage at HVAC Box pin 11 Faulty ACCESSORY RELAY K-018 or asso-
ciated wiring. See Fuse and relay box -
Testing Relay Testing (A.50.A) and Fuse
and relay box - Testing Accessory Relay
Control (A.30.A)
Faulty BLOWER SWITCH S-020 Electronic A/C control - Testing Blower
Switch (E.40.C)
Faulty Fan Relay (internal to HVAC Box) Electronic A/C control - Testing HVAC
Box (E.40.C)
Faulty Electric Fan Motor (internal to HVAC Electronic A/C control - Testing HVAC
box) Box (E.40.C)
Faulty HVAC Box ground wiring Use ELECTRICAL POWER SYSTEM -
Testing General Wire Testing (A.30.A) to
ensure proper ground from HVAC Box pin
1
Only high speed fan Faulty Resistor (internal to HVAC Box) Electronic A/C control - Testing HVAC
available Box (E.40.C)
Only one fan speed is not Wiring problem common to HVAC BOX Use ELECTRICAL POWER SYSTEM -
available A-003 (Resistor) and BLOWER SWITCH Testing General Wire Testing (A.30.A) to
S-020 locate faulty wire
84423865 25/07/2011
E.40.C / 26
Compressor - Testing A/C Compressor

NOTE: Use schematics Wiring harness - Electrical schematic frame 17 (A.30.A)
With ignition off, use ELECTRICAL No wire problems. Wire problems are found.
POWER SYSTEM - Testing Gen- Action Action
eral Wire Testing (A.30.A) to Go to test 2 Locate and repair or replace broken
Check ground wire.
wire condition between A/C
COMPRESSOR ground pin and
ground.
Disconnect connector X-AC_COMP 12 V 0V
from the A/C COMPRESSOR. With ig- Action Action
nition on, The A/C COMPRESSOR has failed. Go to test 3
Check Replace the compressor.
for voltage from connector
X-AC_COMP power pin and ground.
With ignition off, use ELECTRICAL No wire problems. Wire problems are found.
POWER SYSTEM - Testing Gen- Action Action
eral Wire Testing (A.30.A) to Locate and repair or replace broken
Check See the following for further testing wire 841 (White).
wire condition between A/C • ENVIRONMENT CON-
COMPRESSOR power pin and TROL Air-conditioning
X-HVC1 pin 12. system - Problem solv-
ing HVAC (E.40.C)
• Electronic A/C control
- Testing HVAC Box
(E.40.C)
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Condenser - Testing HVAC Condenser Fan

NOTE: Without the Condenser Fan, the Air Conditioning will work poorly. If Air Conditioning does not work at all, see
ENVIRONMENT CONTROL Air-conditioning system - Problem solving HVAC (E.40.C)
Disconnect connector X-74 from the No wire problems. Wire problems are found.
HVAC CONDENSER FAN. Use ELEC- Action Action
TRICAL POWER SYSTEM - Test- Go to test 2 Locate and repair or replace broken
ing General Wire Testing (A.30.A) wire 1084 (Black).
to
Check
ground wire condition between X-74
pin A and ground.
With ignition on, 12 V 0V
Check Action Action
for voltage from connector X-74 pin The HVAC CONDENSER FAN has Go to test 3
B and ground. failed. Replace the fan.
Disconnect connector X-111 from No wire problems. Wire problems are found.
the CONDENSER RELAY. Use ELEC- Action Action
TRICAL POWER SYSTEM - Test- Locate and repair or replace broken
ing General Wire Testing (A.30.A) See the following for further testing wire 237 (White).
to • Fuse and relay box -
Check Testing Condenser Re-
wire condition between X-74 pin B lay Control (A.30.A)
and X-111 pin 87.
• ENVIRONMENT CON-
TROL Air-conditioning
system - Problem solv-
ing HVAC (E.40.C)
84423865 25/07/2011
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Electronic A/C control - Testing Blower Switch

NOTE: Ensure Electronic A/C control - Testing HVAC Box (E.40.C) test is satisfactory prior to performing this test
Disconnect connector X-270 from 0 Ω when selecting a fan speed, no Any other readings
the BLOWER SWITCH S-020. continuity when fan is selected off. Action
Check Action The BLOWER SWITCH has failed. Re-
for resistance between BLOWER Go to test 2 place the switch.
SWITCH
pins 1 and 2 while cycling the Blower
Switch.
2 Check Result Result
for resistance between BLOWER For each resistance check, 0 Ω in 0 Ω in more than one position or infi-
SWITCH one position, infinite resistance in all nite resistance in all positions.
pins 2 and 3 (Low) others. Action
pins 2 and 4 (Medium) Action The BLOWER SWITCH has failed. Re-
pins 2 and 5 (High) Go to test 3 place the switch.
while cycling the BLOWER SWITCH.
ing (A.30.A) to Locate and repair or replace broken
Check See the following for further testing wire 821/846/842 (Orange) or adja-
wire condition between X-HVC1 pin • ENVIRONMENT CON- cent wiring.
10 and connector X-270 pin 2. TROL Air-conditioning
ing HVAC (E.40.C)
- Testing HVAC Box
(E.40.C)
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Electronic A/C control - Testing A/C Switch

NOTE: See schematic
NOTE: Ensure Electronic A/C control - Testing Blower Switch (E.40.C) test is satisfactory prior to performing this
test
Use ENVIRONMENT CON- Light on Light not on
TROL Air-conditioning system - Action Action
Overview HVAC System (E.40.C) Go to test 3 Go to test 2
to set up conditions for the AC sys-
tem to turn on.
Check
that AC switch indicator light is on.
Disconnect connector X-275 from 12 V 0V
the AC SWITCH S-017. Use ENVI- Action Action
RONMENT CONTROL Air-condi- Go to test 3 There is an open on wire 825 (Or-
tioning system - Overview HVAC ange). Repair the wire.
System (E.40.C) to set up condi-
tions for the AC system to turn on.
Check
for voltage between X-275 pins 1
and ground.
Disconnect connector X-275 from No circuit problems. No change in circuit response.
the AC SWITCH S-017. Connect a Action Action
jumper between connector X-275 The AC SWITCH S-017 has failed. Go to test 4
pins 1 and 2. Replace the switch.
Check
ing (A.30.A) to Locate and repair or replace bro-
Check See the following for further testing ken wire 829/837 (White) or adjacent
wire condition between X-275 pin 2 • ENVIRONMENT CON- wiring.
and connector X-HVC1 pin 6. TROL Air-conditioning
ing HVAC (E.40.C)
- Testing HVAC Box
(E.40.C)
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Electronic A/C control - Testing HVAC Box

NOTE: Ensure HVAC FUSE F-001
COMPRESSOR FUSE F-002 and
ACCESSORY RELAY K-018 are working correctly prior to performing this test.
NOTE: See Electronic A/C control - Overview HVAC Box (E.40.C) for additional information
Disconnect connector X-HVC2 from 12 V for each check 0V
X-HVC1. With the ignition on, Action Action
Check Go to test 2 There is a problem in the DC distri-
for voltage from connector X-HVC1 bution system upstream of X-HVC1
pin 2 and ground, 11 and ground, pin 2, 11, or 14.
and 14 and ground.
for resistance between HVAC BOX 0Ω Greater than 15 Ω
A-003 pins 1 and 8 and from pins 1 Action Action
and 11. Go to test 3 Either the Compressor Relay or Fan
Relay, both internal to the HVAC
Box, has failed. Replace the ser-
viceable component.
for resistance between HVAC BOX Open 0Ω
A-003 pins 2 and 12 and from pins Action Action
10 and 14. Go to test 4 Either the Compressor Relay or Fan
Relay, both internal to the HVAC
Box, has failed. Replace the ser-
viceable component.
for resistance between HVAC BOX The sum of the resistances from pins For any other readings,
A-003 3 and 4 and from pins 4 and 5 should Action
pins 3 and 4 equal the resistance from pins 3 and The Resistor, internal to the HVAC
pins 4 and 5 5. Box, has failed. Replace the service-
pins 3 and 5. Action able component.
Go to test 5
for resistance between HVAC BOX 10 Ω Either 0 Ω or greater than 1000 Ω
A-003 pins 1 and 5 Action Action
Go to test 6 The Electric Fan Motor, internal to
the HVAC Box, has failed. Replace
the serviceable component.
Check wire 1012 (Black/White) or adjacent
X-HVC1 pin 9 and ground.
Check See the following for further testing wire 935/1087 or 935/1088 (Black)
wire condition between connector • ENVIRONMENT CON- or adjacent wiring.
X-HVC1 pin 1 and ground. TROL Air-conditioning
ing HVAC (E.40.C)
84423865 25/07/2011
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Electronic A/C control - Testing HVAC Heat Components

the TEMPCONTROL Z-017 poten- Action Action
tiometer. With ignition on, Go to test 2 Go to test 3
Check
for voltage from connector X-252 pin
3 and ground.
the WATER VALVE Z-019. With igni- Action Action
tion on, Go to test 4 Go to test 3
Check
for voltage from connector X-271 pin
A and ground.
Check See the following for further testing wire 823 (Pink) or 822/846/842 (Or-
wire condition between X-HVC1 pin • ENVIRONMENT CON- ange) or adjacent wiring.
10 and connector X-271 pin A and TROL Air-conditioning
between X-HVC1 pin 10 and con- system - Problem solv-
nector X-252 pin 3. ing HVAC (E.40.C)
- Testing HVAC Box
(E.40.C)
for resistance between Varying resistance with potentiome- 0 Ω, or infinite resistance, or con-
TEMPCONTROL Z-017 potentiometer ter movement. stant value
pins 2 and 3 while moving poten- Action Action
tiometer. Go to test 5 The TEMPCONTROL potentiometer
has failed. Replace the potentiome-
ter.
for resistance between WATER 20 Ω 0 Ω, or greater than 1 K Ω
VALVE Z-019 pins A and C. Action Action
Go to test 6 The WATER VALVE has failed. Re-
place the valve.
Check wire 824 (Yellow).
signal wire condition between X-252
pin 2 and connector X-271 pin D.
ing (A.30.A) to The WATER VALVE has failed. Re- Locate and repair or replace broken
Check place the valve. wire 912 (Black) or 1013 (Black).
ground wire condition between
X-252 pin 1 and ground and between
connector X-271 pin C and ground.
84423865 25/07/2011
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Sensing system - Testing HVAC High Pressure Switch

NOTE: Ensure the HVAC system has no mechanical problems before following this procedure. See ENVIRONMENT
CONTROL Air-conditioning system - Overview HVAC System (E.40.C) for more information on the HVAC System.
Disconnect connector X-76 from the No circuit problems. No change in circuit response, re-
HVAC HIGH PRESSURE SWITCH. Con- Action move jumper.
nect a jumper between connector The HVAC HIGH PRESSURE SWITCH Action
X-76 pins A and B. has failed. Replace the switch. Go to test 2
Check
Use ENVIRONMENT CON-
TROL Air-conditioning system -
Overview HVAC System (E.40.C)
to set up conditions for the A/C
system to turn on. Check circuit op-
eration.
ing (A.30.A) to Go to test 3 Repair or replace broken wire 834
Check (White).
X-76 pin B and connector X-HVC1
pin 8.
ing (A.30.A) to Repair or replace broken wire 833
Check See the following for further testing (White).
wire condition between connector • ENVIRONMENT CON-
X-76 pin A and connector X-HVC1 TROL Air-conditioning
pin 7. system - Problem solv-
ing HVAC (E.40.C)
- Testing HVAC Box
(E.40.C)
84423865 25/07/2011
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Index
FRAME AND CAB - E

