48083742-linked pdf

jhon meneses
RIMAT SAS
SERVICE MANUAL
calle 110 N 10 - 47
barranquilla
atlantico
Colombia
Email address:
jhon.meneses460@gmail.com
1021G
1021G 1121G
1121G Tier 2
Wheel Loader Wheel Loader
1/2 SERVICE MANUAL

Part number 48083742
Part number 48083742

English
July 2018
© 2018 CNH Industrial Italia S.p.A. All Rights Reserved.
SERVICE MANUAL
1021G ZBAR - EH, NEW CAB TIER2

48083742_EN 31/07/2018
EN
Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
Transmission.............................................................................. 21
[21.113] Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
[21.135] Powershift transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
[21.105] Powershift transmission hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3
[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4
Four-Wheel Drive (4WD) system .................................................. 23

[23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1
Front axle system ....................................................................... 25

[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
[25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2
[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3
Rear axle system........................................................................ 27

[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2
[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3
Brakes and controls .................................................................... 33

[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
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[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.752] Hydraulic fan drive cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9
Frames and ballasting ................................................................. 39

[39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
Steering..................................................................................... 41
[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1
[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2
[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3
[41.910] Auxiliary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4
Wheels ...................................................................................... 44
[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1
[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2
Cab climate control ..................................................................... 50

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

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
48083742_EN 31/07/2018
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.5
[55.415] Loader arm and bucket control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.530] Camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9
Front loader and bucket............................................................... 82

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

[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
[90.118] Protections and footboards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2
[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3
[90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4
[90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5
48083742_EN 31/07/2018
INTRODUCTION
48083742_EN 31/07/2018
1
Contents
INTRODUCTION
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . 13
Basic instructions - How to use the maintenance standard and precautions . . . . . . . . . . . . . . . . . 14
Basic instructions - Precaution for disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Basic instructions - Electrical equipment precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Consumables - Biodiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Product identification - Machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
48083742_EN 31/07/2018
2
INTRODUCTION
Safety rules
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. These precautions are intended for the personal safety of you and those working with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
48083742_EN 31/07/2018
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INTRODUCTION
Personal safety
Carefully read this Manual before proceeding with main-
tenance, repairs, refuelling or other machine operations.
Repairs have to be carried out only by authorized and in-

structed staff; specific precautions have to be taken when
grinding, welding or when using mallets or heavy ham-
mers.
Non-authorized persons are not allowed to repair or carry

out maintenance on this machine. Do not carry out any
work on the equipment without prior authorization.
Ask your employer about the safety instructions in force

and safety equipment.
TULI12WEX2004AA 1
Nobody should be allowed in the cab during machine

maintenance unless he is a qualified operator helping
with the maintenance work.
If it is necessary to move the equipment to carry out re-

pairs or maintenance, do not lift or lower the equipment
from any other position than the operator’s seat.
Never carry out any operation on the machine when the
engine is running, except when specifically indicated.
Stop the engine and ensure that all pressure is relieved

from hydraulic circuits before removing caps, covers,
valves, etc.
All repair and maintenance operations should be carried

out with the greatest care and attention.
Service stairs and platforms used in a workshop or in the

field should be built in compliance with the safety rules in
force.
TULI12WEX2005AA 2
Any functional disorders, especially those affecting the
safety of the machine, should therefore be rectified im-
mediately.
DANGER
Unexpected movement!
Make sure parking brake is applied. Secure
machine with wheel chocks.
Failure to comply will result in death or serious
injury.
D0013A
Before performing any work on the machine, attach a

maintenance in progress tag. This tag can be applied on
the left-hand control lever, safety lever or cab door.
48083742_EN 31/07/2018
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INTRODUCTION
Emergency
Be prepared for emergencies. Always keep a fire extin-
guisher and first aid kit readily available. Ensure that the
fire extinguisher is serviced in accordance with the man-
ufacturer’s instructions.
SMIL12WEX0174AA 3
Equipment
Wear close fitting clothing and safety equipment appropri-
ate for the job:
• Safety helmet
• Safety shoes
• Heavy gloves
• Reflective clothing
• Wet weather clothing
If working conditions require, the following personal safety

equipment should be on hand:
4
• Respirators (or dust proof masks) TULI12WEX2008AA
• Ear plugs or acoustic ears protections

• Goggles with lateral shield or masks for eye protection
Do not wear rings, wristwatches, jewelry, unbuttoned or

flapping clothing such as ties, torn clothes, scarves, open
jackets or shirts with open zips which could get caught into
moving parts.
Engine - Radiator
Never leave the engine running in enclosed spaces with-
out proper ventilation which is able to evacuate toxic ex-
haust gases- Keep the exhaust manifold and tube free
from combustible materials.
Do not refuel with the engine running, especially if hot, as

this increases fire hazard in case of fuel spillage.
Never attempt to check or adjust the belts when the en-

gine is running.
Never lubricate the machine with the engine running.
TULI12WEX2009AA 5
48083742_EN 31/07/2018
5
INTRODUCTION
Pay attention to rotating components and do not allow

anyone to approach these areas to avoid becoming en-
tangled.
Hands, clothing or tools getting caught in the fan blades or

engine belts, can cause amputations, violent hemorrages
and generate conditions of grave danger. For this reason
avoid touching or approaching all rotating or moving parts.
A surging spray of the coolant from the radiator can cause

serious burns and scalds.
Before checking the coolant level, shut-off the engine

and allow machine to cool down the radiator and hoses.
TULI12WEX2010AA 6
Slowly unscrew the cap to release any residual pressure.
If it is necessary to remove the cap while engine is hot,
wear safety clothes and equipment, then loosen the cap
slowly to relieve the pressure gradually.
When checking the fuel, oil and coolant levels, use lights
and lamps explicitly designated as explosion proof. If
these types of lamps are not used, fires or explosions may
occur.
TULI12WEX2011AA 7
Hydraulic systems
Jets of fluids under pressure can penetrate the skin caus-
ing serious injuries.
Avoid this hazard by relieving pressure before disconnect-

ing hydraulic or other lines.
Relieve the residual pressure by moving the hydraulic

control levers several times.
Tighten all connections before applying pressure.
To protect the eyes wear a facial shield or safety goggles.
Protect your hands and body from possible jets of fluids

8
under pressure. TULI12WEX2012AA
Swallowing hydraulic oil is a severe health hazard.
48083742_EN 31/07/2018
6
INTRODUCTION
When hydraulic oil has been swallowed, avoid vomiting,

but consult a doctor or go to a hospital.
If an accident occurs, see a doctor familiar with this type

of injury immediately.
Any fluid penetrating the skin must be removed within a

few hours to avoid serious infections.
Flammable splashes may originate because of heating

near lines with fluids under pressure, resulting in serious
burns. Do not weld or use torches near lines containing
fluids or other flammable materials.
TULI12WEX2013AA 9
Lines under pressure can accidentally be pierced when
the heat expands beyond the area immediately heated.
Arrange for temporary fire resistant shields to protect

hoses or other components during welding or torch use.
Have any visible leakage repaired immediately.
Discharged oil pollutes the environment. Soak up any

oil that has spilled with a proper binding agent. Sweep
up binding agent and dispose of it separately from other
waste.
Never search for leakages with fingers; instead, use a

piece of cardboard and always wear goggles.
Never repair a damaged line; always replace it. Replace

hydraulic hoses immediately on detecting any damaged
or moist areas.
Always store hydraulic oil in the original containers.
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INTRODUCTION
Hoses and tubes

Always replace hoses and tubes if the cone end or the
end connections on the hose are damaged.
When installing a new hose, loosely connect each end

and make sure the hose takes up the correct position be-
fore tightening the connections. Clamps should be tight-
ened sufficiently to hold the hose without crushing and to
prevent chafing.
After replacing a hose on a moving component, check that

the hose does not fall by moving the component through
the complete range of travel. Be sure any hose which has
been installed is not kinked or twisted.
TULI12WEX2014AA 10
Hose connections which are damaged, dented, crushed
or leaking, restrict oil flow and the productivity of the com-
ponents being served. Connectors which show signs of
movement from the original position have failed and will
ultimately separate completely.
A hose with a frayed outer sheath will allow water penetra-

tion. Concealed corrosion of the wire reinforcement could
subsequently occur along the hose length with resultant
hose failure.
Ballooning of the hose indicates an internal leakage due to

structural failure. This condition rapidly deteriorates and
total hose failure soon occurs.
Kinked, crushed, stretched or deformed hoses generally

suffer internal structural damage which can result in oil
restriction, a reduction in the speed of operation and ulti-
mate hose failure.
Free-moving, unsupported hoses must never be allowed

to touch each other or related working surfaces. This
causes chafing which reduces hose life.
O-rings
Replace O-rings, seal rings and gaskets whenever they
are disassembled.
Never mix new and old seals or O-rings, regardless of

condition. Always lubricate new seal rings and O-rings
with hydraulic oil before installation to relevant seats.
This will prevent the O-rings from rolling over and twisting
during mounting which will jeopardize sealing.
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INTRODUCTION
Battery
Batteries give off explosive gases.
Never handle open flames and unshielded light sources

near batteries. (No smoking is addressed in the next in-
struction).
To prevent any risk of explosion, observe the following

instructions:
• When disconnecting the battery cables, always discon-

nect the negative (-) cable first.
• To reconnect the battery cables, always connect the
negative (-) cable last.
TULI12WEX2015AA 11
• Never short-circuit the battery terminals with metal ob-
jects.
• Do not weld, grind or smoke near a battery.
Battery electrolyte causes severe burns. The battery con-

tains sulphuric acid. Avoid any contact with the skin, eyes
or clothing.
Treatment:
• EXTERNAL: Rinse well with water, removing any soiled

clothing.
• INTERNAL: Avoid vomiting. Drink water to rinse your
mouth. Consult a doctor.
• EYES: Rinse abundantly with water for 15 min and con-
sult a doctor.
• When the electrolyte of a battery is frozen, it can ex-
plode if you attempt to charge the battery or if you try to
start the engine using a booster battery. Always keep
the battery charged to prevent the electrolyte freezing.
TULI12WEX2016AA 12
Provide good ventilation when changing a battery or using
a battery in an enclosed space. Always protect your eyes
when working near a battery.
Never set tools down on the battery. They may induce
a short circuit, causing irreparable damage to the battery
and injuring persons.
Never wear metal necklaces, bracelets or watch straps

when working on the battery. The metal parts may induce
a short circuit resulting in burns.
Dispose of used batteries separately from other waste in

the interests of environmental protection.
TULI12WEX2017AA 13
48083742_EN 31/07/2018
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INTRODUCTION
Flammable liquids
When handling flammable liquids:
• Do not smoke.
• Keep away from unshielded light sources and open
flames.
Fuels often have a low flash point and are readily ignited.
Never attempt to extinguish burning liquids with water.