Compressor - Testing A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Compressor Belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
L223, L225, L230, C227, C232, C238
Compressor Belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
L213, L215, L218, L220
Condenser - Testing HVAC Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ENVIRONMENT CONTROL Air-conditioning system - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENVIRONMENT CONTROL Air-conditioning system - Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ENVIRONMENT CONTROL Air-conditioning system - Evacuate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ENVIRONMENT CONTROL Air-conditioning system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENVIRONMENT CONTROL Air-conditioning system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENVIRONMENT CONTROL Air-conditioning system - Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENVIRONMENT CONTROL Air-conditioning system - Problem solving HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ENVIRONMENT CONTROL Air-conditioning system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electronic A/C control - Overview HVAC Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electronic A/C control - Testing A/C Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Electronic A/C control - Testing Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Electronic A/C control - Testing HVAC Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Electronic A/C control - Testing HVAC Heat Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Sensing system - Testing HVAC High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
84423865 25/07/2011
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FRAME AND CAB - E
SAFETY SECURITY ACCESSORIES Safety - 50.B
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
84423865 25/07/2011
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Contents
FRAME AND CAB - E
SERVICE
Back up alarm
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSTIC
Audible alert
Testing Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84423865 25/07/2011
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FRAME AND CAB - SAFETY SECURITY ACCESSORIES Safety
Back up alarm - Remove

1. Locate and open engine hood (1) and rear service
door (2).
93107449A1 1
2. Remove electrical leads (1) from the backup alarm

H-002 (2).
931001672 2
3. Remove hardware (1) retaining backup alarm H-002

(2).
4. Remove backup alarm H-002 (2).
931001673 3
84423865 25/07/2011
E.50.B / 3
Back up alarm - Install

1. Insert retaining hardware and tighten bolts (1) secur-
ing the backup alarm H-002 (2).
931001673 1
2. Connect connectors X-BKUP-GND (1) and

X-BKUP-PWR (2) to the backup alarm H-002 (3).
931001672 2
84423865 25/07/2011
E.50.B / 4
Audible alert - Testing Horn


Remove IGNITION FUSE from the 0Ω Fuse is blown.
MAIN POWER DISTRIBUTION FUSE Action Action
BLOCK 1 Z-2008. Go to test 2 Replace the fuse with same type and
Check amp rating.
for continuity across IGNITION FUSE.
With the fuse removed and ignition 12 V 0V
on, Action Action
Check Go to test 3 There is a problem in the DC distri-
for voltage from MAIN POWER bution system upstream of IGNITION
DISTRIBUTION FUSE BLOCK 1 Z-2008 FUSE.
pin C3 and ground.
Check wire 891/357/351 (Orange) or adja-
wire condition between connector cent wiring.
X-408 pin 4 (EH) X-405 pin A (Mech)
and MAIN POWER DISTRIBUTION FUSE
BLOCK 1 Z-2008 pin C4.
Using a multi-meter, check for resis- For each resistance check, 0 Ω in 0 Ω in all positions or infinite resis-
tance between HORN SWITCH S-023 one position, infinite resistance in the tance in all positions.
X-408 pins 4 and 8 (EH) X-405 pins other. Action
A and B (Mech) while cycling the Action The HORN SWITCH has failed. Re-
switch. Go to test 5 place the LEFT HAND CONTROL
HANDLE.
Check wire 892 (White) or adjacent wiring.
X-408 pin 8 (EH) X-405 pin B (Mech)
and connector X-HORN-PWR pin 1.
ing (A.30.A) to The HORN has failed. Replace the Locate and repair or replace broken
Check HORN. wire 955/968/983 (Black) or adjacent
X-HORN-GND pin 1 and ground.
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Index
FRAME AND CAB - E

Audible alert - Testing Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Back up alarm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Back up alarm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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STABILISING Ballasting - 20.B
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
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Contents
SERVICE
Rear ballasting
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
L213, L215
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
L213, L215
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
L218, L220, L223, L225, L230, C227, C232, C238
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
L218, L220, L223, L225, L230, C227, C232, C238
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FRAME POSITIONING - STABILISING Ballasting
Rear ballasting - Remove

L213, L215
DANGER
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.
D0076A
1. With proper support under the bumper weight re-

move mounting hardware (1).
2. Remove center bumper .
931001656 1
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Rear ballasting - Install

L213, L215
DANGER
Heavy objects!
D0076A
1. Place rear center bumper (1) in position.
931001656 1
2. Install center bumper mounting hardware .
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Rear ballasting - Remove

L218, L220, L223, L225, L230, C227, C232, C238
DANGER
Heavy objects!
D0076A
Prior operation:
Battery - Remove (A.30.A).
1. Remove left hand side corner mounting hardware

(1).
931001655 1
2. Remove left hand side counterweight.
931001658 2
NOTE: Perform the same operation on the right hand side.

3. Remove center bumper mounting hardware (1).
93107449 3
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F.20.B / 5
4. Remove center bumper mounting hardware (1).

5. Remove center bumper (2).
931001656 4
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Rear ballasting - Install

L218, L220, L223, L225, L230, C227, C232, C238
DANGER
Heavy objects!
D0076A
1. Place rear center bumper (1) in position.

2. Install center bumper mounting hardware (2).
931001656 1
3. Install left hand side counterweight and secure in

place with mounting hardware (3).
931001655 2
NOTE: Perform the came operation on right hand side.
Next operation:
Battery - Install (A.30.A).
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Index

Rear ballasting - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
L213, L215
Rear ballasting - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
L218, L220, L223, L225, L230, C227, C232, C238
Rear ballasting - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
L213, L215
Rear ballasting - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
L218, L220, L223, L225, L230, C227, C232, C238
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LIFTING - 10.A
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
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Contents
LIFTING - 10.A
TECHNICAL DATA
Cylinder
L218
L218
L223, L225, L230, C232, C238
L223, L225, L230, C232, C238
L213, L215
C227
L220
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
L220
SERVICE
Command
Adjust for direct mechanical foot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
L213, L215, L218, L220, L223, L225, L230
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
C227, C232, C238
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TOOL POSITIONING - LIFTING
Cylinder - General specification

L218
Cylinder Lift
Collapsed length 983.0 mm (38.7 in)
Extended length 1663.7 mm (65.5 in)
Stroke length 680.7 mm (26.8 in)
Tube bore diameter 57.2 mm (2.3 in)
Rod diameter 34.9 mm (1.4 in)
Tube end diameter 38.2 mm (1.5 in)
Rod end diameter 38.2 mm (1.5 in)
End width 40.6 mm (1.6 in)
Supply port size 3/4-16 SAE O-ring boss
Return port size 3/4-16 SAE O-ring boss
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L218
Cylinder Lift
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L223, L225, L230, C232, C238
Cylinder Lift
Tube end width 40.6 mm (1.6 in)
Rod end width 50.8 mm (2 in)
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L223, L225, L230, C232, C238
Cylinder Lift
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L213, L215
Cylinder Lift
Collapsed length 989 mm (38.9 in)
Stroke length 645 mm (25.4 in)
Tube end pin diameter 38.3 mm (1.5 in)
Rod end pin diameter 38.3 mm (1.5 in)
Rod end width 40 mm (1.6 in)
Tube end width 40 mm (1.6 in)
Tube port size 3/4-16 SAE O-ring boss
Rod port size 3/4-16 SAE O-ring boss
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C227
Cylinder Lift
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L220
Cylinder Lift
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L220
Cylinder Lift
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Command - Adjust for direct mechanical foot controls

L213, L215, L218, L220, L223, L225, L230
Adjustment for direct mechanical foot controls

1. Raise machine off ground and place securely on jack
stands.
2. Loosen Clamp Bolts (1), but leave snug.
3. Take engine to high idle.
4. Move wear plate until pump is centered.
5. Tighten clamp bolts and move handle in both direc-
tions to confirm neutral is set. Adjust again if needed.
6. Repeat for other pump.
23112917 1
7. Set handle position by loosing the left hand thread

jam nut (2) and right hand thread jam nut (3) and ro-
tating the control rod (4) until handle is in the correct
position of 75 °. Then tighten both jam nuts.
8. Set travel stops. Refer to Direct Hand Control in-
structions for details. STEERING Mechanical - Ad-
just for hand controls with direct mechanical hy-
drostatic pump (D.20.B)
23112918 2
23112922 3
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Command - Adjust
C227, C232, C238
1. Remove Tag along springs (1) (both sides).
23112920 1
2. Set handle position by loosening left hand jam nut

(2) and right hand jam nut (3) and rotating control
rod (6) until handle is in the correct position, of 75 °
then tighten the jam nuts.
23112922 2
3. Loosen roller (4) and position in center of cam (5).

Then tighten the roller.
4. Reinstall the Tag along springs that was removed in
the 1st step.
5. Repeat steps 2 and 3 for other pump.
6. Set stop bolts and drift – Same as Direct Mechanical.
STEERING Mechanical - Adjust for hand con-
trols with direct mechanical hydrostatic pump
(D.20.B)
7. See Servo Hand Controls for instructions to align
Handles after setting drift. STEERING Mechanical -
23112919A 3
Adjust hand controls with servo operated pump
(D.20.B)
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Index
LIFTING - 10.A
Command - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
C227, C232, C238
Command - Adjust for direct mechanical foot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
L213, L215, L218, L220, L223, L225, L230
Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
L218
L218
L223, L225, L230, C232, C238
L223, L225, L230, C232, C238
L213, L215
C227
L220
Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
L220
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TILTING - 20.A
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
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Contents
TILTING - 20.A
TECHNICAL DATA
Cylinder
L213, L215
C227
L218
L220
L223, L225, L230, C232, C238
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TOOL POSITIONING - TILTING

L213, L215
Cylinder Bucket
Collapsed length 594 mm (23.4 in)
Tube end width 76 mm (3 in)
Rod end width 46 mm (1.8 in)
Tube end port size 9/16-18 UNF-2B SAE O-ring boss
Rod end port size 9/16-18 UNF-2B SAE O-ring boss
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C227
Cylinder Tilt
Collapsed length 609.6 mm (24 in)
Tube end width 76.2 mm (3 in)
Supply port size 9/16-18 UNF-2B SAE O-ring boss
Return port size 9/16-18 UNF-2B SAE O-ring boss
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L218
Cylinder Bucket
Collapsed length 610 mm (24 in)
Tube end width 76 mm (3 in)
Rod end width 45.7 mm (1.8 in)
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L220
Cylinder Tilt
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L223, L225, L230, C232, C238
Cylinder Tilt
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Index
TILTING - 20.A
L213, L215
C227
L218
L220
L223, L225, L230, C232, C238
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LEVELLING - 30.A
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
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Contents
LEVELLING - 30.A
TECHNICAL DATA
Control valve
General specification of the 60% self level valve on medium and large frame . . . . . . . . . . . . . . . . . . . . . . . 3
L220, L225, L230, C232, C238
General specification of the 48% self level valve on small frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

L213, L215
General specification of the 50% self level valve on medium frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

C227
General specification of the 40% self level valve on medium frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

L218
SERVICE
Command
Remove Self Level Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install Self Level Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Command valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Control valve
Remove Self level valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install Self level valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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TOOL POSITIONING - LEVELLING
Control valve - General specification of the 60% self level valve on

medium and large frame
L220, L225, L230, C232, C238
Manufacturer Eaton - Part Number 39055-EEG
Proportional Flow Divider Settings: Port D = 60 %

Port B = 40 %
Hydraulic Requirements: Flow = 57 l/min (15 US gpm)

System Pressure = 210 bar (3050 psi)
Electrical Requirements: Operating Voltage = 14 V

Maximum Power = 22 W
Self Level Override Solenoid Connection Type: Deutsch DT series.
Proportional Flow Divider Adjustment: Remove plastic cap.

Turn counter clockwise to increase flow to the tilt cylinders.
Turn clockwise to decrease flow to the tilt cylinders.
Operating Temperature Range: -30 - 107 °C (-22 - 225 °F)
Port Identification Chart: (A) Lift Cylinder Rod End

(B) CV Work Port B1
(C) Tilt Cylinder Rod End
(D) Tilt Cylinder Base End
Control valve - General specification of the 48% self level valve

on small frame
L213, L215
Manufacturer Eaton - Part Number 39055-EEJ

Port B = 52 %



(B) CV Work Port B1
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on medium frame
C227
Manufacturer Eaton - Part Number 39055-EEH

Port B = 50 %

Intermittent Pressure Spikes = 276 bar (4000 psi)
Maximum Pressure Drop Across Valve = 10 bar (150 psi) @ 57 l/min (15
US gpm)



(B) CV Work Port B1
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on medium frame
L218
Manufacturer Eaton - Part Number 39055-EEK

Port B = 60 %



(B) CV Work Port B1
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Command - Remove Self Level Valve Solenoid

Prior operation:
Tilt system - Tilt cab, secure the lift arm in the raised position. (E.34.A)
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:
Command - Install Self Level Valve Solenoid (G.30.A)
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Command - Install Self Level Valve Solenoid

Prior operation:
Command - Remove Self Level Valve Solenoid (G.30.A)
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
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Command valve - Remove

WARNING
Pressurized system!
System is still under pressure. Release pressure according to instructions in this manual.
W1044A
NOTE: Never loosen any hydraulic lines without first relieving all pressure in the system. Refer to PRIMARY HY-
DRAULIC POWER SYSTEM - Depressurising (A.10.A)
1. Label and disconnect electrical connection (1).
931001722 1
2. Label and disconnect bucket hydraulic tubes (1) and

cap open ports.
931001720 2
3. Label and disconnect supply tube (1) and cap open

ports.
931001720 3
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4. Label and disconnect drain hose (1).
931001720 4
5. Remove mounting hardware (2).
931001720 5
6. Remove command valve.
931001721 6
Next operation:
Command - Install (G.30.A)
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Command valve - Install

1. Locate where the command valve (1) is positioned
on the body.
931001720 1
2. Install mounting hardware (1).
931001720 2
3. Connect valve drain hose (1).
931001720 3
4. Connect valve supply tube (1).
931001720 4
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5. Connect bucket hydraulic tubes (2).
931001720 5
6. Connect electrical connection (1).
931001722 6
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Control valve - Remove Self level valve

Prior operation:
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
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4. Disconnect lower tubes (1) and cap ports.
931001981 4
5. Disconnect front tube (1) and cap port.
931001981 5
931001981 6
7. Remove control valve.
931001707 7
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Control valve - Install Self level valve

1. Install control valve (1) onto body in correct location.
931001804 1
931001981 2
3. Connect front tube (1).
931001981 3
4. Connect lower tubes (1).
931001981 4
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5. Connect hydraulic tube (1).
931001702 5
6. Connect electrical connection (1).
931001701 6
Next operation:
Tilt system - Lower (E.34.A)
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Index
LEVELLING - 30.A
Command - Install Self Level Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Command - Remove Self Level Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Command valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Command valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Control valve - General specification of the 40% self level valve on medium frame . . . . . . . . . . . . . . . . . . . . . . . . . . 5
L218
Control valve - General specification of the 48% self level valve on small frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
L213, L215
Control valve - General specification of the 50% self level valve on medium frame . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C227
Control valve - General specification of the 60% self level valve on medium and large frame . . . . . . . . . . . . . . . . . 3
L220, L225, L230, C232, C238
Control valve - Install Self level valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Control valve - Remove Self level valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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SECONDARY FUNCTIONS Hydraulic - 90.C
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
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Contents
FUNCTIONAL DATA
Control valve
Overview High Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview Auxiliary Override Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSTIC
Control valve
Testing 2nd Aux Extend Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Testing 2nd Aux Retract Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Testing 2nd Aux Hyd Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing High Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
84423865 25/07/2011
G.90.C / 2
TOOL POSITIONING - SECONDARY FUNCTIONS Hydraulic
Control valve - Overview High Flow

The Operator can command additional flow to the auxiliary circuit by engaging Auxiliary High flow Function. This will
provide increase flow and pressure to the auxiliary circuit. Of up to 128 l/min (35 US gpm) and up to 215 bar (3050
psi).
High Flow feature is engaged by pressing the On/Off switch mounted on left hand A post. The switch selects Standard
or Enhance High Flow and is illuminated when High Flow or Enhanced High Flow is on. Allows the operator to enable/
disable the function depending on the attachment requirements. The attachment flow is controlled with the switch in
the Left Hand Control Handle.
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. Hydraulic Enable switch is activated
The Operator can command additional pressure to the auxiliary circuit by engaging the Enhanced Auxiliary High flow
function. This will provide increase pressure to the auxiliary circuit. Flow is 128 l/min (35 US gpm) and pressure up
to 275 bar (4000 psi). The loader control valve standard auxiliary circuit is unaffected when High Flow is disabled.
When Standard or Enhanced High Flow 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 the attachment.
High Flow feature is engaged by pressing the On/Off switch mounted on left hand A post. Allows the operator to
enable/disable the function depending on the attachment requirements.
The Enhanced High Flow Auxiliary Control can be controlled only if all of the following conditions are met
2. Operator Restraint engaged
4. Engine is running
6. Multifunction high pressure interlock plug connected ("HP" mode only)
84423865 25/07/2011
G.90.C / 3
Control valve - Overview Auxiliary Override Control

The machine can be used to operate auxiliary attachments which require the operator to exit the cab. The operator can
engage the auxiliary hydraulics such that they will remain on full flow so that the attachment will be provide hydraulic
lines for P and T. The attachment will most likely contain its own control valve.
Operator must press the Auxiliary Hydraulic Interlock Override switch on the instrument cluster. This will override the
seat switch and restraint bar. A lamp will flash indicating that the override is activated and the operator must leave
the seat within 30 seconds otherwise the feature will deactivate.
When the button is pressed (press and release within 10 sec) the following conditions will be set
1. Park brake engaged
2. Loader arm and bucket disabled
3. Engage port locks
4. Loader Pilot interlock unlocked
The operator can put the thumbwheel into the forward detented position, before or after Aux Override is pressed. Any
reverse flow command will be ignored.
If the operator does not leave the seat within 30 seconds, the SSL will go into hydraulics disable state and the operator
must re-enabled hydraulics to regain control of the machine.
When the operator re-enters the SSL AND the seat switch THEN lap bar are down, the machine will enter hydraulics
disable state. Otherwise Aux override will remain active. He will have to meet the Hydraulics Enable Function Enable
Conditions to re-enable hydraulics.
At any time the Aux override or the hydraulics enable button can be pressed to deactivate the feature.
Auxiliary Override is functional with the standard flow and high flow. Not allowed with enhanced high flow option.
The Auxiliary Override Feature can be activated only if all of the following conditions are met
2. Operator Restraint is engaged
Valve Logic Enabled Disabled

Port Lock Locked not controlled
Park Brake Activated not controlled
Ground Drive Interlock Locked not controlled
Loader Interlock Unlocked not controlled
84423865 25/07/2011
G.90.C / 4
Control valve - Testing 2nd Aux Extend Solenoid

Disconnect connector X-AUX_EXT Normal resistance. 0 Ω, or greater than 1 K Ω
from the 2ND AUX EXTEND SOLENOID Action Action
Check Go to test 2 The 2ND AUX EXTEND SOLENOID has
for resistance between 2ND AUX failed. Replace the solenoid.
EXTEND SOLENOID pins 1 and 2 (EH)
pins A and B (Mech).
X-AUX_EXT pin 2 (EH) pin B (Mech)
and ground.
ing (A.30.A) to Repair or replace broken wire
Check See the following for further testing 554 (White) (EH) 554/454 (White)
wire condition between X-AUX_EXT • Control valve - Testing (Mech).
pin 1 (EH) pin A (Mech) and connec- 2nd Aux Hyd Switch
tor X-408 (EH) X-407 (Mech) pin 2. (G.90.C)
• Control valve - Test-
ing High Flow Switch
(G.90.C)
• Electrical control - Test-
ing Hydraulic Coupler
Switch and Solenoid
(J.80.C)
• OPTION RELAY in ELEC-
TRICAL POWER SYS-
TEM - Component iden-
tification Relay Index
(A.30.A)
84423865 25/07/2011
G.90.C / 5
Control valve - Testing 2nd Aux Retract Solenoid

Disconnect connector X-AUX_RET Normal resistance. 0 Ω, or greater than 1 K Ω
from the 2ND AUX RETRACT Action Action
SOLENOID Go to test 2 The 2ND AUX RETRACT SOLENOID
Check has failed. Replace the solenoid.
for resistance between 2ND AUX
RETRACT SOLENOID pins 1 and 2
(EH) pins A and B (Mech).
X-AUX_RET pin 2 (EH) pin B (Mech)
and ground.
ing (A.30.A) to Repair or replace broken wire 552
Check See the following for further testing (White).
wire condition between X-AUX_RET • Control valve - Testing
pin 1 (EH) pin A (Mech) and connec- 2nd Aux Hyd Switch
tor X-408 (EH) X-407 (Mech) pin 3. (G.90.C)
(G.90.C)
Switch and Solenoid
(J.80.C)
• OPTION RELAY in ELEC-
TRICAL POWER SYS-
TEM - Component iden-
tification Relay Index
(A.30.A)
84423865 25/07/2011
G.90.C / 6
Control valve - Testing 2nd Aux Hyd Switch

Remove HIGH FLOW / COUPLER 0Ω Fuse is blown.
FUSE from the ACCESSORY POWER Action Action
DISTRIBUTION. Go to test 2 Replace the fuse with same type and
Check amp rating.
for continuity across HIGH FLOW /
COUPLER FUSE.
on, Action Action
for voltage from ACCESSORY POWER tion system upstream of HIGH FLOW
DISTRIBUTION pin E11 and ground. / COUPLER FUSE.
Disconnect connector X-408 (EH) For each resistance check, 0 Ω in 0 Ω in multiple positions or infinite
X-407 (Mech). one position, infinite resistance in all resistance in all positions.
Check others. Action
Using a multi-meter, check for resis- Action The 2ND AUX HYD SWITCH has failed.
tance between LEFT HAND CONTROL Go to test 4 Replace the LEFT HAND CONTROL
HANDLE HANDLE.
pins 1 and 2
pins 1 and 3
while cycling the 2ND AUX HYD
SWITCH S-033.
Check See the following for further testing wire 558/744 (Orange) or adjacent
wire condition between ACCESSORY • Control valve - Testing wiring.
POWER DISTRIBUTION pin E12 and 2nd Aux Extend Sole-
connector X-408 pin 1. noid (G.90.C)
(G.90.C)
Switch and Solenoid
(J.80.C)
84423865 25/07/2011
G.90.C / 7
Control valve - Testing High Flow Switch


Remove HIGH FLOW / COUPLER 0Ω Fuse is blown.
FUSE from the ACCESSORY POWER Action Action
DISTRIBUTION. Go to test 2 Replace the fuse with same type and
Check amp rating.
for continuity across HIGH FLOW /
COUPLER FUSE.
on, Action Action
for voltage from ACCESSORY POWER tion system upstream of HIGH FLOW
DISTRIBUTION pin E11 and ground. / COUPLER FUSE.
the HIGH FLOW SWITCH. Reconnect Action move jumper.
all other connectors. Connect a The HIGH FLOW SWITCH has failed. Action
jumper between connector X-303 Replace the switch. Go to test 4
pins B and C.
Check
Check circuit operation.
Check See the following for further testing wire 753/744 (Orange) or adjacent
wire condition between ACCESSORY • Control valve - Testing wiring.
POWER DISTRIBUTION pin E12 and 2nd Aux Hyd Switch
connector X-303 pin B. (G.90.C)
• Hydraulic line - Testing
Std High Flow Solenoid
(H.20.B)
84423865 25/07/2011
G.90.C / 8
Index

Control valve - Overview Auxiliary Override Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Control valve - Overview High Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Control valve - Testing 2nd Aux Extend Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Control valve - Testing 2nd Aux Hyd Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control valve - Testing 2nd Aux Retract Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control valve - Testing High Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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G.90.C / 9
BOOM Lift - 20.B
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
84423865 25/07/2011
H.20.B / 1
Contents
BOOM Lift - 20.B
DIAGNOSTIC
Control valve
Testing Loader Lockout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic
controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro
hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls
Hydraulic line
Testing Std High Flow Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84423865 25/07/2011
H.20.B / 2
HITCH AND WORKING TOOL - BOOM Lift
Control valve - Testing Loader Lockout Switch

L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic
controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238
Electro hydraulic controls