Use:
• Dry powder
• Carbon dioxide
TULI12WEX2016AA 14
• Foam
Water used for extinguishing purposes would vaporize in-

stantaneously on contact with burning substances and
spread burning oil, for example, over a wide area. Water
generates short circuits in the electrical system, possibly
producing new hazards.
Stay away from open flames during refilling of hydraulic
oil or fuel.
Fuel or oil spills can cause slipping hazards; thoroughly

contain and clean affected areas.
Always tighten the safety plugs of fuel tank and hydraulic

oil tank firmly.
Never use fuel to clean machine parts that will be exposed

to dirt or debris.
Use a non-flammable product for cleaning parts.

15
Always perform fuel or oil refilling in well aired and venti- TULI12WEX2018AA
lated areas.
During refuelling hold the pistol firmly and always keep it
in contact with the filler neck until the end of the refuelling,
to avoid arcing due to static electricity.
Do not overfill the tank but leave a space for fuel expan-
sion.
Never refuel when the engine is running.
Take all the necessary safety measures when welding,

grinding or when working near an exposed flame.
TULI12WEX2019AA 16
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INTRODUCTION
Tires
Before inflating the tires, always check the condition of
rims and the outer condition of tires for the presence of
dents, cuts, tears of reinforcement plies or other faults.
Before inflating a tire, make sure that there are no nearby
persons, then position yourself at tread side.
When inflating tires, ensure tire pressure does not exceed

that prescribed by the tire manufacturer. Ensure that the
pressure of the right tire corresponds to the pressure of
the left tire.
NOTE: The front and rear tire pressures may be different.
Never use reconditioned rims because possible welds,

17
heat treatments or brazings not performed correctly can TULI12WEX2020AA
weaken the wheels and cause damage or failure. Deflate

the tires before their disassembly.
Before taking out possible jammed objects from the rims,

it is necessary to deflate the tires. Inflate tires by means
of an inflation pistol complete with extension and pressure
control valve.
Use an inflation cage.
Cleaning
Clean the exterior of all components before carrying out
any form of repair. Dirt and dust can reduce the efficient
working life of a component and lead to costly replace-
ment.
Solvents should be checked that they are suitable for the

cleaning of components and also that they do not risk the
personal safety of the user.
Dirt, oil, grease and scattered tools are dangerous for peo-
ple, because they can create slipping or tripping hazards.
For machine cleaning, use a jet of warm water or steam

under pressure and commercial detergents. Never use
TULI12WEX2021AA 18
fuel, petroleum or solvents, because they can leave an
oily residue that attracts dust, and solvents (even if weak)
damage the paint and can lead to the formation of rust.
Never use water jets or steam on sensors, connectors or

other electric components.
Avoid direct spray of seals and seams to prevent water

penetration inside the cab.
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INTRODUCTION
Waste disposal
Improperly disposing of waste can threaten the environ-
ment.
Each country has its own Regulations on this subject. It

is therefore advisable to prepare suitable containers to
collect and store momentarily all solid and fluid materials
that must not be scattered in the environment to avoid
pollution.
These products will be delivered at preset intervals follow-

ing the forward environmental regulation.
Below are listed some products from the machine requir-

ing disposal:
TULI12WEX2022AA 19
• Lubricating oil
• Brake system oil
• Coolant mixture, condensation rests and pure an-
tifreeze
• Fuel
• Filter elements, oil and fuel filters
• Filter elements, air filters
• Battery
Also polluted rags, paper, sawdust and gloves must be

disposed in compliance with the same procedures.
Do not use food or beverage containers that may mislead

someone into drinking from them. Do not pour waste onto
the ground, down a drain, or into any water source. Air
conditioning refrigerants escaping into the air can damage
the Earth’s atmosphere. Government regulations may re-
quire a certified air conditioning service centre to recover
and recycle used air conditioning refrigerants. Obtain in-
formation on the proper way to recycle or dispose of waste
from your local environmental or recycling centre, or from
your Dealer.
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INTRODUCTION
Basic instructions - Important notice regarding equipment servicing

All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu-
facturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for
continuous improvement. Some information could not be updated due to modifications of a technical or commercial
type, or changes to the laws and regulations of different countries.
In case of questions, refer to your CASE CONSTRUCTION Sales and Service Networks.
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13
INTRODUCTION
Basic instructions - How to use the maintenance standard and

precautions
Application
WHEN THE MACHINE IS NEW
Confirm that the performances are in accordance with standard specifications as compared to the performance stan-
dards.
AT SPECIFIC SELF INSPECTION (RULE BY COUNTRY)
Use the data for the criterion, for the purpose of correction, adjustment and replacement.
WHEN PERFORMANCES ARE DETERIORATED
Determine whether it is caused by a fault or end of service life after long hours of operation, to be used for safety and
economical considerations.
WHEN MAIN COMPONENTS ARE REPLACED
For example, use data to restore performances of pumps and others.
Terminology
STANDARD VALUES
Values to be used to condition or assemble a new machine. Where special notes are not given, these values represent
standard specifications (machine with standard attachments and standard tires).
REFERENCE VALUES FOR REMEDY
Values at which readjustment is required. In order to ensure performance and safety it is strictly prohibited to use the
machine over the specified values.
SERVICE LIMIT
This is the limit value at which reconditioning is impossible without replacement of parts. If the value is expected
to exceed the service limit before next inspection and correction are performed, replace the parts immediately. The
operation over the specified values causes increase of damage and requires the down time of machine, and also
causes safety problems.
Cautions to be exercised at judgment

EVALUATION OF MEASURED DATA
Disagreement of measuring conditions, variations of data peculiar to a new machine, and measuring errors are to be
evaluated. Determine generally at what levels measured values are located, instead of determining whether or not
values fall within or run out of the reference values.
DETERMINING CORRECTION, ADJUSTMENT OR REPLACEMENT
Machine performances deteriorate with time as parts wear and some deteriorated performances may be restored to
new levels. Therefore, determine correction, adjustment or replacement, depending upon the operating hours, kind of
work and circumstances in which the machine is placed, and condition the machine performances to its most desirable
levels.
Other cautions to be exercised

PARTS LIABLE TO DEGRADE
Rubber products, such as, hydraulic hoses, O-rings, and oil seals deteriorate with time; replace them at regular inter-
vals or at overhauls.
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INTRODUCTION
PARTS REQUIRING REGULAR REPLACEMENT
Critical hoses that are necessary to secure safety, we designate as Very Important Parts (V.I.P.) and recommend that
they should be replaced regularly.
INSPECTION AND REPLACEMENT OF OILS AND GREASES
In performing maintenance, it is necessary for the user to familiarize themselves with the machine and handle safely.
Use caution when inspecting and replacing oils and grease. Refer to the Operators Manuals as well.
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INTRODUCTION
Basic instructions - Precaution for disassembly and assembly

Preparations for disassembly
• Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause
machine components to be contaminated during disassembling/assembling, resulting in damage to machine com-
ponents, as well as decreased efficiency in service work.
• Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help avoid incorrect
disassembling of components as well as personal injury.
• Check and record the items listed below to prevent problems from occurring in the future.
1. The machine model, machine serial number, and hour meter reading.
2. Reason for disassembly (symptoms, failed parts, and causes).
3. Clogging of filters and oil, water or air leaks, if any.
4. Capacities and condition of lubricants.
5. Loose or damaged parts.
• Prepare the necessary tools to be used and the area for disassembling work.
• Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves.
• Confirm ready access to a first-aid kit and fire extinguisher, as well as appropriate emergency personnel contacts
in the case of a medical accident or fire.
• Before performing any work on the machine, follow lockout/tagout procedures by attaching a “maintenance in
progress tag”. This tag can be applied on the left-hand control lever, safety lever or cab door. Notify those with
access to the machine that you will be performing the maintenance.
Disassembling and assembling hydraulic equipment

• Before removing lines, release the pressure of hydraulic oil tank, or open the cover on the return side to tank, and
take out the filter.
• Drain the oil in removed lines into an appropriate container to prevent oil contamination.
• Protect open connections with plugs or caps to prevent oil from leaking and debris from contaminating the system.
• Thoroughly clean the outside of components before disassembling, and drain hydraulic oil and gear oil before dis-
assembly.
Disassembling hydraulic equipment

• Impaired performance and function of hydraulic equipment after unauthorized service may not be covered under
warranty by the manufacturer. Consult your local dealer for service.
• If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified
through service training.
• Make match mark on parts for reassembling.
• Before disassembling, read instructions in advance, and determine if the service is required to be performed by an
authorized dealer.
• Use appropriate specialty tools and jigs if required.
• If parts can not be removed as specified by the procedure, never force removal. Check for other failures that may
be causing binding or interference.
• Inspect parts for wear and clearance; record the measured values. Replace components if the values fall outside
of the recommended range.
• If an abnormality is detected, repair or replace the parts.
• When removing parts, use appropriate markings or labels to ensure they can be reinstalled in the correct order and
location without confusion.
• For common parts, pay attention to the quantity and locations of each group of components.
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INTRODUCTION
Reassembling hydraulic equipment

• Clean parts in a well ventilated room.
• Remove residual oil with compressed air, and apply fresh hydraulic oil or gear oil to surfaces before reassembly.
• Replace removed o-rings, back-up rings and oil seals with new ones. Apply gear oil on them before reassembling.
• Thoroughly clean and dry surfaces on which liquid sealant must be reapplied.
• Before assembling, remove rust preventives on new parts.
• Use special tools to fit bearings, bushing and oil seal.
• Assemble parts matching to the marks.
• After completion, check that there is no omission of parts.
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INTRODUCTION
Basic instructions - Electrical equipment precautions

WARNING
Battery acid causes burns. Batteries contain
sulfuric acid.
Avoid contact with skin, eyes or clothing. An-
tidote (external): Flush with water. Antidote
(eyes): flush with water for 15 minutes and
seek medical attention immediately. Antidote
(internal): Drink large quantities of water or
milk. Do not induce vomiting. Seek medical
attention immediately.
Failure to comply could result in death or se-
rious injury.
W0111A
• The disassembly of electrical equipment is not allowed.