Use ELECTRICAL POWER SYS- No wire problems If wire problems are found,
TEM - Testing General Wire Test- Action repair or replace broken wire 301
ing (A.30.A) to check wire condition Go to test 2 (Orange) / 305 (Yellow) / 311 (Or-
between connector X-306 pin B and ange).
connector X-C23 pin 23.
ing (A.30.A) to check wire condition Go to test 3 (Yellow).
between connector X-306 pin A and
connector X-CN3B pin 26.
ing (A.30.A) to check wire condition Go to test 4 (Yellow).
between connector X-306 pin C and
connector X-CN2B pin 22.
TEM - Testing General Wire Test- Action repair or replace broken wire 924/
ing (A.30.A) to check wire condition Go to test 5 941/942/1090 (Black).
between connector X-306 pin E and
ground.
Use Data bus - General specifica- No resistance problems If resistance problems are found,
tion Instrument Cluster pin infor- Action replace the Instrument Cluster.
mation (A.50.A) to check Instrument The Loader Lockout Switch S-005
Cluster pin 23. has failed. Replace the Loader Lock-
out Switch S-005.
84423865 25/07/2011
H.20.B / 3
HITCH AND WORKING TOOL - BOOM Lift
Hydraulic line - Testing Std High Flow Solenoid

Wiring harness - Electrical schematic frame 25 (A.30.A) (EH)
Wiring harness - Electrical schematic frame 02 (A.30.A) (Mech)
Disconnect connector X-HFLO from Normal resistance. 0 Ω, or greater than 1 K Ω
the HIGH FLOW SOLENOID Action Action
Check Go to test 2 The HIGH FLOW SOLENOID has failed.
for resistance between HIGH FLOW Replace the solenoid.
SOLENOID pins 1 and 2.
Check 984 (Black).
X-HFLO pin 1 and ground.
ing (A.30.A) to See Control valve - Testing High Repair or replace broken wire 750
Check Flow Switch (G.90.C) for further (White).
wire condition between X-HFLO pin testing.
2 and connector X-303 pin C.
84423865 25/07/2011
H.20.B / 4
Index
BOOM Lift - 20.B

Control valve - Testing Loader Lockout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls,
L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls,
C232 Electro hydraulic controls, C238 Electro hydraulic controls
Hydraulic line - Testing Std High Flow Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84423865 25/07/2011
H.20.B / 5
84423865 25/07/2011
H.20.B / 6
ARM TOOL ATTACHMENT Tilt - 30.C
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
84423865 25/07/2011
H.30.C / 1
Contents
SERVICE
Relief valve
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84423865 25/07/2011
H.30.C / 2
HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt
Relief valve - Pressure test

PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A)
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. By connecting directly to the control valve,
you avoid the possibility of a bad reading because of
cylinder movement.
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 indica-
tions are correct.
11. Compare the indication with the specification Pump
- General specification (C.20.F). If 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.
84423865 25/07/2011
H.30.C / 3
HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt
Relief valve - Flow test

Prior operation:
Relief valve - Flow test (A.10.A) Relief valve - Flow test (A.10.A) .
1. Start the engine and run the engine at 2300 r/min

(rpm).
2. Hold the bucket control lever in the ROLLBACK po-
sition and close the pressure valve on the flowmeter
until the pressure gauge indicates 124 bar (1800 psi).
Adjust the engine speed to keep the engine running
at 2300 r/min (rpm). Read the flow gauge and record
the reading as test number 7.
3. Hold the bucket control lever in the DUMP position
and adjust the pressure valve on the flowmeter un-
til the pressure gauge indicates 124 bar (1800 psi).
Adjust the engine speed to keep the engine running
at 2300 r/min (rpm). Read the flow gauge and record
the reading as test number 8.
NOTE: Understanding the results of the tests are outlined
in the steps below.
4. Refer to Hydraulic pump - Flow test (A.10.A) Hy-
draulic pump - Flow test (A.10.A) If the flow indica-
tion for a circuit was approximately the same as the
flow indication at the same pressure in Test Number 1
of the Hydraulic Pump Flow Test , the circuit is good.
5. If the flow indication for a circuit was more than 3.8
L/min (one gpm) less than the flow indication at
the same pressure in Hydraulic pump - Flow test
(A.10.A) Test Number 1, there is leakage in that
circuit.
6. Leakage in the tilt circuits can be caused by any of
the following problems:
A. Damaged or worn packing in one or both of the tilt
cylinders.
B. Damaged or worn spool or spool bore in the loader
control valve.
C. Self-leveling valve (if equipped) is sticking or has
worn spools.
D. Defective circuit relief valves.
E. Inadequate control spool travel.
7. If the flow indication for every circuit tested was more
than 3.8 L/min (one gpm) less than the flow indica-
tion at the same pressure in test number. 1, there
is leakage at a point common to the entire system.
A probable cause is a damaged or worn main relief
valve or seals.
84423865 25/07/2011
H.30.C / 4
Index

Relief valve - Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Relief valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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84423865 25/07/2011
H.30.C / 6
SINGLE ARM Lift - 40.B
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
84423865 25/07/2011
H.40.B / 1
Contents
TECHNICAL DATA
Accumulator
FUNCTIONAL DATA
Control valve
Overview loader lock control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE
SINGLE ARM Lift

Remove single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
C227
Install single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

C227
Remove single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

L218, L220, L223, L225, L230, C232, C238
Install single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

L218, L220, L223, L225, L230, C232, C238
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control valve
Remove loader valve extend solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install Loader Valve Extend Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remove loader valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install loader valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remove bucket valve extend solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install Bucket Valve Extend Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
L230, C227
Remove bucket valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

L230, C227
Install bucket valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

L230, C227
Remove proportional auxiliary valve extend solenoid on EH machines . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

L230, C227
Install proportional auxiliary valve extend solenoid (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

L230, C227
Remove proportional auxiliary valve retract solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Install proportional auxiliary valve retract solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
84423865 25/07/2011
H.40.B / 2
Remove loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
C227 Mechanical hydraulic controls, C232 Mechanical hydraulic controls, C238 Mechanical hydraulic controls
Install loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

C227, C232, C238
Remove loader control valve (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

L213, L215
Install loader control valve (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

L213, L215
Remove proportional auxiliary valve retract solenoid on EH machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro
hydraulic controls
Install proportional auxiliary valve extend solenoid (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

hydraulic controls
Remove Proportional aux valve extend solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220
Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical
hydraulic controls
Install proportional auxiliary valve extend solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220
Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical
hydraulic controls
Remove Boom position/Bucket position/ Auxiliary position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

hydraulic controls
Install Boom position/Bucket position/ Auxiliary position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

hydraulic controls
Remove Loader port lock solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Install Loader port lock solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Ride control valve
Install Glide Ride valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Remove Glide Ride valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Relief valve
Pressure test Loader Valve Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Cylinder
Remove lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
L213, L215, C227
Install lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

L230, C227
Remove lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

L218, L220, L223, L225, L230, C232, C238
Install lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

L218, L220, L223, L225, L230, C232, C238
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Accumulator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
84423865 25/07/2011
H.40.B / 3
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
DIAGNOSTIC
SINGLE ARM Lift

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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H.40.B / 4
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 767 Anti-seize Cylinder - Install lift arm cylinder H.40.B / 69
Loctite® 767 Anti-seize Cylinder - Install lift arm cylinder H.40.B / 74
Loctite® 242 Cylinder - Assemble H.40.B / 78
Loctite® 242 Cylinder - Assemble H.40.B / 78
84423865 25/07/2011
H.40.B / 5
HITCH AND WORKING TOOL - SINGLE ARM Lift
Accumulator - General specification

Manufacturer Parker
Fluid Capacity 750 ml (25.4 US fl oz)
Charge with dry nitrogen 2070 kPa (300.2 psi)
Max operating pressure 27580 kPa (4000.1 psi)
Port Internal straight thread 3/4-16 UNF - 2B
84423865 25/07/2011
H.40.B / 6
Control valve - Overview loader lock control valve

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.
Operator to place bucket and loader in the appropriate position. Operator then switches the loader lock to 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.
84423865 25/07/2011
H.40.B / 7
SINGLE ARM Lift - Remove single lift arm

C227
WARNING
Heavy objects!
W0398A
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
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
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
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
NOTICE: Before removing components from the hydraulic system, depressurize the system you are working on. See
reference PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A).
1. If applicable, disconnect case drain hose (1).
93107451A 1
84423865 25/07/2011
H.40.B / 8
2. Label and disconnect auxiliary hydraulic hoses and

cap open ports
931002065 2
3. Label and disconnect bucket cylinder hoses and cap

open ports.
931002066 3
4. Disconnect electrical connections (1).
931001737 4
5. Raise and support the lift arm (1) using appropriate

straps.
931001620A 5
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H.40.B / 9
6. Remove rod end snap rings (1).
931001618 6
7. Remove rod end pins and washers (1).

NOTE: Right hand side has lock out
931001616 7
8. Lower cylinders (1) down
931001625 8
9. lower the lift arm and reposition the lifting device and
straps.
931002067A 9
NOTICE: If equipped with an electrical harness, remove harness now.
84423865 25/07/2011
H.40.B / 10
10. Remove left hand side and right hand lift arm retain-
ing bolts (1).
931001622 10
11. Remove left hand side and right hand side lift arm
pins (1).
931002068 11
12. Remove lift arm.
931001624A 12
Next operation:
SINGLE ARM Lift - Install single lift arm (H.40.B)
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H.40.B / 11
SINGLE ARM Lift - Install single lift arm

C227
WARNING
Heavy objects!
W0398A
Prior operation:
SINGLE ARM Lift - Remove single lift arm (H.40.B)
1. Using appropriate lifting device and straps raise lift

arm into proper location on the unit.
931001624A 1
2. Install left hand side and right hand side lift arm pins
(1).
931002068 2
3. Install left hand side and right hand side lift arm re-
taining bolts (1).
931001622 3
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H.40.B / 12
4. Reposition lifting device and straps and raise lift arm

(1).
931001620A 4
5. Raise cylinders (1) up.
931001625 5
6. Insert cylinders into arm and secure with rod end pins
and washers (1).
NOTE: Right hand side has lock out.
931001616 6
7. Install rod end snap rings (1).
931001618 7
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8. Connect bucket cylinder hoses.
931002066 8
9. Connect auxiliary hydraulic hoses (1).
931002065 9
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H.40.B / 14
SINGLE ARM Lift - Remove single lift arm

L218, L220, L223, L225, L230, C232, C238
WARNING
Heavy objects!
W0398A
WARNING
Burn hazard!
W0241A
WARNING
W0358A
WARNING
Pressurized system!
W0905A
WARNING
4. Shut off engine.
W0047A
reference PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A)
1. If applicable, disconnect the case drain hose (1).
93107451A 1
84423865 25/07/2011
H.40.B / 15
2. Label and disconnect auxiliary hydraulic hoses (1)

and cap open ports.
931002065 2
3. Label and disconnect bucket cylinder hoses and cap

open ports.
931002066 3
4. Label and disconnect quick detach hoses and cap

open ports.
931001736 4
5. Unplug electrical connection (1).
931001737 5
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H.40.B / 16
6. Support the lift arm (1) using the appropriate straps

and hoist.
80112878 6
7. Remove lift cylinder rod end snap rings (1).
931001618 7

931001616 8
9. Lower cylinders (1) down.
931001625 9
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10. Lower lift arm and reposition lifting device and straps.
931002067A 10
retaining bolts (1).
931001622 11
pins (1).
931002068 12
13. Remove lift arm.
931001624A 13
Next operation:
SINGLE ARM Lift - Install single lift arm (H.40.B)
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H.40.B / 18
SINGLE ARM Lift - Install single lift arm

L218, L220, L223, L225, L230, C232, C238
WARNING
Heavy objects!
W0398A
Prior operation:
SINGLE ARM Lift - Remove single lift arm (H.40.B)
1. Using appropriate lifting device and straps raise lift

arm (1) into mounting location.
80112878 1
2. Install left hand side and right hand side lift arm pins
(1).
931002068 2
3. Install left hand side and right hand side lift arm re-
taining bolts (1).
931001622 3
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H.40.B / 19
4. Reposition lifting device and straps and raise lift arm

(1).
931001620A 4
5. Raise cylinders (1) up.
931001625 5
6. Insert cylinders into arm and secure with rod end pins
and washers (1).
931001616 6
931001618 7
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H.40.B / 20
8. Connect electrical connections (1).
931001737 8
9. Connect quick connect hoses.
931001736 9
10. Connect bucket cylinder hoses.
931002066 10
11. Connect auxiliary hydraulic hoses (1).
931002065 11
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H.40.B / 21
SINGLE ARM Lift - Pressure test

1. If the hydraulic oil is not at operating temperature run
the engine at full throttle and hold the bucket con-
trol lever in the ROLLBACK position for 30 seconds.
Then return the bucket control lever to NEUTRAL for
15 seconds. Repeat this cycle until the temperature
of the oil is at least 52°C (125°F).
2. Disconnect the hydraulic lines from the implement
controller where they connect to the loader control
valve.
3. Connect a 4,137 kPa (41 bar) (600 psi) pressure
gauges to pilot line at spool ends.
4. Start the engine and run at high idle. Read the pres-
sure gauge and record the EH Pressure reading at
high idle. Pressure should be 0 bar (0.0 psi) with
lever in neutral.
5. Move the implement controller lever (1) to raise the
loader control arms. Read the pressure gauge and
record the EH pressure reading.
6. Move the implement controller lever (1) to lower the
loader control arms. Read the pressure gauge and
record the EH pressure reading.
7. Move the implement controller lever (1) to tilt the
loader bucket. Read the pressure gauge and record
the EH pressure reading.
8. Move the implement controller lever (1) to dump the
loader bucket. Read the pressure gauge and record
the EH pressure reading.
9. The pressure readings should vary from 0 kPa (0 bar)
(0 psi) to 2482 kPa (24.8 bar) (360 psi) at high idle
for a given angle on the implement control handle.
10. 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 loader control valve.
84423865 25/07/2011
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Control valve - Remove loader valve extend solenoid

Prior operation:
1. Locate loader valve extend solenoid Y-009 (1) on

the loader valve block (2) on the right hand side of
machine.
931001711 1
2. Disconnect connector X-28 (1) from the loader valve

extend solenoid Y-009 (2).
931001711 2
3. Remove the two bolts securing the loader valve ex-

tend solenoid Y-009 (2) on the loader valve block.
Next operation:
Control valve - Install Loader Valve Extend Solenoid (H.40.B)
84423865 25/07/2011
H.40.B / 23
Control valve - Install Loader Valve Extend Solenoid

Prior operation:
Control valve - Remove loader valve extend solenoid (H.40.B)
1. Insert loader valve extend solenoid Y-009 into the

loader valve block.
2. Insert the two retaining screws into loader valve ex-
tend solenoid Y-009. Tighten to 5 N·m (3.7 lb ft).
3. Reconnect connector X-28 to the loader valve extend
solenoid Y-009.
Next operation:
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Control valve - Remove loader valve retract solenoid

Prior operation:
1. Locate loader valve retract solenoid Y-007 (1) next to

the loader valve extend solenoid Y-009 (2). These
are located on the loader valve block (3) on right
hand side of machine.
931001711 1
2. Disconnect connector X-27 (1) from the loader valve

retract solenoid Y-007 (2). Loader valve retract sole-
noid Y-007 is next to the loader valve extend solenoid
Y-009 (3).
931001711 2
3. Remove the two bolts securing the loader valve re-

tract solenoid Y-007 on the loader valve block.
Next operation:
Control valve - Install loader valve retract solenoid (H.40.B)
84423865 25/07/2011
H.40.B / 25
Control valve - Install loader valve retract solenoid

Prior operation:
Control valve - Remove loader valve retract solenoid (H.40.B)
1. Insert loader valve retract solenoid Y-007 into the

loader valve block.
2. Insert the two retaining screws into loader valve re-
tract solenoid Y-007. Tighten to 5 N·m (3.7 lb ft).
3. Reconnect connector X-27 to the loader valve retract
solenoid Y-007.
Next operation:
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H.40.B / 26
Control valve - Remove bucket valve extend solenoid

Prior operation:
1. Locate bucket valve extend solenoid Y-006 (1) on

machine.
931001711 1
2. Disconnect connector X-26 (1) from the bucket valve

extend solenoid Y-006 (2).
931001711 2
3. Remove the two bolts securing the bucket valve ex-

tend solenoid Y-006 on the loader valve block.
Next operation:
Control valve - Install Bucket Valve Extend Solenoid (H.20.B)
84423865 25/07/2011
H.40.B / 27
Control valve - Install Bucket Valve Extend Solenoid

L230, C227
Prior operation:
Control valve - Remove bucket valve extend solenoid (H.40.B)
1. Insert bucket valve extend solenoid Y-006 into the

loader valve block.
2. Insert the two retaining screws into bucket valve ex-
tend solenoid Y-006. Tighten to 5 N·m (3.7 lb ft).
3. Reconnect connector X-26 to the bucket valve ex-
tend solenoid Y-006.
Next operation:
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H.40.B / 28
Control valve - Remove bucket valve retract solenoid

L230, C227
Prior operation:
1. Raise the boom (1) and tilt cab forward (2).
931002289 1
2. Locate bucket valve retract solenoid Y-003 (1) on

machine.
931001711 2
3. Disconnect connector X-25 (1) from the bucket valve

retract solenoid Y-003 (2).
931001711 3
4. Remove the two bolts securing the bucket valve re-

tract solenoid Y-003 on the loader valve block.
Next operation:
Control valve - Install bucket valve retract solenoid (H.20.B)
84423865 25/07/2011
H.40.B / 29
Control valve - Install bucket valve retract solenoid

L230, C227
Prior operation:
Control valve - Remove bucket valve retract solenoid (H.20.B)
1. Insert bucket valve retract solenoid Y-003 into the

loader valve block.
2. Insert the two retaining screws into bucket valve re-
tract solenoid Y-003. Tighten to 5 N·m (3.7 lb ft).
3. Reconnect connector X-25 to the bucket valve retract
solenoid Y-003.
Next operation:
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H.40.B / 30
Control valve - Remove proportional auxiliary valve extend solenoid

on EH machines
L230, C227
Prior operation:
1. Raise the boom (1) and tilt cab forward (2).
931002289 1
2. Locate proportional auxiliary valve extend solenoid

(1) on the loader valve block (2) next to the propor-
tional aux retract solenoid (3) on the right hand side
of machine.
931001711 2
3. Disconnect connector (1) from the proportional aux-

iliary valve extend solenoid (2).
931001711 3
4. Remove the two bolts securing the proportional aux-

iliary valve extend solenoid on the loader valve block.
Next operation:
Control valve - Install proportional auxiliary valve extend solenoid (EH) (H.20.B)
84423865 25/07/2011
H.40.B / 31
Control valve - Install proportional auxiliary valve extend solenoid

(EH)
L230, C227
Prior operation:
Control valve - Remove proportional auxiliary valve extend solenoid on EH machines (H.20.B)
1. Insert proportional auxiliary valve extend solenoid

into the loader valve block .
931001711 1
2. Insert the two retaining screws into proportional aux-

iliary valve extend solenoid. Tighten to 5 N·m (3.7 lb
ft).
931001711 2
3. Reconnect connector (1) to the proportional auxiliary

valve extend solenoid.
20111502 3
Next operation:
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H.40.B / 32
Control valve - Remove proportional auxiliary valve retract solenoid

(Mechanical)
Prior operation:
1. Locate proportional auxiliary valve retract solenoid

(1) on the loader valve block (2).
931002092B 1
84423865 25/07/2011
H.40.B / 33

iliary valve retract solenoid (2).
931002095 2

iliary valve retract solenoid on the loader valve block.
Next operation:
Control valve - Install proportional auxiliary valve retract solenoid (Mechanical) (H.40.B)
84423865 25/07/2011
H.40.B / 34
Control valve - Install proportional auxiliary valve retract solenoid

(Mechanical)
1. Insert the proportional auxiliary valve retract solenoid
(1).
931002095 1
2. Connect connector (1) to the proportional auxiliary

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

auxiliary valve retract solenoid. Tighten to 5 N·m (3.7
lb ft).
931002095 3
84423865 25/07/2011
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Control valve - Remove loader control valve

WARNING
Burn hazard!
W0241A
WARNING
W0358A
WARNING
Pressurized system!
W0905A
WARNING
4. Shut off engine.
W0047A
Prior operation:
Bucket - Remove (J.20.B).
Prior operation:
1. Remove drain plug (1) and drain hydraulic oil reser-

voir.
931001657 1
84423865 25/07/2011
H.40.B / 36
2. Label and disconnect the rear solenoid connections

(1).
931001708 2
3. Label and disconnect both linkages or six solenoid

connections from valve, depending on your configu-
ration.
931002075 3
931001709 4
4. Label and disconnect the two front solenoid connec-

tions (1).
931001709 5
84423865 25/07/2011
H.40.B / 37
5. Label and disconnect six hydraulic tubes (1) from

control valve and cap open ports.
931001713 6
6. Label and disconnect drain hoses (1) from control

valve.
931001715 7
7. Label and disconnect two hoses (1) and one tube (2)
from top of control valve.
931001710 8
8. Disconnect hydraulic tubes (1) located at bottom of

valve block.
931001714 9
84423865 25/07/2011
H.40.B / 38
9. Disconnect hydraulic hoses (1) from solenoid block.
931001711 10
10. Remove the three valve mounting bolts (1) (one

shown).
931001718 11
11. Remove loader valve.
931001719 12
Next operation:
Control valve - Install loader control valve (H.40.B)
84423865 25/07/2011
H.40.B / 39
Control valve - Install loader control valve

C227, C232, C238
Prior operation:
Control valve - Remove loader control valve (H.40.B)
1. Position loader valve in proper location on skid steer

chassis.
931002096B 1
2. Install the three loader valve mounting bolts (1) (one

shown) securing the valve to the chassis.
931002096B 2
84423865 25/07/2011
H.40.B / 40
3. Connect electrical connections (1), (2), and (3).

NOTE: The electrical connection in picture 931002094a is
located on the top right hand side of chain case
931002094 B 3
931002095B 4
4. Connect control linkage (1) and (2).
931002093B 5
5. Connect hydraulic tube (1) and hydraulic hose (2) to

solenoid block.
931002092B 6
84423865 25/07/2011
H.40.B / 41
6. Install hydraulic tube (1) located at the bottom of

valve block.
931002091C 7
7. Connect hoses (1) and (2) and tube (3) to the top of
control valve.
931002090A 8
8. Connect the two drain hoses (1) to control valve.
931002089A 9
84423865 25/07/2011
H.40.B / 42
9. Connect the six hydraulic tubes to control valve in the

correct ports, as shown.
931002088A 10
10. Install hydraulic oil reservoir drain plug (1) and fill to
the correct level.
931001657 11
Next operation:
Tilt system - Lower (E.34.A).
Next operation:
Bucket - Install (J.20.B).
84423865 25/07/2011
H.40.B / 43
Control valve - Remove loader control valve (EH)

L213, L215
WARNING
Burn hazard!
W0241A
WARNING
W0358A
WARNING
Pressurized system!
W0905A
WARNING
4. Shut off engine.
W0047A
Prior operation:
Prior operation:
1. Apply vacuum to hydraulic reservoir. Use CAS10192

and CAS1871.
2. Label and disconnect the four rear solenoid connec-
tions (1).
931001708 1
84423865 25/07/2011
H.40.B / 44
3. Label and disconnect the six front solenoid connec-

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

control 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
84423865 25/07/2011
H.40.B / 45
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
Next operation:
Control valve - Install loader control valve (EH) (H.40.B)
84423865 25/07/2011
H.40.B / 46
Control valve - Install loader control valve (EH)

L213, L215
Prior operation:
Control valve - Remove loader control valve (EH) (H.40.B)
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
84423865 25/07/2011
H.40.B / 47
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
84423865 25/07/2011
H.40.B / 48
8. Connect the six front solenoid connections (1).
931001709 8
9. Connect rear solenoid connections (1).
931001708 9
Next operation:
Tilt system - Lower (E.34.A).
Next operation:
84423865 25/07/2011
H.40.B / 49
Control valve - Remove proportional auxiliary valve retract solenoid

on EH machines
controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls
Prior operation:
1. Locate proportional auxiliary valve retract solenoid