• Handle equipment with care so as not to drop it or bump
it.
• Connector should be removed by unlocking while hold-
ing the connector.
• Never disconnect electrical plugs by pulling on the
wires. Always use only the electrical connectors to
make the disconnection.
• Check that connector is connected and locked com-
pletely.
• Engine key off before removing and connecting connec-
tor.
• Engine key off before touching terminals of starter and
alternator.
• Wash machine with care so as not to splash water on
electrical equipment and connector.
• If water has entered a sealed connection, thoroughly
dry both connectors before reconnecting
• Remove battery grounding terminal before beginning
work close to battery and battery relay with tools.
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INTRODUCTION
Consumables - Biodiesel Fuel

Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with
methyl esters.
NOTICE: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN
14214 or ASTM D6751.
NOTICE: Verify with your local dealer which blends are approved for your engine. Use of biodiesel fuel that does not
comply with the Standards EN14214 or ASTM D6751 could lead to severe damage to engine and fuel system. Use
of non-approved biodiesel fuels may void warranty coverage.
Biodiesel Fuel Usage Conditions

Biodiesel fuels must be purchased from a trusted supplier that understands the product and maintains good fuel
quality. Biodiesel fuels must be pre-blended by the supplier. Mixing biodiesel fuels on site can result in an incorrect
mixture which can damage engine and fuel system.
Engine performance is effected by the use of biodiesel fuels. There may be up to 12 percent reduction in power or
torque depending on the blend used.
NOTICE: DO NOT modify the engine and/or fuel injection pump settings to recover reduced performance.
The reduced power must be accepted if using any biodiesel fuel blends.
NOTICE: The use of high biodiesel fuel blends is not recommended in cold weather conditions.
Using biodiesel fuels may require changing engine oil, engine oil filters, and fuel filter elements more frequently.
Biodiesel fuels can remove rust and other particles that adhere to the inside of the fuel tank. These particles are
trapped by vehicle filters and may cause shortened filter life or filter blockages. Blockages are more common in cold
weather conditions. Consult your dealer for information on cold weather operation and proper maintenance intervals
when using any biodiesel fuel blend.
Biodiesel fuel may degrade natural rubber gaskets and hoses, as it is more solvent than petro-diesel. Frequently
inspect hoses and other engine components when using biodiesel fuel.
DO NOT allow water to collect in the fuel or storage tanks. Biodiesel fuel attracts moisture from the atmosphere.
Keep fuel tanks and storage tanks as full as possible to limit the amount of air and water vapors. It may be necessary
to drain machine fuel filter more frequently. Potential oxidation and stability could create a problem with fuel stored in
the machine.
Biodiesel Storage
NOTICE: DO NOT store machines for more than three months with biodiesel blends in the fuel system. DO NOT
store biodiesel fuel in on-site storage tanks for more than three months.
If long periods of storage are required, run the machine for 20 hours using regular diesel fuel to flush the biodiesel
fuel from the engine fuel system.
NOTICE: Biodiesel fuels must not be stored in on-site storage tanks for more than 3 months. Any spillage of biodiesel
fuels must be cleaned up immediately before it can cause damage to the environment or the paint finish of the ma-
chine. Before using biodiesel fuel blends, you should consult with your dealer to receive full information about the
approved blend for your machine and any detailed conditions of its usage. Failure to follow the requirements and
conditions of biodiesel fuel usage will void your machine’s warranty.
NOTE: B7 is the highest biodiesel (7% blend) that should be used in this machine.
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INTRODUCTION
Consumables
1021G Capacities and specifications
Engine
Type of oil CASE AKCELA UNITEK NO. 1™ SBL CJ-4
Technical specifications SAE 10W-40
API CJ-4
CASE CONSTRUCTION specifications MAT3521
Type of oil CASE AKCELA UNITEK NO. 1™ SSL CJ-4 SAE 0W-40
(cold weather)
API CJ-4
Capacity (with filter change) 28.5 l (30.1 US qt)
Cooling system
Type of coolant CASE AKCELA ACTIFULL™ OT EXTENDED LIFE
COOLANT
System capacity 56.8 l (60.0 US qt)
Fuel system
System capacity 473.0 l (125.0 US gal)
Hydraulic system
Type of fluid CASE AKCELA HY-TRAN® ULTRACTION
Technical specifications ISO VG-46
CASE CONSTRUCTION specifications MAT 3540
Technical specifications CASE AKCELA HY-TRAN® ULTRACTION SSL
(low temperature)
Total system capacity 250.0 l (66.0 US gal)
Reservoir capacity 134.0 l (35.4 US gal)
Transmission
Type of oil CASE AKCELA NEXPLORE™ FLUID
Service capacity - with filter change 45.4 l (48.0 US qt)
Axles
Type of oil CASE AKCELA TRANSAXLE FLUID 80W-140
API GL-4
Front axle 42.0 l (44.4 US qt)
Rear axle 42.0 l (44.4 US qt)
Front axle with axle cooler 51.5 L (54.4 US qt)
Rear axle with axle cooler 46.7 L (49.3 US qt)
Heavy duty Front axle 62.0 l (65.5 US qt)
Heavy duty Front axle with cooler 71.5 L (75.6 US qt)
Heavy duty Rear axle 42.0 l (44.4 US qt)
Heavy duty Rear axle with cooler 46.7 L (49.3 US qt)
Grease fittings, as required CASE AKCELA MOLY GREASE
CASE CONSTRUCTION specifications MAT3550 Grade C
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20
INTRODUCTION
1121G Capacities and specifications

Engine
Type of oil CASE AKCELA UNITEK NO. 1™ SBL CJ-4
API CJ-4
Type of oil CASE AKCELA UNITEK NO. 1™ SSL CJ-4 SAE 0W-40
(cold weather)
API CJ-4
Capacity (with filter change) 28.5 l (30.1 US qt)
Cooling system
Type of coolant CASE AKCELA ACTIFULL™ OT EXTENDED LIFE
COOLANT
System capacity 56.8 l (60.0 US qt)
Fuel system
System capacity 473.0 l (125.0 US gal)
Hydraulic system
Type of fluid CASE AKCELA HY-TRAN® ULTRACTION
Technical specifications ISO VG-46
Technical specifications CASE AKCELA HY-TRAN® ULTRACTION SSL
(low temperature)
Total system capacity 250.0 l (66.0 US gal)
Reservoir capacity 134.0 l (35.4 US gal)
Transmission
Type of oil CASE AKCELA NEXPLORE™ FLUID
Service capacity - with filter change 45.4 l (48.0 US qt)
Axles
Type of oil CASE AKCELA TRANSAXLE FLUID 80W-140
API GL-4
Front axle (Standard and Heavy Duty) 62 L (65.5 US qt)
Rear axle (Standard and Heavy Duty) 64.0 l (67.6 US qt)
Front axle with axle cooler (Standard and Heavy 71.5 L (75.6 US qt)
Duty)
Rear axle with axle cooler (Standard and Heavy Duty) 68.7 L (72.6 US qt)
Grease fittings, as required CASE AKCELA MOLY GREASE
CASE CONSTRUCTION specifications MAT3550 Grade C
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21
INTRODUCTION
Hydraulic contamination
Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination
is any foreign material in the hydraulic oil.
Contamination can enter the hydraulic system in several ways:

• When you drain the oil or disconnect any line
• When you disassemble a component
• From normal wear of the hydraulic components
• From damaged seals or worn seals
• From a damaged component in the hydraulic system
All hydraulic systems operate with some contamination. The design of the components in this hydraulic system per-
mits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause
problems in the hydraulic system.
The following list includes some of these problems:

• Cylinder rod seals that leak
• Control valve spools that do not return to neutral
• Movement of control valve spools is difficult
• Hydraulic oil that becomes too hot
• Pump gears, housing, and other parts that wear rapidly
• Relief valves or check valves held open by dirt
• Quick failure of components that have been repaired
• Slow cycle times or a lack of power.
If your machine has any of these problems, check the hydraulic oil for contamination.
There are two types of contamination: microscopic and visible.
Microscopic contamination occurs when very fine particles of foreign material are suspended in the hydraulic oil.
These particles are too small to see or feel. Microscopic contamination can be found by identification of the following
problems or by testing in a laboratory.
Examples of problems caused by microscopic contamination:

• Cylinder rod seals that leak
• Control valve spools that do not return to neutral
• The hydraulic system has a high operating temperature
Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause
a sudden failure of components.
Examples of problems caused by visible contamination:

• Particles of metal or dirt in the oil
• Air in the oil
• Dark or thick oil
• Oil with an odor of burned oil
• Water in the oil
If you find contamination, use a portable filter to clean the hydraulic system.
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INTRODUCTION
Product identification - Machine orientation

MACHINE SIDES
The terms “right-hand”, “left-hand”, “front”, and “rear”,

when used in this manual, indicate the sides of the ma-
chine as they are seen from the operator’s seat.
1. Front side
2. Rear side
3. Left hand side
4. Right hand side
ITIL11WC0004C0B 1
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23
INTRODUCTION
Product identification
LEIL16WHL2581FA 1
1. Cab door and hand holds 6. Roll Over Protection System (ROPS) cab
2. Steps 7. Loader lift arms
3. Bucket (Z-bar version) 8. Battery access
4. Timed disconnect switch and battery jump post 9. Hand rails
5. Bucket cylinder
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24
INTRODUCTION
LEIL16WHL2582FA 2
1. Hand rails 5. Battery access

2. Pre-cleaner 6. Bucket (Z-bar version)
3. Cab air filter access 7. Windshield washer reservoir
4. Bucket cylinder 8. Steps
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INTRODUCTION
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SERVICE MANUAL
Engine

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10
Contents
Engine - 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
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10
Engine - 10
Engine and crankcase - 001

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10.1 [10.001] / 1
Contents
Engine - 10
TECHNICAL DATA
Engine
General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
(*) See content for specific models
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10.1 [10.001] / 2
Engine - Engine and crankcase
Engine - General specification

1021G ZBAR - EH, NEW CAB TIER2 ANZ --- APAC --- LA --- MEA
Engine with 4 Speed Transmission

A. Low idle 870-930 RPM
Alternate low idle 670-730 RPM
Alternate accelerated idle 1270-1330 RPM
Working idle (setting from factory) 1020-1080 RPM
B. Maximum No Load RPM 2162-2212 RPM
C. Converter Stall 1973-2123 RPM
D. Hydraulic Stall 1885-2195 RPM
E. Converter & Hydraulic Stall 1487-1797 RPM
Temperature of the torque converter oil 82 – 104 °C (180 – 219 °F)
Temperature of the hydraulic oil 54 – 57 °C (129 – 135 °F)
NOTE: hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the
bucket held rolled back and the engine at Wide Open Throttle (WOT) in max power mode.
Engine - General specification