(3) on the loader valve block (2) next to the propor-
tional aux extend solenoid (1) on the right hand side
of machine.
931001711 1

iliary valve retract solenoid (2).
931001711 2

84423865 25/07/2011
H.40.B / 50

(EH)
1. Insert proportional auxiliary valve retract solenoid (1)

into the loader valve block .
931001711 1

auxiliary valve retract solenoid. Tighten to 5 N·m (3.7
lb ft).
931001711 2
3. Reconnect connector (1) to the proportional auxiliary

valve retract solenoid.
20111502 3
84423865 25/07/2011
H.40.B / 51
Control valve - Remove Proportional aux valve extend solenoid

(Mechanical)
L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223
Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls
Prior operation:
1. Locate proportional auxiliary valve extend solenoid

(1) on the loader valve block (2).
931002092B 1
84423865 25/07/2011
H.40.B / 52

iliary valve extend solenoid (2).
931002095 2

84423865 25/07/2011
H.40.B / 53

(Mechanical)
L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223
Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls
1. Insert the proportional auxiliary valve extend sole-

noid (1).
931002095 1
2. Connect connector (1) to the proportional auxiliary

valve extend solenoid (2).
931002095 2

auxiliary valve extend solenoid. Tighten to 5 N·m (3.7
lb ft).
931002095 3
84423865 25/07/2011
H.40.B / 54
Control valve - Remove Boom position/Bucket position/ Auxiliary

position
1. Locate the control valve (1) on the right hand side of

the machine.
20111502 1
2. Locate the different position sensors. The boom po-

sition sensor (1), bucket position sensor (2), and aux-
iliary sensor (3) are located here.
20111502 2
3. Remove the nut holding the sensor. Pull sensor off.
84423865 25/07/2011
H.40.B / 55
Control valve - Install Boom position/Bucket position/ Auxiliary

position
1. Insert the sensor onto the loader control valve. The

boom position sensor (1), bucket position sensor (2),
and auxiliary sensor (3) are located here.
20111502 1
2. Thread nut (1) onto sensor. Tighten to proper torque.
20111502 2
84423865 25/07/2011
H.40.B / 56
Control valve - Remove Loader port lock solenoid

1. Locate the loader control valve (1) on the right hand
side of the machine.
931002090 1
2. Disconnect the electrical connector (1) from the so-

lenoid.
931002090 2
3. Remove the nut from the solenoid (1).
931002090 3
4. Remove the solenoid.
84423865 25/07/2011
H.40.B / 57
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
84423865 25/07/2011
H.40.B / 58
Ride control valve - Install Glide Ride valve

Prior operation:
Ride control valve - Remove Glide Ride valve (H.40.B)
1. Locate valve (1) position on body.
931001804 1
931001698 2
3. Connect upper tubes (1).
931001698 3
4. Connect the lower hydraulic tube (1).
931001693 4
84423865 25/07/2011
H.40.B / 59
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. See Tilt sys-
tem - Lower (E.34.A)
84423865 25/07/2011
H.40.B / 60
Ride control valve - Remove Glide Ride valve

WARNING
Burn hazard!
W0241A
WARNING
W0358A
WARNING
Pressurized system!
W0905A
WARNING
4. Shut off engine.
W0047A
Prior operation:
1. Locate ride control valve (1) on the skid steer chas-

sis.
931001804 1
84423865 25/07/2011
H.40.B / 61
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
84423865 25/07/2011
H.40.B / 62
931001698 6
7. Remove valve.
931001700 7
Next operation:
Ride control valve - Install Glide Ride valve (H.40.B)
84423865 25/07/2011
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Relief valve - Pressure test Loader Valve Relief Valve

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. By connecting directly to the control valve,
you avoid the possibility of a bad reading because of
cylinder movement.
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 indica-
tions are correct.
11. Compare the indication with the specification Pump
- General specification (C.20.F). If 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.
84423865 25/07/2011
H.40.B / 64
Relief valve - Flow test

Prior operation:
Relief valve - Flow test (A.10.A) Relief valve - Flow test (A.10.A)
1. Start the engine and run the engine at 2300 r/min

(rpm).
2. Hold the lift control lever in the LIFT position and
adjust the pressure valve on the flowmeter until the
pressure gauge indicates 124 bar (1800 psi). Adjust
the engine speed to keep the engine running at 2300
r/min (rpm). Read the flow gauge and record the
reading as test number 9.
3. Hold the lift control lever in the LOWER position and
adjust the pressure valve on the flowmeter until the
pressure gauge indicates 124 bar (1800 psi). Adjust
the engine speed to keep the engine running at 2300
r/min (rpm). Read the flow gauge and record the
reading as test number 10.
NOTE: Understanding the results of the tests are outlined
in the steps below.
4. Refer to Hydraulic pump - Flow test (A.10.A) Hy-
draulic pump - Flow test (A.10.A) If the flow indica-
tion for a circuit was approximately the same as the
flow indication at the same pressure in Test Number 1
of the Hydraulic Pump Flow Test , the circuit is good.
5. If the flow indication for a circuit was more than 3.8
L/min (one gpm) less than the flow indication at
the same pressure in Hydraulic pump - Flow test
(A.10.A) Test Number 1, there is leakage in that
circuit.
6. Leakage in the lift circuits can be caused by any of
the following problems:
A. Damaged or worn packing in one or both of the lift
cylinders.
B. Damaged or worn spool or spool bore in the loader
control valve.
C. Defective circuit relief valves.
D. Inadequate control spool travel.
7. If the flow indication for every circuit tested was more
than 3.8 L/min (one gpm) less than the flow indica-
tion at the same pressure in test number. 1, there
is leakage at a point common to the entire system.
A probable cause is a damaged or worn main relief
valve or seals.
84423865 25/07/2011
H.40.B / 65
Cylinder - Remove lift arm cylinder

L213, L215, C227
WARNING
Heavy objects!
W0398A
WARNING
Burn hazard!
W0241A
WARNING
W0358A
WARNING
Pressurized system!
W0905A
WARNING
4. Shut off engine.
W0047A
Prior operation:
84423865 25/07/2011
H.40.B / 66
1. Label and disconnect cylinder hoses (1) and cap

open ports
931001628 1
2. Remove lift cylinder rod end snap rings (1) from

boom arm.
931001621 2
931001616 3
931001625 4
84423865 25/07/2011
H.40.B / 67
5. Remove lock nut (1) and pin retaining bolt (2) on both
sides of the lift arm.
931001629 5
6. Remove rod end pins and washers from both sides

of the lift arm.
931001630 6
7. Remove cylinders
931001632 7
Next operation:
Cylinder - Install lift arm cylinder (H.20.B)
84423865 25/07/2011
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Cylinder - Install lift arm cylinder

L230, C227
WARNING
Heavy objects!
W0398A
Prior operation:
Cylinder - Remove lift arm cylinder (H.40.B)
1. Lubricate the rod end pins, (1), with LOCTITE® 767

ANTI-SEIZE 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
84423865 25/07/2011
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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. Tilt system - Tilt cab, secure the
lift arm in the raised position. (E.34.A)
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
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Cylinder - Remove lift arm cylinder

L218, L220, L223, L225, L230, C232, C238
WARNING
Heavy objects!
W0398A
WARNING
Burn hazard!
W0241A
WARNING
W0358A
WARNING
Pressurized system!
W0905A
WARNING
4. Shut off engine.
W0047A
1. Label and disconnect cylinder hoses (1) and cap

open ports
93112872 1
84423865 25/07/2011
H.40.B / 71
2. Remove lift cylinder rod end pin (2) and retaining bolt
(1) and nut (3) from boom arm.
93112873 2
931001616 3
93112875 4
5. Remove lock nut (1) and pin retaining bolt (2) on

frame.
93112874 5
84423865 25/07/2011
H.40.B / 72
6. Remove rod end pins and washers from both sides

of the frame.
931001630 6
7. Remove cylinders
931001632 7
Next operation:
Cylinder - Install lift arm cylinder (H.40.B)
84423865 25/07/2011
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Cylinder - Install lift arm cylinder

L218, L220, L223, L225, L230, C232, C238
WARNING
Heavy objects!
W0398A
Prior operation:
Cylinder - Remove lift arm cylinder (H.40.B)
1. Lubricate the rod end pins, (1), with LOCTITE® 767

ANTI-SEIZE 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
84423865 25/07/2011
H.40.B / 74
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
84423865 25/07/2011
H.40.B / 75
Cylinder - Disassemble
Prior operation:
Cylinder - Remove (H.40.B)
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 equip-
ment 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 dam-
age 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
(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
84423865 25/07/2011
H.40.B / 76
Cylinder - Assemble
Prior operation:
Cylinder - Disassemble (H.40.B)
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 cylin-
der bore with hydraulic oil.
2. Lubricate a new seal (8) with clean hydraulic oil. In-
sert 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.
5. Lubricate a new O-ring (9) with clean hydraulic oil.
Insert 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.
84423865 25/07/2011
H.40.B / 77
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 ham-
mer 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).
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.
84423865 25/07/2011
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Accumulator - Remove
WARNING
4. Shut off engine.
W0047A
WARNING
Pressurized system!
DO NOT attempt to disassemble any accumulator until the nitrogen charge is properly discharged.
W0974A
Prior operation:
Accumulator - Discharging (H.40.B)
bs04d011 1
Ride Control Accumulator

(1) - Hose connection (3) - Clamps (5) - Ride control valve
(2) - Accumulator (4) - Electrical harness
84423865 25/07/2011
H.40.B / 79
1. Remove the cap CAS1871 from the hydraulic reser-

voir.
2. Connect a vacuum pump CAS10192 to the hydraulic
reservoir.
3. Start the vacuum pump. Refer to Reservoir - Apply
vacuum (A.10.A)
4. Loosen and remove the hydraulic hose connection
(1) from the accumulator (2). Install a plug in the hose
and a cap on the fitting.
5. Stop the vacuum pump.
6. Loosen and remove the two clamps (3) which mount
the accumulator (2) to the chassis. Remove the ac-
cumulator from the chassis.
bs04d012 2
Ride Control Component Location
(1) - Ride control accumulator (2) - Ride control valve
Next operation:
Accumulator - Disassemble (H.40.B) or Accumulator - Install (H.40.B)
84423865 25/07/2011
H.40.B / 80
Accumulator - Install
Prior operation:
Accumulator - Remove (H.40.B)
1. Install the accumulator (2) into the chassis mounting

location.
2. Install the clamps (3) around the accumulator (2) and
tighten the clamps (3).
3. Start the vacuum pump.
4. Remove the plug from the hose and the cap from the
fitting.
5. Install the hydraulic hose connection (1) onto the ac-
cumulator (2). Tighten the hydraulic hose connection
(1).
6. Stop the vacuum pump. Remove vacuum pump from
reservoir.
bs04d011 1
Ride Control Accumulator

(1) - Hose connection (3) - Clamps (5) - Ride control valve
(2) - Accumulator (4) - Electrical harness
7. Stop the vacuum pump.
8. Remove the vacuum pump from the hydraulic reser-
voir. Install the filler cap on the reservoir.
9. Follow the procedure for Accumulator Charging with
dry nitrogen. Accumulator - Charging (H.40.B)
10. Start and run the engine at low idle for 2 to 5 minutes
and check for any leaks.
84423865 25/07/2011
H.40.B / 81
11. Stop the engine.

12. Check the hydraulic oil level in the reservoir and
add hydraulic oil as required. Reservoir - Filling
(A.10.A)
84423865 25/07/2011
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84423865 25/07/2011
H.40.B / 83
Accumulator - Assemble
BS96H068 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 (H.40.B)
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.
84423865 25/07/2011
H.40.B / 84
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. In-
stall and tighten the gas valve assembly (10)in the
gland (2).
13. Install the cap (11).
14. Charge the accumulator with dry nitrogen. Please
refer to Accumulator - Charging (H.40.B)
15. Install the guard (9) and cap screws (8).
Next operation:
Accumulator - Install (H.40.B)
84423865 25/07/2011
H.40.B / 85
Accumulator - Disassemble
Prior operation:
Accumulator - Remove (H.40.B)
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

84423865 25/07/2011
H.40.B / 86
Next operation:
Accumulator - Visual inspection (H.40.B)
84423865 25/07/2011
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Accumulator - Discharging
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).
9. Partially open valve (B) to discharge the accumula-
tor. The accumulator charge will bleed down through
the regulator.
10. Once the accumulator is fully discharged, disconnect
valve (F) from the accumulator stem.
84423865 25/07/2011
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Accumulator - Charging
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.
84423865 25/07/2011
H.40.B / 89
BT09C458 3
Nitrogen Charging Kit
BT09B037-01 4
Accumulator located on the right side of machine behind side skirt.
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
84423865 25/07/2011
H.40.B / 90
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.
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
escaping 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).
After a few minutes open valve (E) and check the
accumulator 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
escaping from the accumulator as the hose is re-
moved.
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 accumu-
lator pressure valve.
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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.
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Accumulator - Visual inspection
BS96H067 1

Prior operation:
Accumulator - Disassemble (H.40.B)
1. Clean all parts in cleaning solvent.

2. Illuminate the inside of the tube (1). Inspect the in-
side of the tube for deep grooves or other damage.
If the tube is damaged, replace with a new tube or
cylinder.
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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 corro-
sion. 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 (H.40.B)
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Accumulator - Pressure test
BS04D004 1
1. Ensure that the oil side of the accumulator is com-

pletely 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 re-
lease 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.
12. Remove the cap from the valve stem on the accumu-
lator.
13. Connect valve (F) to the valve stem.
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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.
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SINGLE ARM Lift - Troubleshooting

Incorrect or No Loader 1. Check to ensure the cab door is fully A. Is there still a problem?
Function closed. No: Troubleshooting complete.
Yes: Go to Step 2.
2. Check the cab door switch (If equipped A. Check power to and from the cab door
with cab door). switch.
B. Is there still a problem?
No: Troubleshooting complete.
Yes: Go to Step 3.
3. Check the Implement Controller inter- A. Check power to and from the Implement
lock valve power/function. Controller interlock valve. Repair as re-
quired.
B. Check the Implement Controller inter-
lock valve function. Repair or replace as
required.
C. Is there still a problem?
Yes: Go to Step 4.
4. Check the charge pressure. A. Do - Checking the Charge Pressure/
Flow.
Refer to Charge pump - Pressure test
(A.10.A) for the procedure.
B. Charge pressure OK? Stroke the control
lever. A 20 psi or greater drop indicates a
leaky servo. Repair as required.
Yes: Go to Step 5.
5. Check the pilot pressure from the Im- Go to step 6.
plement Controller to the Loader Control
Valve.
6. Do Check 1 - Checking the Pilot Pres- A. Is there still a problem?
sure. No: Troubleshooting complete.
Refer to SINGLE ARM Lift - Pressure test Yes: Go to Step 8.
(H.40.B)
8. Check the loader control valve function. A. Is there still a problem?
Yes: Go to Step 9.
9. Repair or replace the loader control
valve.
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Index

Accumulator - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Accumulator - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Accumulator - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Accumulator - Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Accumulator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accumulator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Accumulator - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Accumulator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Accumulator - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Control valve - Install Boom position/Bucket position/ Auxiliary position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls
Control valve - Install Bucket Valve Extend Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
L230, C227
Control valve - Install Loader Valve Extend Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Control valve - Install Loader port lock solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Control valve - Install bucket valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
L230, C227
Control valve - Install loader control valve (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
L213, L215
Control valve - Install loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
C227, C232, C238
Control valve - Install loader valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control valve - Install proportional auxiliary valve extend solenoid (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
L230, C227
Control valve - Install proportional auxiliary valve extend solenoid (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Control valve - Install proportional auxiliary valve extend solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical
hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls
Control valve - Install proportional auxiliary valve retract solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Control valve - Overview loader lock control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control valve - Remove Boom position/Bucket position/ Auxiliary position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Control valve - Remove Loader port lock solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Control valve - Remove Proportional aux valve extend solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical
hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls
Control valve - Remove bucket valve extend solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control valve - Remove bucket valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
L230, C227
Control valve - Remove loader control valve (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
L213, L215
Control valve - Remove loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Control valve - Remove loader valve extend solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Control valve - Remove loader valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control valve - Remove proportional auxiliary valve extend solenoid on EH machines . . . . . . . . . . . . . . . . . . . . . . 31
L230, C227
Control valve - Remove proportional auxiliary valve retract solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Control valve - Remove proportional auxiliary valve retract solenoid on EH machines . . . . . . . . . . . . . . . . . . . . . . 50
Cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Cylinder - Install lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
L230, C227
Cylinder - Install lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
L218, L220, L223, L225, L230, C232, C238
Cylinder - Remove lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
L213, L215, C227
Cylinder - Remove lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
L218, L220, L223, L225, L230, C232, C238
Relief valve - Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Relief valve - Pressure test Loader Valve Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Ride control valve - Install Glide Ride valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Ride control valve - Remove Glide Ride valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SINGLE ARM Lift - Install single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
C227
SINGLE ARM Lift - Install single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
L218, L220, L223, L225, L230, C232, C238
SINGLE ARM Lift - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SINGLE ARM Lift - Remove single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
C227
SINGLE ARM Lift - Remove single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
L218, L220, L223, L225, L230, C232, C238
SINGLE ARM Lift - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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SINGLE ARM TOOL ATTACHMENT Tilt - 50.C
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
84423865 25/07/2011
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Contents
DIAGNOSTIC
SINGLE ARM TOOL ATTACHMENT Tilt

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84423865 25/07/2011
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HITCH AND WORKING TOOL - SINGLE ARM TOOL ATTACHMENT Tilt
SINGLE ARM TOOL ATTACHMENT Tilt - Troubleshooting

Incorrect or No Loader 1. Check to ensure the cab door is fully A. Is there still a problem?
Function closed. No: Troubleshooting complete.
Yes: Go to Step 2.
2. Check the cab door switch (If equipped A. Check power to and from the cab door
with cab door). switch.
B. Is there still a problem?
Yes: Go to Step 3.
3. Check the Implement Controller inter- A. Check power to and from the Implement
lock valve power/function. Controller interlock valve. Repair as re-
quired.
B. Check the Implement Controller inter-
lock valve function. Repair or replace as
required.
Yes: Go to Step 4.
4. Check the charge pressure. A. Do - Checking the Charge Pressure/
Flow.
Refer to Charge pump - Pressure test
(A.10.A) for the procedure.
B. Charge pressure OK? Stroke the control
lever. A 20 psi or greater drop indicates a
leaky servo. Repair as required.
Yes: Go to Step 5.
5. Check the pilot pressure from the Im- Go to step 6.
plement Controller to the Loader Control
Valve.
6. Do Check 1 - Checking the Pilot Pres- A. Is there still a problem?
sure. No: Troubleshooting complete.
Refer to SINGLE ARM Lift - Pressure test Yes: Go to Step 7.
(H.40.B)
7. If the pressure readings are correct,
the test is complete. If the pressure read-
ings are not correct, repair or replace the
charge/hydrostatic pump assembly or the
loader control valve.
8. Check the loader control valve function. A. Is there still a problem?
Yes: Go to Step 9.
9. Repair or replace the loader control
valve.
84423865 25/07/2011
H.50.C / 3
Index

SINGLE ARM TOOL ATTACHMENT Tilt - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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DIGGING Non-articulated digging tools - 20.B
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
84423865 25/07/2011
J.20.B / 1
Contents
SERVICE
Bucket
Remove - Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install - Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove - Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install - Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
Bucket - Remove - Mechanical

1. Position loader on flat surface.
93106896 1
2. Pull up on locking handles (1) to disengage pins.
931002056 2
3. Start engine.
931001679 3
4. Tilt face plate (2) down to disengage.
931002057 4
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J.20.B / 3
5. Lower lift arm (3).
931002057 5
6. Reverse skid steer to remove bucket.
931002058 6
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Bucket - Install - Mechanical

1. Start engine.
931001679 1
2. Lower lift arm (1) and tilt faceplate (2) down before
inserting faceplate into saddles.
931002058 2
3. Slowly raise lift arm (1) ensuring face plate is seated

in the saddles (3).
931002057 3
4. Tilt face plate (2) up to engage.
931002057 4
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J.20.B / 5
5. Push down on locking handles (4) to secure bucket.
931002056 5
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Bucket - Remove - Hydraulic

1. Position loader on a flat surface.
9310748611 1
2. Start engine.
931002111 2
3. Unlock the pins (1) then use the electronic controls

(2) to retract quick release cylinders.
931002112 3
931007524 4
84423865 25/07/2011
J.20.B / 7
4. Tilt face plate (3) down to disengage.
931002057 5
5. Lower lift arm (4).
931002057 6
6. Remove bucket.
931002058 7
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Bucket - Install - Hydraulic

1. Start engine.
931002111 1
2. Lower lift arm (1) and tilt faceplate down (2) before
inserting into saddles (3).
931002058 2
3. Slowly raise lift arm (1) ensuring faceplate seats into

saddles.
931002057 3
4. Tilt face plate up to engage.
931002057 4
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J.20.B / 9
5. Use electronic controls (4) on the right hand side joy-

stick to engage quick release cylinders.
931007524 5
6. Lock the pins in place using the lock control (5) on

the left hand side column.
931002112 6
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J.20.B / 10
Index

Bucket - Install - Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bucket - Install - Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bucket - Remove - Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bucket - Remove - Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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CARRYING Unarticulated tools - 50.B
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
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Contents
TECHNICAL DATA
Tool
Bucket - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Tool
Cutting edge - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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EXCAVATING AND LANDSCAPING - CARRYING Unarticulated tools
Tool Bucket - General specification
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)
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Tool Cutting edge - Replace

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 400ºF (204ºC). 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
welding 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 work-
ing 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.
10. Bolt On Cutting Edge Replacement:
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.
13. Dirt Tooth Kit Installation
14. Bucket Dirt Tooth Kit
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15. The dirt tooth kit consists of six teeth that are welded
to the bucket cutting edge as indicated at (1). 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
16. Tooth Point Replacement

17. The points of the teeth are a replaceable "pin-on"
design and can be obtained from Parts.
18. 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.
19. Place the new point over the shank and insert the
retaining pin into the hole, (1). With a punch that
contacts 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
20. Tooth Location and Installation

21. 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.
22. Slide the replaceable points in place but do not at-
tach with the steel/rubber pins as the rubber may be
damaged during the welding process.
SH88034 4
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J.50.B / 5
23. Locate the teeth on the bucket edge as indicated.
bs04e165 5
24. Bucket Tooth Spacing

NOTE: Position the teeth at these spacings, then re-center
if necessary for equal spacing.
bs04f076 6
25. 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 replace-
able 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 7
26. Weld in the direction shown at (1).