Engine with 4 Speed Transmission

A. Low idle 870-930 RPM
Alternate low idle 670-730 RPM
Alternate accelerated idle 1270-1330 RPM
Working idle (setting from factory) 1020-1080 RPM
B. Maximum No Load RPM 2162-2212 RPM
C. Converter Stall 1973-2123 RPM
D. Hydraulic Stall 1885-2195 RPM
E. Converter & Hydraulic Stall 1487-1797 RPM
Temperature of the torque converter oil 82 – 104 °C (180 – 219 °F)
Temperature of the hydraulic oil 54 – 57 °C (129 – 135 °F)
NOTE: hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the
bucket held rolled back and the engine at Wide Open Throttle (WOT) in max power mode.
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10.1 [10.001] / 3
Engine - Remove
Prior operation:
Engine hood - Remove (90.105)
1. Park the machine on a level surface and lower the

bucket to the ground. Put the articulation lock (1) in
LOCKED position.
LEIL15WHL1782AA 1
2. Push the hydraulic functions lock-out switch in the nor-

mal operation position.
LEIL16WHL1125AA 2
3. Move the loader hydraulic control handle to the raise

and lower position in order to release any hydraulic
pressure in the lift circuit.
4. Move the loader control handle in and out of the tilt
position several times, this will relieve any pressure in
the pilot accumulator.
5. Release the pressure in the ride control accumulator
with the bleeder valve in the ride control valve load
travel stabilizer.
6. Actuate the brake pedal several times to discharge
brake accumulators.
LEIL15WHL0564AA 3
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10.1 [10.001] / 4
7. Slowly loosen the filler cap on the hydraulic oil tank to

release air pressure.
LEIL15WHL0825AA 4
8. Locate the timed disconnect switch in the battery box.

Put the timed disconnect switch in the OFF position.
LEIL15WHL0663AA 5
9. Tag and disconnect the positive cable (battery to isola-

tor) cable (1) and the positive cable (isolator to starter)
(2) from the battery isolator.
Disconnect the connector (3) from the timed disconnect
switch.
LEIL16WHL1528AB 6
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10. Loosen and remove the bolts that hold the battery
cover in place on both the left-hand and right-hand
rear of the machine.
Disconnect the battery cable from the battery.
LEIL16WHL0891AB 7
LEIL15WHL1489AA 8
11. Open the access cover.

Place a suitable container below radiator drain, re-
move the radiator cap and coolant drain plug (arrow)
to drain the engine coolant. Reinstall the drain plug
and radiator cap after the coolant has drained.
NOTE: see machine specifications for cooling system vol-
ume.
LEIL15WHL0719AB 9

Place a suitable container below the engine oil drain.
Remove the drain plug and drain the oil into the con-
tainer. Reinstall drain plug.
NOTE: see machine specifications for engine oil sump vol-
ume.
RCPH11WHL104AAH 10
13. Loosen the clamp on the air intake hose under the air
inlet engine hood.
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14. Remove the mounting bolts (arrows) from engine

compartment top cover (1).
15. Attach a suitable lifting device and lift strap to the en-
gine compartment cover and exhaust stack. Carefully
remove the cover (1), the exhaust stack (2) and the
precleaner (3) as an assembly.
LEIL15WHL0679AB 11
16. Disconnect the radiator vent hose (1) from the radia-
tor. Remove the P-clamps that secure the hose to the
left-hand muffler support bracket.
Tag and disconnect the ENG_H connector.
LEIL17WHL0307AB 12
17. Remove the hydraulic oil lines (1) and related fittings.
LEIL15WHL0682AB 13
18. Remove the two bolts, washers and nuts (2) to un-
fix the exhaust pipe support bracket (1) from the hy-
draulic tank.
Remove the clamp saddle (5), U-bolt (6), washers and
nuts to separate the exhaust system pipe (4) from the
bracket (1).
LEIL17WHL0302AB 14
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19. Loosen the clamp (2) to disconnect the exhaust sys-

tem pipe (1) from the engine.
LEIL17WHL0301AB 15
fix from the muffler the bracket (1) that supports the
check valve (2). Loosen the clamp (4) to disconnect
the aspirator engine hose from the muffler.
LEIL17WHL0300AB 16
21. Attach a suitable lift equipment to the left-hand and

right-hand support brackets (1), (4).
Remove the hardware to unfix the left-hand and right-
hand support brackets (1), (4) from the hydraulic tank
and engine wall.
Move the exhaust system assembly (left-hand and
right-hand support brackets (1), (4), muffler supports
(2), muffler (3)) out of the machine.
NOTE: be sure all wire harness connections and hoses are
out of the way during removal.
LEIL17WHL0304AB 17
22. Loosen the V-band clamp (1) to disconnect the air

intercooler inlet elbow (2). Discard the O-ring.
Loosen the clamps (3) to disconnect the air intercooler
inlet tube (4).
NOTE: for clarity, the engine wall is not shown in the figure.
LEIL17WHL0259AB 18
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23. Loosen the clamps (3) to disconnect the air intake tube
(4).
LEIL17WHL0260AB 19
24. Loosen the clamps (2) to disconnect the upper radia-

tor tube (1).
25. Remove the V-band clamp (1) to disconnect the air
intake elbow (2) from the turbocharger. Discard the
O-ring.
LEIL17WHL0261AB 20
LEIL17WHL0262AB 21
26. Remove the oil dipstick P-clamp (2). Pull the oil dip-
stick tube (1) through the wall.
LEIL15WHL0819AB 22
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27. Tag and disconnect the cable (grid heater power relay
to heater) (1) and cable (ground heater) (2).
LEIL17WHL0303AB 23
28. Tag and disconnect the WSH connector (1) from the
fuel pre-filter. Remove the bolt, washer and nut (2)
to unfix the P-clamp securing the wire to the support
bracket.
Tag and disconnect the WIF connector from the fuel
pre-filter.
LEIL17WHL0297AB 24
29. Remove the bolt, washer and nut to unfix the P-clamp
securing the pressure hoses of the air conditioning
compressor to the support bracket.
LEIL17WHL0296AB 25
30. Disconnect the fuel hose (tank to pre-filter) (2) and fuel
hose (pre-filter to engine) (1).
LEIL17WHL0299AB 26
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31. Remove the bolts, washers and nuts (2), (3) to unfix
fuel pre-filter (1) from the support bracket.
NOTE: pay attention to the GRD_WIF wire release at the
location (2); tag the wire.
LEIL17WHL0298AB 27
32. Loosen the clamp (2) on the crankcase vent hose (1).
33. Remove the bolt (3) with related washers and nut to
separate the two clamps (4) from the hose support
bracket (5).
34. Loosen the clamp (6) on the crankcase vent hose (1).
35. Cut the straps (7).
36. Remove the crankcase vent hose (1).
LEIL15WHL0669AB 28
37. Loosen the P-clamps (2) on the engine to crankcase

vent filter hose (1).
38. Remove the engine to the crankcase vent filter hose
(1).
39. Remove the drain hose filter (3) from the crankcase
vent filter.
LEIL15WHL0670AB 29
40. Loosen the bolts (2) to remove the crankcase vent

filter (1) from the machine.
LEIL15WHL1138AB 30
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41. Loosen the four nuts (2) and related washers (3) that
hold the support bracket (1) of the crankcase vent filter
to the rear chassis.
NOTE: one of these four nuts (2) is used to secure a
P-clamp that hold the wiring harness to the support bracket
(1).
LEIL15WHL1140AB 31
42. Remove the two washers and nuts (5) to unfix the air
intake bracket (1) from the hydraulic tank.
43. Remove the saddle, U-bolt, washers and nuts (2) to
separate the air intake upper hose (3) from the air
intake bracket (1).
44. Loosen the clamp (4) to disconnect the air intake up-
per hose (3).
LEIL17WHL0270AB 32
LEIL17WHL0269AB 33
45. Tag and disconnect the air restriction switch (7) from
the air cleaner. Cut the strap.
46. Loosen the clamps (6) to disconnect the air intake
hose (3) from the plenum and engine turbocharger.
47. Loosen the clamp (5) to disconnect the air intake
plenum (2) from the elbow.
48. Loosen the clamp (4) to disconnect the air intake el-
bow (1) from the air filter housing.
LEIL17WHL0268AB 34
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49. Remove the bolts, washers and nuts (1) to unfix the
air cleaner bracket (2) from the engine wall.
50. Remove the four nuts and washers (3) to unfix the air
cleaner bracket (2) from the rear chassis. Move the
air cleaner (4) with the air cleaner bracket (2) out of
the machine.
LEIL17WHL0267AB 35
51. Disconnect the engine heater cable from the engine.
LEIL17WHL0305AB 36
52. Cut the cable ties (9).

53. Remove the bolt, washers, nut and two P-clamps (8)
from the bracket (4).
54. Remove the bolt, washers, nut and P-clamp (7) from
the bracket (4).
55. Remove the clamp (6) to disconnect the engine vent
hose (5) from the engine.
56. Disconnect the fill hose (2) from the 90° elbow (1).
Disconnect the 90° elbow (1) from the engine. Discard
the O-ring.
57. Remove the brackets (3) and (4) from the engine LEIL17WHL0264AB 37
block.
58. Loosen the clamps (7) to disconnect the heater return
tube (2) and heater supply tube (3).
Remove the bolt, washer, nut (1) and two P-clamps
(4) to separate the tubes from the engine.
Remove the bolt, washer (5) and two P-clamps (4) to
separate the tubes from the bracket (6).
LEIL17WHL0256AB 38
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59. Remove the bolt, washer (6) and two P-clamps (4) to
separate the heater supply and return tubes (3), (2)
from the bracket (5).
Remove the bolts and washers (7), (8) to unfix the
bracket (5) from the engine.
Disconnect the heater supply tube (3) from the engine.
Disconnect the heater return tube (2) from the zinc
lower radiator tube (1).
LEIL17WHL0255AB 39
60. Loosen the clamp (1) to disconnect the zinc lower ra-
diator tube (2) from the elbow radiator hose.
Remove the two bolts and washers (arrows) to discon-
nect the zinc lower radiator tube (2) from the engine.
Discard the O-ring.
LEIL17WHL0253AB 40
61. Attach a lifting equipment to the engine wall (2). Re-

move the engine wall hold-down bolts (1) to unfix the
engine wall from the rear chassis. Lift and remove the
engine wall.
NOTE: prior to remove the engine wall to be sure that all
the P-clamp installed on the wall are be removed.
LEIL15WHL1055AB 41
62. Remove the drive belt on the engine.
LEIL17WHL0266AB 42
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63. Tag and disconnect the ALT_B and ALT_5 connectors

(4), (5).
Remove the bolts, washers and nut (2), (3) to discon-
nect the alternator (1) from the engine.
LEIL17WHL0265AB 43
64. Cut the cable strap (5). Tag and disconnect the
ACT_10 connector from air compressor clutch con-
nector (4).
Recovery the refrigerant as indicated in Air condi-
tioning - Service instruction (50.200).
Disconnect the low-pressure line (3) from the suction
port (compressor to condenser hose) and the high-
pressure line (2) from the discharge port (cab to com-
pressor hose) of the air-conditioning compressor. Im-
mediately install protective caps on the open ports and
lines.
Remove the mounting bolts (6) to disconnect the air
conditioning compressor (1).
LEIL17WHL0263AB 44
65. Remove the P-clamps that secure the wires

to the engine block. Tag and disconnect the
GND_ENG1, GND_ENG3, GND_ENG4 terminals
and GND_CENG1, GND_CENG2 terminals.
LEIL17WHL0306AB 45
66. Disconnect the electrical connector to the engine con-

trol unit.
LEIL15WHL1085AA 46
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67. Tag and disconnect the ST wire (1) from the engine
starter.
LEIL15WHL1299AB 47
68. Tag and disconnect the negative cable (starter to

ground) (1), the negative cable (battery to starter) (2)
from the engine starter.
Tag and disconnect the positive cable (battery isolator
to starter) (3) and CPWR, XM1C connectors (4), (5)
from the engine starter.
LEIL16WHL1527AB 48
69. Remove the three nuts (1) from the engine starter.
Remove the engine starter.
LEIL15WHL1331BB 49
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70. Disconnect the hydraulic fittings (2) and (3) from the
hydraulic oil supply tube (1).
LEIL17WHL0258AB 50
71. Loosen the two clamps to disconnect the hydraulic oil

return tube (2) from the lower hose (1).
LEIL17WHL0257AB 51
72. Connect a suitable lifting equipment to the engine lift-

ing brackets (1).
Take up all slack in lifting equipment.
LEIL15WHL1086AB 52
73. Loosen and remove the bolts (1) that fasten the center
drive shaft (2) to the transmission.
NOTICE: the bolts (1) that fasten the center drive shaft (2)
to the transmission must be replaced when removed.
LEIL15WHL1207AB 53
NOTE: steps 74 and 75 are related only to CASE CONSTRUCTION 1021G.
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74. Remove the bolts (1) and related washers.

Remove the converter housing cover plate (2) and re-
move the flex plate bolts.
LEIL15WHL1330AB 54
75. Remove the twelve flex plate bolts (1).
LEIL15WHL1019AB 55

76. Remove the cover (1). Remove the plug (2) to gain
access to the flywheel.
77. Turn the flywheel (clockwise as seen from the engine
front) until one of the torque converter bolts is visible
through the hole, and remove the bolt. Continue turn-
ing the flywheel (clockwise) in 30° increments to ex-
pose each bolt, until all the twelve bolts are removed.
LEIL15WHL1502AB 56
78. Remove the twelve bell housing bolts (1).
LEIL15WHL1020AB 57
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79. Loosen the oil drain hose (15) and the O-ring (14) from
the elbow (13).
80. Separate the engine mounting brackets (8) from the
engine.
Remove the engine bracket upper bolts (11) and the
related washers (12).
Remove the engine bracket upper bolts (9) and the
related washers (10).
Separate the engine mounting brackets (8) from the
engine mounting plate (7). Remove the bolt (1), the
washers (2), rubber lower isolator (3), the rubber up-
per isolator (4) the washer (5) and the nut (6).
LEIL15WHL1326BB 58
81. Slowly raise the engine from the rear chassis. Be sure
that all the wire harness connections and the hoses
have been disconnected and are clear of the engine.
Guide the oil drain hose from the frame as the engine
is lifted. Remove the engine from machine.
LEIL15WHL1082AA 59
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Engine - Install
1. Attach a suitable lifting equipment to the engine lifting
brackets (1).
LEIL15WHL1142AB 1
2. Install the two engine mounting brackets (8) to the en-

gine.
Tighten the engine bracket upper bolts (11) and related
washers (12) to a torque of 170 – 231 N·m (125.4 –
170.4 lb ft).
Tighten the engine bracket lower bolts (9) and related
washers (10) to a torque of 69.6 – 79.6 N·m (51.3 –
58.7 lb ft).
3. Inspect the engine mounts. If the engine rubber isola-
tors require replacement, remove and discard the isola-
tors (3) and (4). Place the engine over the rear chassis.
Install the bolts (1), washers (2), rubber lower isolators
(3), engine mounting plate (7), rubber upper isolators
(4), washers (5) and nuts (6) to fix the engine to the
rear chassis. Tighten the bolts (1) to a torque of 397 –
447 N·m (292.8 – 329.7 lb ft).
Install new rubber lower isolator (2) and new upper iso-
lator (4).
4. Tighten the oil drain hose (15) with a new O-ring (14)
to the elbow (13).
LEIL15WHL1326BB 2
5. Install the twelve bell housing bolts (1). Tighten the bell
housing bolts (1) to a torque of 54 – 60 N·m (40 – 44 lb
ft).
LEIL15WHL1020AB 3
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6. Install the twelve flex plate bolts (1). Tighten the flex
plate bolts (1) to a torque of 33 – 41 N·m (24 – 30 lb
ft).
LEIL15WHL1019AB 4
7. Apply DOW 732 RTV SILICONE CLEAR to the converter

housing cover plate (1).
Install the converter housing cover plate (2).
LEIL15WHL1330AB 5
NOTE: step 8 is related only to CASE CONSTRUCTION 1121G.

front) until one of the torque converter bolts location is
visible through the hole, and install the bolt. Continue
turning the flywheel (clockwise) in 30 ° increments to
expose each bolt location, until all the twelve bolts are
installed.
Install the plug (2). Install the cover (1).
LEIL15WHL1502AB 6
9. Hold the center drive shaft (2) in position and install

the bolts (1) that fasten the center drive shaft (2) to the
transmission.
Tighten the bolts to a torque of 136 – 149 N·m (100 –
110 lb ft).
LEIL15WHL1207AB 7
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10. Use two clamps to connect the hydraulic oil return tube
(2) to the lower hose (1) and secure them.
LEIL17WHL0257AB 8
11. Connect the hydraulic fittings (2) and (3) to the hy-
draulic oil return tube (1).
LEIL17WHL0258AB 9
12. Position the engine starter on the machine.

Install the three flange nuts (1) to secure the engine
starter to the engine. Tighten the flange nuts to 40 –
48 N·m (30 – 35 lb ft).
LEIL15WHL1331BB 10
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13. Install the negative cable (starter to ground) (1), the

negative cable (battery to starter) (2) on the engine
starter. Tighten the related nut.
Use existing hardware to mount the positive cable
(battery isolator to starter) (3) and CPWR, XM1C con-
nectors (4), (5) to the engine starter. Torque to 22.5 –
29.4 N·m (16.6 – 21.7 lb ft).
LEIL16WHL1527AB 11
14. Install and tighten the ST wire (1) to the engine starter.
LEIL15WHL1299AB 12
15. Connect the electrical connector to the engine control

unit.
LEIL15WHL1085AA 13
16. Secure the wires to the engine block with clamps.

Connect the GND_ENG1, GND_ENG3, GND_ENG4
terminals and GND_CENG1, GND_CENG2 termi-
nals.
LEIL17WHL0306AB 14
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17. Install the air conditioning compressor (1) with the

mounting bolts (6).
Connect the low-pressure line (3) to the suction port
(compressor to condenser hose). Connect the high-
pressure line (2) to the discharge port (cab to com-
pressor hose) of the air-conditioning compressor.
Connect the ACT_10 connector to air compressor
clutch connector (4) and secure it to the compressor
with the cable strap (5).
LEIL17WHL0263AB 15
18. Install the alternator (1) to the engine with bolts, wash-
ers and nut (2), (3). Connect the ALT_B and ALT_5
connectors (4), (5).
LEIL17WHL0265AB 16
19. Install the drive belt on the engine.
LEIL17WHL0266AB 17
20. Attach lifting equipment to the engine wall (2). Posi-

tion the engine wall in the correct position on the ma-
chine and install the engine wall hold-down bolts (1).
LEIL15WHL1055AB 18
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21. Connect the zinc lower radiator tube (2) to the elbow
radiator hose with the clamp (1). Torque the clamp to
10.1 – 11.3 N·m (7.4 – 8.3 lb ft).
Install the zinc lower radiator tube (2) to the engine
with two bolts and washers (arrows). Use a new
O-ring at the tube-engine joining.
LEIL17WHL0253AB 19
22. Connect the heater return tube (2) to the zinc lower
radiator tube (1).
Connect the heater supply tube (3) to the engine.
Torque to 21 – 27 N·m (15.5 – 19.9 lb ft).
Install the bracket (5) to the engine with bolts and
washers (7), (8). Install the two P-clamps (4) to the
bracket (5) with bolt and washer (6), so to secure the
heater supply and return tubes (3), (2).
LEIL17WHL0255AB 20
23. Connect the heater return tube (2) and heater supply
tube (3) with the clamps (7).
Secure the tubes with two P-clamps (4) fixed to the
engine with bolt, washer and nut (1).
Secure the tubes with two P-clamps (4) fixed to the
bracket (6) with bolt and washer (5).
LEIL17WHL0256AB 21
24. Install the brackets (3) and (4) to the engine block with
two bolts and washers.
25. Connect the fill hose (2) to the engine through the 90°
elbow (1). Use a new O-ring and Loctite 592 sealant.
26. Connect the engine vent hose (5) to the engine with
the clamp (6). Torque the clamp to 1.1 N·m (0.8 lb ft).
27. Install the P-clamp (7) to the bracket (3) with bolt,
washers and nut and secure the fill hose (2).
28. Install the two P-clamps (8) to the bracket (4) with
bolt, washers and nut and secure the fill hose (2) and
engine vent hose (5).
LEIL17WHL0264AB 22
29. Secure the fill hose (2) and engine vent hose (5) with
the cable ties (9).
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30. Connect the engine heater cable to the engine.
LEIL17WHL0305AB 23
31. Place the air cleaner (4) with the air cleaner bracket
(2) in the correct position. Install the four nuts and
washers (3) to fix the air cleaner bracket (2) to the rear
chassis.
32. Tighten the bolts (1) with related washers and nuts to
install the air cleaner bracket (2) to the engine wall.
LEIL17WHL0267AB 24
33. Connect the air intake elbow (1) to air filter housing
with clamp (4). Torque the clamp to 4 – 4.5 N·m (3 –
3.3 lb ft).
34. Connect the air intake plenum (2) to elbow with clamp
(5). Torque the clamp to 4 – 4.5 N·m (3 – 3.3 lb ft).
35. Connect the air intake hose (3) to plenum and engine
turbocharger with two clamps (6). Torque the clamps
to 4 – 4.5 N·m (3 – 3.3 lb ft).
36. Connect the air restriction switch (7) to the air cleaner
and secure the wire with strap.
LEIL17WHL0268AB 25
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37. Install the air intake bracket (1) to the hydraulic tank
with two washers and nuts (5).
38. Install and tighten the clamp (2) to air intake bracket
(1).
39. Connect the air intake upper hose (3) with clamp (4).
Torque the clamp to 4 – 4.5 N·m (3 – 3.3 lb ft).
LEIL17WHL0270AB 26
LEIL17WHL0269AB 27
40. Tighten the four nuts (2) and related washers (3) to
install the support bracket (1) of the crankcase vent
filter to the rear chassis.
LEIL15WHL1140AB 28
41. Tighten the two bolts and washers (2) to install the
crankcase vent filter (1) on the support bracket.
LEIL15WHL1138AB 29
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42. Connect the oil drain hose (3) to the crankcase vent
filter.
43. Tighten the two clamps (2) to connect the hose (1) to
engine and crankcase vent filter.
LEIL15WHL0670AB 30
44. Place the crankcase vent hose (1) in the correct posi-
tion on the engine.
45. Install new four straps (7) to secure the two hoses from
crankcase vent filter.
46. Tighten the clamp (6) to connect the hose (1) to the
crankcase vent filter.
47. Tighten the bolt (3) with related washers and nut to in-
stall the two P-clamps (4) on the hose support bracket
(5).
NOTE: install the P-clamps (4) in such a way to secure the
two hoses from crankcase vent filter.
LEIL15WHL0669AB 31
48. Install the clamp (2) to connect the hose (1) to air
cleaner tube.
49. Install the fuel pre-filter (1) to the support bracket with
the bolts, washers and nuts (2), (3).
NOTE: use installation at the location (2) to attach
GRD_WIF wire.
LEIL17WHL0298AB 32
50. Connect the fuel hose (tank to pre-filter) (2) and fuel
hose (pre-filter to engine) (1).
LEIL17WHL0299AB 33
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51. Use a bolt, washer and nut to install a P-clamp to the