27. 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 8
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Index

Tool Bucket - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tool Cutting edge - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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COUPLING Mechanical coupling - 80.B
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
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Contents
FUNCTIONAL DATA
COUPLING Mechanical coupling

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
COUPLING Mechanical coupling

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling
COUPLING Mechanical coupling - Exploded view

Mounting Plate
(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
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bs04e150 1
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COUPLING Mechanical coupling - Remove

1. WARNING
Avoid injury! Always do the following be-
fore lubricating, maintaining, or servicing
the machine.
3. Lower all attachments to the ground, or
raise and engage all safety locks.
4. Shut off engine.
Failure to comply could result in death or
serious injury.
W0047A
Before removing the coupler, remove any attach-

ment from the machine.
2. Tilt the coupler forward until the face of the plate
is resting on the ground. At this point you can re-
lieve the pressure in the system. See PRIMARY
HYDRAULIC POWER SYSTEM - Depressurising
(A.10.A).
3. On the left hand side of the coupler, remove the hard-
ware (1) securing the pin (2) attached to the tilt cylin-
der.
4. Remove the pin (2) from the coupler. This will re-
move 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) se-
curing the coupler to the machine.
7. Repeat step six for the left hand side.
8. Coupler is now unattached from the machine.
20115831 2
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COUPLING Mechanical coupling - Disassemble

Prior operation:
COUPLING Mechanical coupling - Remove (J.80.B)
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
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J.80.B / 6
4. While supporting coupler handle, remove handle

pivot pin (1).
931001788 4
5. Remove handle and locking pin assembly from cou-

pler.
20115824 5
6. To disassemble the locking pin assembly carefully

unthread pin (1), from bolt (2) and check parts for
wear.
20115823 6
Next operation:
COUPLING Mechanical coupling - Assemble (J.80.B)
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COUPLING Mechanical coupling - Assemble

Prior operation:
COUPLING Mechanical coupling - Disassemble (J.80.B)
1. Assemble the handle and locking pin assembly by

inserting pin (1) through hole (2) in the handle. Install
bolt (3) through pin (2). Install bushing spacer (4),
compression 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
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J.80.B / 8
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
Next operation:
COUPLING Mechanical coupling - Install (J.80.B)
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J.80.B / 9
COUPLING Mechanical coupling - Install

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, se-
curing 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.
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Index

COUPLING Mechanical coupling - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COUPLING Mechanical coupling - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COUPLING Mechanical coupling - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COUPLING Mechanical coupling - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
COUPLING Mechanical coupling - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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COUPLING Hydraulic coupling - 80.C
C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230
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Contents
TECHNICAL DATA
Control valve
L218, L220, L223, L225, L230, C227, C232, C238
L218, L220, L223, L225, L230, C227, C232, C238
Cylinder
L218, L220, L223, L225, L230, C227, C232, C238
SERVICE
COUPLING Hydraulic coupling

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSTIC
Electrical control
Testing Hydraulic Coupler Switch and Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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EXCAVATING AND LANDSCAPING - COUPLING Hydraulic coupling
Control valve - General specification

L218, L220, L223, L225, L230, C227, C232, C238
Valve P/O (Pilot operated) double check

Flow 30.3 l/min (8 US gpm)
Body material 2024 Aluminum
Pressure 206.9 bar (3000 psi)
Port size 9/16-18 SAE-6
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Control valve - General specification

L218, L220, L223, L225, L230, C227, C232, C238
Valve Coupler
Solenoid valve configuration 4 way, 2 position direct acting, spool type hydraulic cartridge valve
Hydraulic requirements:
Flow 30.3 l/min (8 US gpm)
System pressure 210 bar (3045.0 psi)
Relief valve pressure 172 bar (2494.0 psi)
Electrical requirements:
Operating voltage 14 V
Operating temperature range -30 - 107 °C (-22.0 - 224.6 °F)
Port size SAE-6
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L218, L220, L223, L225, L230, C227, C232, C238
Cylinder Hydraulic coupler

Supply port size 7/16-20 UNF-2B
Return port size 7/16-20 UNF-2B
Maximum working pressure 206.9 bar (3000 psi)
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COUPLING Hydraulic coupling - Remove

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!
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
Burn hazard!
W0241A
WARNING
4. Shut off engine.
W0047A
concept.
1. Before removing the coupler, remove any attach-
ment from the machine.
2. Tilt the coupler forward until the face of the plate
is resting on the ground. At this point you can re-
lieve the pressure in the system. See PRIMARY
HYDRAULIC POWER SYSTEM - Depressurising
(A.10.A).
84423865 25/07/2011
J.80.C / 6
3. On the right hand side of the coupler, remove the

hardware (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 get-
ting contaminated.
20111349 2
7. Remove the hardware (1) from the pivot pin (2) se-
curing 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
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COUPLING Hydraulic coupling - Install

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, se-
curing 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.
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Cylinder - Remove
WARNING
Burn hazard!
W0241A
WARNING
W0358A
WARNING
Pressurized system!
W0905A
WARNING
4. Shut off engine.
W0047A
Prior operation:
1. Remove snap ring (1).
931001791 1
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J.80.C / 9
2. Remove retaining pin (1).
931001788 2
3. Disconnect hydraulic hoses (1) and (2), from mani-

fold.
931001786 3
4. Remove rod end hydraulic hose (1).
931001789 4
5. Disengage the roll pin and bucket locking pin (1).
931001783 5
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J.80.C / 10
6. Remove cylinder.
931001784 6
Next operation:
Cylinder - Install (J.80.C)
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J.80.C / 11
Cylinder - Install
Prior operation:
Cylinder - Remove (J.80.C)
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
4. Connect the rod end hydraulic hose (1).
931001789 4
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5. WARNING
Unexpected movement!
When cylinders are connected to the
machine hydraulic system, cycle the hy-
draulic 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 unexpectedly.
Failure to comply could result in death or
serious injury.
W1083A
Connect hydraulic hoses (1) and (2), to the manifold.

931001786 5
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Electrical control - Testing Hydraulic Coupler Switch and Solenoid

Wiring harness - Electrical schematic frame 25 (A.30.A) (EH)
Wiring harness - Electrical schematic frame 02 (A.30.A) (Mech)

With the ignition on, 12 V 0V
Check Action Action
for voltage from ACCESSORY POWER Go to test 2 There is a problem in the DC distribu-
DISTRIBUTION pin E12 and ground. tion system upstream of HIGH FLOW
/ COUPLER FUSE.
ing (A.30.A) to check wire condi- Go to test 3 744 (Orange).
tion between ACCESSORY POWER
DISTRIBUTION pin E12 and connector
X-300 pin E.
ing (A.30.A) to check wire condition Go to test 4 940/942/1094 (Black).
between connector X-300 pin F and
ground.
ing (A.30.A) to check wire condition Go to test 5 (White).
between connector X-CPLR pin 1
and connector X-300 pin A.
ing (A.30.A) to check wire condition Go to test 6 1008/1014 (Black).
between connector X-CPLR pin 2
and ground.
Disconnect connector X-CPLR from Normal resistance 0 Ω or greater than 500 Ω,
the HYDRAULIC COUPLER SOLENOID Action Action
Y-013. The HYDRAULIC COUPLER SWITCH The solenoid has failed. Replace the
Check S-009 has failed. Replace the switch solenoid.
Using a multi-meter, check for resis-
tance between HYDRAULIC COUPLER
SOLENOID pins 1 and 2.
84423865 25/07/2011
J.80.C / 14
Index

COUPLING Hydraulic coupling - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COUPLING Hydraulic coupling - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
L218, L220, L223, L225, L230, C227, C232, C238
Control valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
L218, L220, L223, L225, L230, C227, C232, C238
L218, L220, L223, L225, L230, C227, C232, C238
Cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical control - Testing Hydraulic Coupler Switch and Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
84423865 25/07/2011
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SCHEMAS INDEX
IU PAGE
Connector - Component diagram 01 - Connector X-10 to Connector X-13 A.30.A / 49
Connector - Component diagram 14 - Connector X-502A to Connector X-510 A.30.A / 104
Connector - Component diagram 15 - Connector X-512 to Connector X-52A A.30.A / 107
Connector - Component diagram 16 - Connector X-52B to Connector X-74 A.30.A / 109
Connector - Component diagram 18 - Connector X-93 to Connector X-AC_COMP A.30.A / 116
Connector - Component diagram 19 - Connector X-ACC to Connector X-C01A A.30.A / 119
Connector - Component diagram 20 - Connector X-C01B to Connector X-CAB_GNDB A.30.A / 123
Connector - Component diagram 21 - Connector X-CC1A to Connector X-CHS_GND_RR A.30.A / 128
Connector - Component diagram 22 - Connector X-CN1A to Connector X-CN4A A.30.A / 134
Connector - Component diagram 23 - Connector X-CN4B to Connector X-ECC2A A.30.A / 141
Connector - Component diagram 24 - Connector X-ECC2B to Connector X-ECC6B A.30.A / 146
Connector - Component diagram 25 - Connector X-EGR to Connector X-FUEL A.30.A / 152
Connector - Component diagram 26 - Connector X-FUSE1 to Connector X-HORN-GND A.30.A / 155
Connector - Component diagram 27 - Connector X-HORN-PWR to Connector X-K-C4 A.30.A / 162
Connector - Component diagram 28 - Connector X-NEG_TERM_A to Connector A.30.A / 164
X-POS_TERM_A
Connector - Component diagram 29 - Connector X-POS_TERM_B to Connector X-UJMR A.30.A / 169
Connector - Component diagram 99 Engine connectors A.30.A / 176
PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Mechanical A.10.A / 104
two speed track drive assembly
PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Single speed A.10.A / 96
drive assembly
drive assembly
PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed A.10.A / 64
drive assembly
drive assembly
drive assembly
drive assembly
track drive assembly
drive assembly
drive assembly
PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly A.10.A / 80
84423865 25/07/2011
IU PAGE
drive assembly
PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Enhanced A.10.A / 82
high flow option
high flow option
high flow option
Wiring harness - Electrical schematic frame 01 A.30.A / 179
84423865 25/07/2011
SPECIAL TOOL INDEX
Genuine IU PAGE
CAS10162A [Portable Filter PRIMARY HYDRAULIC POWER SYSTEM - Cleaning A.10.A / 112
Caddy]
CAS1871 [Adapter] PRIMARY HYDRAULIC POWER SYSTEM - Cleaning A.10.A / 112
CAS10192 [Vacuum Pump] PRIMARY HYDRAULIC POWER SYSTEM - Cleaning A.10.A / 112
CAS10508 [Fitting Kit For PRIMARY HYDRAULIC POWER SYSTEM - Cleaning A.10.A / 113
Unions]
CAS1808 [Flowmeter Fitting Relief valve - Pressure test Loader valve main relief A.10.A / 120
Kit]
CAS1871 [Adapter] Reservoir - Apply vacuum A.10.A / 133
CAS10193 [ Kit For Vacuum Reservoir - Apply vacuum A.10.A / 133
Pump]
CAS10192 [Vacuum Pump] Control valve - Remove loader control valve H.40.B / 44
CAS1871 [Adapter] Control valve - Remove loader control valve H.40.B / 44
CAS1871 [Adapter] Accumulator - Remove H.40.B / 80
CAS10192 [Vacuum Pump] Accumulator - Remove H.40.B / 80
Kit IU PAGE
CAS10899 [Nitrogen Charging Accumulator - Discharging H.40.B / 88
Kit]
25/07/2011
19

Ls 5 SM ENG

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SERVICE MANUAL

L213 / L215 / L218 / L220

C227 / C232 / C238

FRAME AND CAB - E

Part number 84522921

FRAME Primary frame - 10.B

FRAME AND CAB - E

FRAME Primary frame - 10.B

FRAME Primary frame

FRAME Primary frame - Overview Model Frame Identification

L215 Small ISM 39 kW (53.0 Hp)

L218 Medium ISM 45 kW (61.2 Hp)

L220 Medium ISM 45 kW (61.2 Hp)

L223 Large F5C 55 kW (74.8 Hp)

L225 Large F5C 61 kW (82.9 Hp)

L230 Large F5C 67 kW (91.1 Hp)

C227 Medium F5C 55 kW (74.8 Hp)

C232 Large F5C 61 kW (82.9 Hp)

C238 Large F5C 67 kW (91.1 Hp)

FRAME AND CAB - E

FRAME Primary frame - 10.B

FRAME AND CAB - E

Engine hood - Remove

2. Remove hardware (2) from filter base and remove

3. Disconnect back up alarm electrical connections (3).

4. If applicable, disconnect rear light electrical connec-

5. Remove door hardware (5).

6. Remove rear door and grill assembly (6).

Engine hood - Install

3. Connect back up alarm electrical connection (3).

FRAME AND CAB - E

USER CONTROLS AND SEAT - 32.A

FRAME AND CAB - E

USER CONTROLS AND SEAT - 32.A

Console Left - Remove Left hand side console

2. Remove left console mounting hardware (1).

3. Remove connector from the switch (1).

4. Unclip the switch from the console.

Console Left - Install Left hand side console

Instrument panel Digital instrument cluster - Remove

2. Remove hardware (1) retaining the instrument clus-

3. Disconnect connector X-C23 from the instrument

Instrument panel Digital instrument cluster - Install

1. Connect connector X-C23 to the instrument cluster

2. Place instrument cluster (1) into right hand frame

Instrument panel - Remove Right hand side console

2. Remove the mounting hardware from the left side (1)

3. Disconnect connector from the switch. Remove

Instrument panel - Install Right hand side console

FRAME AND CAB - E

USER CONTROLS AND SEAT - 32.A

USER CONTROLS AND SEAT Operator seat - 32.C

FRAME AND CAB - E

USER CONTROLS AND SEAT Operator seat - 32.C

Command - Testing Seat Switch

Command - Testing Operator Restraint Switch

N° Test Point Expected Result Other Result (Possible Cause)

Heater - Testing Seat Heat Switch

FRAME AND CAB - E