support bracket and secure the pressure hoses of the
air conditioning compressor.
LEIL17WHL0296AB 34
52. Connect the WSH connector (1) to the fuel pre-filter.

Secure the wire with a P-clamp installed to the support
bracket with bolt, washer and nut (2).
Connect the WIF connector to the fuel pre-filter.
LEIL17WHL0297AB 35
53. Connect the cable (grid heater power relay to heater)

(1) and cable (ground heater) (2).
LEIL17WHL0303AB 36
54. Slip the oil dipstick tube (1) through the wall. Install
the oil dipstick P-clamp (2).
LEIL15WHL0819AB 37
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55. Use the clamps (2) to install the upper radiator tube
(1). Torque the clamps to 10.1 – 11.3 N·m (7.4 – 8.3 lb
ft).
LEIL17WHL0261AB 38
LEIL17WHL0262AB 39
56. Install the V-band clamp (1) and a new O-ring to

connect the air intake elbow (2) to the turbocharger.
Torque the V-band clamp (1) to 5.8 – 7.8 N·m (4.3 –
5.8 lb ft).
Install the air intake tube (4) of the turbocharger with
two clamps (3). Torque the clamps (3) to 10.1 –
11.3 N·m (7.4 – 8.3 lb ft)
57. Secure the air intake tube (4) to the air cooler with two
clamps (3). Torque the clamps (3) to 10.1 – 11.3 N·m
(7.4 – 8.3 lb ft).
LEIL17WHL0260AB 40
58. Install the V-band clamp (1) and a new O-ring to con-
nect the air intercooler inlet elbow (2). Torque the
V-band clamp (1) to 5.8 – 7.8 N·m (4.3 – 5.8 lb ft).
Install the air intercooler inlet tube (4) with two clamps
(3). Torque the clamps (3) to 10.1 – 11.3 N·m (7.4 –
8.3 lb ft)
LEIL17WHL0259AB 41
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59. Attach a suitable lifting to the exhaust system assem-

bly (left-hand and right-hand support brackets (1), (4),
muffler supports (2), muffler (3)). Move the assembly
into the correct position on the machine.
out of the way or positioned correctly for reconnecting.
60. Install the left-hand and right-hand support brackets
(1), (4) to the hydraulic tank and engine wall.
LEIL17WHL0304AB 42
61. Fix the bracket (1) that supports the check valve (2)
to the muffler with two bolts, washers and nuts (3).
Connect the aspirator engine hose to the muffler with
LEIL17WHL0300AB 43
62. Connect the exhaust system pipe (1) to the engine

with the clamp (2). Torque the clamp to 5.4 – 5.9 N·m
(4 – 4.4 lb ft).
LEIL17WHL0301AB 44
63. Connect the exhaust system pipe (4) to the muffler

with clamp (3). Torque the clamp to 18 – 22 N·m (13.3
– 16.2 lb ft).
64. Install the exhaust pipe support bracket (1) to the hy-
draulic tank with two bolts, washers and nuts (2). Se-
cure the exhaust system pipe (4) to the bracket (1)
with the clamp saddle (5), U-bolt (6), washers and
nuts.
LEIL17WHL0302AB 45
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65. Connect the radiator vent hose (1) to the radiator

(through the engine wall). Secure the hose to the
Connect the ENG_H connector at this time.
LEIL17WHL0307AB 46
66. Install the hydraulic oil lines (1) and related fittings.
LEIL15WHL0682AB 47
gine compartment cover (1), the exhaust stack, and
the pre-cleaner (3) as an assembly. Carefully move
the assembly into position on the machine.
Install the mounting bolts (arrows) on the engine com-
partment top cover (1).
LEIL15WHL0679AB 48
68. Tighten the clamp on the air intake hose under the air
inlet engine hood. Torque the clamp to 4 – 4.5 N·m (3
– 3.3 lb ft).
69. Be sure the engine oil drain cap is secured. Refill the
engine with new engine oil.
70. Be sure the engine coolant drain cap is secured. Refill
the cooling system with a 50% CASE AKCELA ACT-
IFULL™ OT EXTENDED LIFE COOLANT and 50%
water solution. Install radiator cap
71. Turn the timed disconnect switch to the ON position.
Reconnect the battery cable to the batteries. Install
the battery cover on the right-hand rear of the ma-
chine.
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72. Connect the positive cable (battery to isolator) cable

(1) and the positive cable (isolator to starter) (2) to the
battery isolator. Remove tags from the cables.
Connect the connector (3) to the timed disconnect
switch.
Install the battery cover on the left-hand rear of the
machine.
LEIL16WHL1528AB 49
73. Start machine and check for exhaust leaks. Confirm

problem has been corrected.
Next operation:
Engine hood - Install (90.105)
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Engine - Test
During these tests the engine runs at full throttle and
works against the torque converter, the hydraulic sys-
tem, or both the torque converter and the hydraulic sys-
tem. The results of these tests will show if the cause of
poor performance is one or more of the following: (1)
engine, (2) torque converter or transmission, and (3)
hydraulic system.
48083742_EN 31/07/2018
10.1 [10.001] / 34
Index
Engine - 10

Engine - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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Engine - 10
Fuel tanks - 216

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10.2 [10.216] / 1
Contents
Engine - 10
Fuel tanks - 216
SERVICE
Fuel tank
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - Fuel tanks
Fuel tank - Remove

1. Locate the timed disconnect switch (1) and the hood
raise switch (2) in the battery box.
Raise the hood and put the timed disconnect switch (1)
in the OFF position.
LEIL15WHL0663AA 1

With a suitable container of the proper capacity under
the drain, open the cap by turning counterclockwise
and drain the coolant from the system.
After all the coolant is drained, secure the drain cap.
NOTE: use compressed air and water, to clean debris from
around drain plug area.
LEIL15WHL0719AB 2
3. To access the cooling box, use the latch to open fan

door.
LEIL15WHL0698AB 3
4. Locate the fuel tank.
LEIL17WHL0314AB 4
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10.2 [10.216] / 3
Engine - Fuel tanks
5. Drain the fuel tank.

NOTE: use compressed air and water, to clean debris from
around drain plug area.
LEIL17WHL0310AB 5
6. Remove the bolts (1) to remove the cover tank plate (2)
from the fuel tank skip plate (3).
LEIL15WHL0764AB 6
7. Remove the two nuts and washers to unfix the fuel fill
cover (1).
Remove the foam block from the cavity above the tank
fill neck.
LEIL17WHL0313AB 7
8. Remove the four bolts to remove the fuel tank cover

plate (1).
LEIL17WHL0308AB 8
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10.2 [10.216] / 4
Engine - Fuel tanks
9. Remove the hose clamp (1) to disconnect the fuel tank

from the fuel fill hose (2).
LEIL17WHL0315AB 9
10. Remove the hose clamps (1) and disconnect the fuel
lines (2), (3) from the fuel sender.
Disconnect the electrical connector from the fuel
sender.
LEIL17WHL0309AB 10
11. Remove the bolts (1), washers (2), spacers (3), and
nuts (4).
Separate the fuel tank skip plate (5) from the rear
chassis frame (6).
LEIL15WHL1092AB 11
12. Support the fuel tank skid plate (5) with a safe support
equipment.
Remove the fuel tank skid plate bolts (1) and (3), and
washers (2) and (4).
Be sure that all the wire harness connections have
been disconnected.
Carefully lower the fuel tank skip plate (5) and the fuel
tank as an assembly from the rear chassis.
LEIL17WHL0318AB 12
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Engine - Fuel tanks
Fuel tank - Install

1. Support the fuel tank skid plate (5) and the fuel tank
as an assembly with a safe support equipment. Lift the
fuel tank skid plate (5) into the rear chassis.
Install the fuel tank skid plate bolts (1) and (3) and
Tighten the bolts (1) to a torque of 300 – 407 N·m (221
– 300 lb ft).
– 121 lb ft).
NOTE: fuel tank skid plate bolts are to be torqued only one
time. Replace as necessary.
LEIL17WHL0318AB 1
2. Join the fuel tank skip plate (5) to the rear chassis frame
(6).
Install the bolts (1), washers (2), spacers (3), and nuts
(4).
– 300 lb ft).
NOTE: fuel tank skid plate bolts are to be torqued only one
time. Replace as necessary.
LEIL15WHL1092AB 2
3. Connect the fuel fill hose (2) to the fuel tank with the
clamp (1).
LEIL17WHL0315AB 3
4. Connect the fuel lines (2), (3) to the fuel sender with the
clamps (1).
Connect the electrical connector to the fuel sender.
LEIL17WHL0309AB 4
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Engine - Fuel tanks
5. Install the fuel tank cover plate (1) with four bolts.
LEIL17WHL0308AB 5
6. Place the foam block in the cavity above the tank fill
neck.
Install the fuel fill cover (1) to the cooling frame mount-
ing plate with two washers and nuts.
LEIL17WHL0313AB 6
7. Install the cover tank plate (2) to the fuel tank skip plate
(3) with four bolts (1).
LEIL15WHL0764AB 7
8. Close the cooling box.

Lower the engine hood.
LEIL15WHL0698AB 8
9. Refill the fuel tank to the required amount.

Refill the engine cooling system to the required amount.
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Engine - Fuel tanks
10. Place the timed disconnect switch in the ON position.

Clear any fault codes.
Start machine and check for fuel and coolant leaks.
Confirm that any error has been fixed.
LEIL15WHL0663AA 9
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Index
Engine - 10
Fuel tanks - 216

Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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10.2 [10.216] / 10
Engine - 10
Air cleaners and lines - 202

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10.3 [10.202] / 1
Contents
Engine - 10
SERVICE
Air pre-cleaner
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air cleaner
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Engine - Air cleaners and lines
Air pre-cleaner - Remove

1. Access to the pre-cleaner located on top of the engine
compartment hood.
LEIL15WHL1273AA 1
2. Loosen the hose clamp (2).

Remove the pre-cleaner (1) with the adaptor (3).
Loosen the hose clamp (5) and remove the adapter (4).
LEIL15WHL1078BB 2
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10.3 [10.202] / 3
Air pre-cleaner - Install

1. Tighten the hose clamp (5) to install the adapter (4).
Tighten the hose clamp (2) to install the new
pre-cleaner (1) with the new adaptor (3).
LEIL15WHL1078BB 1
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10.3 [10.202] / 4
Air cleaner - Remove

1. Park the machine on a level surface. Lower the bucket
to the ground. Put the articulation lock in the LOCKED
position.
LEIL15WHL1272AA 1
2. Raise the engine hood.
LEIL15WHL1148AA 2
3. Put the timed disconnect switch in the OFF position.
LEIL15WHL0663AA 3
4. Use the handle indicated in figure to open the wide rear

fender panel compartment.
LEIL15WHL0775AA 4
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10.3 [10.202] / 5
5. Act on the latch (1) to remove the side body panel (2)
from the right-hand side of machine.
LEIL15WHL0703AB 5
6. Locate the engine air filter housing.
LEIL15WHL0704AB 6
7. Release the clips that secure the air filter element hous-
ing cover.
LEIL15WHL1077AB 7
8. Remove the cover from the air filter element housing.
LEIL15WHL1074AB 8
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10.3 [10.202] / 6
9. Remove the primary filter element. Use the handle to

pull the element down and straight out of housing.
LEIL15WHL1073AB 9
10. Remove the secondary filter element. Use the handle

to pull element down and out of the housing.
NOTE: remove extra debris and wipe the inside of the filter
housing with a clean cloth before installing new filter ele-
ments.
NOTE: do not clean the secondary filter element. Replace
the second filter element if damaged or clogged. Check
both filter elements for damage.
LEIL15WHL1075AB 10
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10.3 [10.202] / 7
Air cleaner - Install

1. Use the locating tab of the new secondary filter element
as a guide to install the new secondary filter element.
LEIL15WHL1076AB 1
2. Position the locating tab into slot within the housing.

Push the filter element up into place.
LEIL15WHL1075AB 2
3. Install the primary filter element by sliding it into housing

and pushing it up into place. Make sure that the filter
element tabs are positioned inside the grooves on the
housing.
NOTE: make sure that the primary and the secondary filter
elements are fully seated and form an effective seal.
LEIL15WHL1073AB 3
4. Replace the housing cover.
LEIL15WHL1074AB 4
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10.3 [10.202] / 8
5. Lock clips and secure filter housing cover.

NOTE: make sure that the tabs of the housing cover are
correctly inserted into the slots of the filter housing. If the
cover does not fit properly, recheck the filter element instal-
lation. The cover will be difficult to install if filter elements
are not properly installed.
LEIL15WHL1077AB 5
6. Install the side body panel (2) on the right-hand side of

machine, acting on the latch (1).
LEIL15WHL0703AB 6
7. Close the wide rear fender panel compartment. Lower

the engine hood.
LEIL15WHL0775AA 7

9. Lower the engine hood.
10. Put the articulation lock in the OPERATING position.
LEIL15WHL1782AA 8
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Index
Engine - 10

Air cleaner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Air cleaner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air pre-cleaner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air pre-cleaner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Engine cooling system - 400

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10.4 [10.400] / 1
Contents
Engine - 10
SERVICE
Radiator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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10.4 [10.400] / 2
Engine - Engine cooling system
Radiator - Remove
bucket to the ground. Apply the parking brake and shut
down the engine. Then place the articulation lock in
locked position.
LEIL15WHL1782AA 1
2. Locate the timed disconnect switch (1) and hood raise

switch (2) in the battery box.
Raise the engine hood and put the timed disconnect
switch (1) in the OFF position.
LEIL15WHL0663AA 2
3. To access the cooling box, use the latch to open fan

door.
LEIL15WHL0698AB 3

Place a suitable container below radiator drain, remove
radiator cap and coolant drain plug (arrow) to drain en-
gine coolant. Then reinstall drain plug and radiator cap
after coolant has drained.
LEIL15WHL0719AB 4
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10.4 [10.400] / 3
5. Loosen the clamp of the overflow hose to the radiator.
LEIL15WHL1288AB 5
6. Loosen the clamp of the upper radiator hose and re-

move the hose from the radiator. Install a plug on the
hose and a cap on the fitting.
LEIL15WHL1287AA-01 6
7. Loosen the clamp of the lower radiator hose and re-

move the lower radiator hose from the radiator. Install
a plug on the hose and a cap on the fitting.
8. Loosen and remove the two bolts (1) and spring lock
washers (2).
Loosen and remove the two bolts (1) with related wash-
ers (4), spring lock washers (6) and nuts (5).
Carefully remove the radiator from the machine.
LEIL15WHL1286AB-01 8
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10.4 [10.400] / 4
Radiator - Install
WARNING
Hot liquid under pressure!
Scalding can result from fast removal of the radiator cap. Check and service the engine cooling sys-
tem according to the maintenance instructions in this manual.
Failure to comply could result in death or serious injury.
W0163A
1. Using a suitable lifting device, position the radiator in

the cooling box.
Install the bolts (3), the washers (4), the spring lock
washers (6), and the nuts (5).
Install the bolts (1) and the spring lock washers (2) to
secure the radiator to the cooling frame.
2. Connect the lower radiator hose. Torque the clamp to

10.1 – 11.3 N·m (7.4 – 8.3 lb ft).
3. Connect the upper radiator hose. Torque the clamp to

10.1 – 11.3 N·m (7.4 – 8.3 lb ft).
48083742_EN 31/07/2018
10.4 [10.400] / 5
4. Connect the overflow hose to the radiator and tighten

the hose clamp.
LEIL15WHL1288AB 4
5. Check that the coolant drain cap is tightened.

6. Fill the engine coolant system with a pre-diluted solu-
tion of CASE AKCELA ACTIFULL™ OT EXTENDED
LIFE COOLANT.
LEIL15WHL0719AB 5
7. Fill the coolant reservoir up to the FULL mark on the

reservoir.
LEIL17WHL0325AB 6
8. Close the fan door.

LEIL15WHL0698AB 7
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10.4 [10.400] / 6
9. Put timed disconnect switch in ON position.

10. Start the engine and run the engine at low idle. Run
the engine at operating temperature for approximately
five minutes to completely mix the CASE AKCELA
ACTIFULL™ OT EXTENDED LIFE COOLANT.
When the coolant is at operating temperature, stop
the engine. When engine has cooled, check the
coolant level at the tank.
LEIL15WHL0663AA 8
LEIL15WHL1782AA 9
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10.4 [10.400] / 7
Index
Engine - 10

Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Fan and drive - 414

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10.5 [10.414] / 1
Contents
Engine - 10
Fan and drive - 414
FUNCTIONAL DATA
Reverse fan control system

Dynamic description - Cooling fan system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Reverse fan control system

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
48083742_EN 31/07/2018
10.5 [10.414] / 2
Engine - Fan and drive
Reverse fan control system - Dynamic description - Cooling fan

system
Overview
The Wheel Loaders have an hydraulically driven cooling system fan. The cooling system module is located at the
rear of the vehicle. The hydraulic reservoir is located at the rear of the cab. The cooling system module includes the
radiator, the engine charge air cooler, the hydraulic oil cooler, the transmission oil cooler, the fuel cooler and the Air
Conditioning condenser. The air flow enters the cooling system module from both the right-hand and left-hand sides
of the machine as well as the top. The air flow exits out the rear of the machine.
Fan hydraulic function

The fan drive system uses oil flow from the fan pump (38) to drive the fan motor (50). Instead, the brake pump (38A)
is used to drive the brake accumulator (15). The both fan pump (38) and brake pump (38A) are mounted to the engine
near the injection pump. Brake actuation is controlled by the foot pedal in the brake valve (15). The oil required to
apply the brakes comes from accumulators which are charged by the brake valve (15).
Non-reversible fan
The standard non-reversible fan drive motor (50) is protected by an external relief valve (51) and a check valve that
allows oil to recirculate as the motor freewheels due to fan inertia when the engine stops. This protection valve (51)
is teed into the inlet and outlet of the fan drive motor (50). Oil returning from the fan drive motor (50) returns to the
hydraulic oil cooler (49) and then to the hydraulic filter (39A). An optional thermal controlled bypass valve (48) allows
the oil to bypass the cooler until the temperature reaches 44 – 53 °C (111 – 127 °F). This thermal bypass gradually
increases the flow through the cooler until all of the fan drive flow passes through the oil cooler by the time the oil
temperature reaches 63 °C (145 °F). The thermal bypass valve is included in the optional cold weather package.
Non-reversible fan circuit legend

1 – Rear axle brakes 38A – Brake pump ( 18.5 cm³) 50 – Fan motor ( 33 cm³)
2 – Front axle brakes 39 – Hydraulic reservoir 51 – External relief valve
4 – Parking brake 39A – Hydraulic oil filter assembly HC – Return from hydraulic circuit
15 – Brake valve 48 – Thermal cooler bypass HP – to hydraulic pump
38 – Fan pump ( 38.5 cm³) 49 – Hydraulic oil cooler
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10.5 [10.414] / 3
LEIL15WHL1345GB 1
48083742_EN 31/07/2018
10.5 [10.414] / 4
Fan reverser and Speed Control (optional)

The cooling fan drive system can be equipped with an optional fan reverser / speed valve (52). The optional fan
reverse/speed control valve can reverse the airflow through the radiator and coolers to clear debris. This allows for
debris to be cleared without stopping for shop maintenance. Also with the reverse fan system, the brake pump (38A)
is used to drive the brake accumulator (15). The fan pump (38) is used to drive the reversible fan motor (50). The
reversible fan motor (50) is protected by two relief valves (52A). These relief valves are part of the reverser valve
assembly (52).
Oil returning from the fan drive motor (50) returns to the hydraulic oil cooler (49) and then to the hydraulic filter (39A).
An optional thermal controlled bypass valve (48) allows the oil to bypass the cooler until the temperature reaches 44
– 53 °C (111 – 127 °F). This thermal bypass gradually increases the flow through the cooler until all of the fan drive
flow passes through the oil cooler by the time the oil temperature reaches 63 °C (145 °F). The thermal bypass valve
is included in the optional cold weather package. This reverser valve also has the ability to control the fan rotating
speed. The Universal Control Module (UCM) controls the fan reverser valve. The AUTO function can be selected
within the display. The AUTO fan operating mode is activated in the Machine settings|Fan screen menu of the display.
In addition to the Auto Fan mode selection in the display, there is a Fan reverser switch in the keypad in the cab. This
switch allows the operator to override the auto fan reverse feature. The MANUAL position of the switch is momentary
contact. In the MANUAL position the operator controls how often that the fan reverses to clear debris. In the AUTO
mode the fan speed is regulated by a proportional solenoid valve (52C) depending on system temperatures. Also
with the switch in the AUTO position, the UCM will initiate a reverse fan cycle, as long as the engine speed is greater
than 1600 RPM and the fan reverser interval time limit has been met. In the OFF mode the fan will operate at full
speed and will not reverse unless manually selected. If either MANUAL or AUTO mode is selected, the fan reversal
is disabled if hydraulic oil temperature is below 10 °C (50 °F).
LEIL16WHL2621FB 2
NOTE: all multifunction keypad buttons are momentary switches with LED indicator of current status. When the LED
is ON the corresponding function is activated.
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10.5 [10.414] / 5
1. Fan reverser
To use the fan reverser let the machine idle in NEUTRAL. Press and hold the fan reverser button and
press the throttle to high idle for a minimum of 10 s or until debris stops blowing out of the coolers.
Return the machine to idle and release the fan reverser button. Press the fan reverser function to
turn ON/OFF the automatic reversing function.
LED color: green.
→ Fan selections
Auto Fan
Fan Reverser Interval
Fan Reverser Duration
LEIL15WHL0532AA 3
When the display AUTO Fan mode is active:

• Fan speed is controlled based upon engine, transmission, air conditioning and hydraulic system temperature inputs
to the UCM to only rotate as fast as required to maintain the temperatures of the machine systems.
• Reversing is active.
• Reversing can then be Manual or Automatic depending on the operator selection of the fan control switch on the
keypad.
When the display AUTO Fan mode is not active:

• Fan speed is set to 100% for that particular model.
• Fan reversing by activating the MANUAL reverse switch on the keypad.
This reverser valve also has the ability to control the fan rotating speed. The UCM controls the fan reverser valve.
Based on a Pulse Width Modulated (PWM) electrical input from the UCM to the fan speed control solenoid valve
(52C), inlet flow will be allowed to bypass the fan motor circuit directly to the TANK port. Oil flowing through this speed
control valve (52C) will reduce and control the speed of the fan drive motor. The PWM electrical amperage signal
from the UCM to the speed control solenoid (52C) varies based on temperature inputs to the UCM from the engine
coolant, engine intake air, transmission, hydraulic circuit temperatures and status of AC switch. The fan speed control
valve (52C) is actually a variable pressure regulator. It takes a given torque output to drive the fan at a specified
speed. Changing the pressure available at the fan motor (50) causes it to rotate at different controlled speeds. The
higher the pressure setting of the proportional solenoid, the faster the fan rotates. Increased pressure is caused by a
reduced electrical signal, hence a higher PWM reading slows the fan.
As a fan reversing cycle is initiated, the UCM regulates the PWM signal to the speed control solenoid (52C). This
dampens the shocks as the blades reverse.
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Service Tip
The reversing pilot valves (52B)-1 (52B)-1 are not identical. If the pilot valves happened to be installed in the opposite
ports, the fan would operate in the wrong direction, i.e. no electrical signal would cause the motor operate in reverse.
If one of either of the pilot valves were replaced with the incorrect one, the fan would not rotate at all.
Reversible fan circuit

1 – Rear axle brakes 39 – Hydraulic reservoir 51 – External relief valve
2 – Front axle brakes 39A – Hydraulic oil filter assembly 52 – Speed control valve
4 – Parking brake 40 – Hydraulic filter HC – Return from hydraulic circuit
15 – Brake valve 48 – Thermal cooler bypass HP – to hydraulic pump
38 – Fan pump ( 38.5 cm³) 49 – Hydraulic oil cooler
38A – Brake pump ( 18.5 cm³) 50 – Fan motor ( 33 cm³)
LEIL15WHL1346GB 4
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Forward Fan Drive

Upon startup with no control input the fan motor (50) would operate in the forward direction. Power beyond oil flow
from the fan pump (38) enters the fan speed and reverser valve (52) inlet port (P). Within the reverser valve this oil is
available to the fan reverse solenoid valve (52D), speed control solenoid valve (52C), forward pilot valve (52B)-1 and
the reverse pilot valve (52B)-2. With no electrical signal, all of the flow will then pass through the forward pilot control
valve (52B)-1, out the M2 port to the fan drive motor (50). Return oil from the fan drive motor (50) then enters the
speed and reverser valve (52) through the M1 port, flows through the reverse pilot valve (52B)-2 and out the TANK
port of the reverser valve (52). The UCM controls the fan reverser valve. The AUTO mode must be selected within
the display for the fan speed and auto reverse feature to function. The display AUTO fan operating mode is activated
in the Machine settings|Fan screen menu of the display.
The reversible fan drive motor is protected by two relief valves (52A). These relief valves are in the reverser valve
assembly. They are teed into both the M1 and M2 motor ports. These relief valves limit the maximum pressure in the
motor port connections. Excessive pressure in these ports would be caused by the inertia of the fan blades driving
the motor as the engine shuts down. As the relief valve opens, the return oil from that valve is ported to the opposite
motor port.
contact with a spring return. In the MANUAL position the operator can initiate a fan reverse cycle to clear debris at
any time required. In the center AUTO position of the switch the fan speed is regulated by a proportional solenoid
valve (52C) depending on system temperatures. Also with the switch in the AUTO position, the UCM will initiate a
reverse fan cycle, as long as the engine speed is greater than 1600 RPM and the fan reverser interval time limit has
been met. In the OFF mode the fan will operate at full speed for that model and will not reverse unless manually
selected. If either MANUAL or AUTO position is selected, the fan reversal is disabled if hydraulic oil temperature is
below 10 °C (50 °F).
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LEIL15WHL1347HB 5
Fan Drive – Forward
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38 - Fan pump ( 38.5 cm³) 50 – Fan drive motor ( 33 cm³) 52B.2 – Reverse pilot control valve
39A – Hydraulic oil filter assembly 52 – Fan speed and reverser valve 52C – Fan speed control solenoid
48 – Oil cooler thermal bypass valve 52A – Fan drive pressure relief 52D – Fan reverse solenoid valve
49 - Hydraulic oil cooler 52B.1 – Forward pilot control valve
Reverse Fan Drive

The cooling fan drive system can be equipped with an optional fan reverser / speed valve (50). The optional fan
reverse/speed control valve can reverse the airflow through the radiator and coolers to clear debris. The fan drive
system uses oil flow from the fan pump (38). The brake pump (38A) is used to drive the brake accumulator (15).
Both fan pump (38) and brake pump (38A) are is mounted to the engine near the injection pump. Brake actuation is
controlled by the foot pedal in the brake valve (15).
An electrical signal can be sent from the UCM to the reverser valve (52A). With the electrical signal input the fan
(50) would operate in the reverse direction. Power beyond oil flow from the fan pump (38) enters the fan speed and
reverser valve (52) inlet port. Within the reverser this oil is available to the fan reverse solenoid valve (52D), the speed
control solenoid valve (52C), forward pilot valve (52B)-1 and the reverse pilot valve (52B)-2. With an electrical signal
to the reverser fan reverse valve (52D), the fan reverse valve sends a pilot signal to both the forward pilot control
valve (52B)-1 and the reverse pilot control valve (52B)-2. As the pilot control valves shift, all of the flow will then pass
through the reverse pilot control valve (52B)-2, out the M1 port to the fan drive motor (50). Return oil from the fan
drive motor (50) then enters the speed and reverser valve (52) through the M2 port, flows through the Forward pilot
valve (52B)-1 and out the TANK port of the reverser valve. The UCM controls the fan reverser valve. The AUTO fan
mode must be selected for the fan speed and auto reverse feature to function. The display AUTO fan operating mode
is activated in the Machine settings|Fan screen menu of the display.
The reversible fan drive motor is protected by two relief valves (52A). These relief valves are in the reverser valve
assembly. They are teed into both the M1 and M2 motor ports. These relief valves limit the maximum pressure in the
motor port connections. Excessive pressure in these ports would be caused by the inertia of the fan blades driving
the motor as the engine shuts down. As the relief valve opens, the return oil from that valve is ported to the opposite
motor port.
contact. In the MANUAL position the operator controls how often that the fan reverses to clear debris. While holding
the MANUAL REVERSE position of the switch, if either the engine or hydraulic temperature increases by more than
3 °C (37.4 °F) the fan will revert back to the forward direction. In the AUTO mode the fan speed is regulated by a
proportional solenoid valve (52C) depending on system temperatures. Also with the switch in the AUTO position, the
UCM will send a reverse signal to the reverse solenoid valve (52D) to initiate a reverse fan cycle as long as the engine
speed is greater than 1600 RPM and the fan reverser interval time limit has been met. In the OFF position the fan
will operate at full speed for that model and will not reverse unless manually selected. If either MANUAL or AUTO is
selected, the fan reversal is disabled if hydraulic oil temperature is below 10 °C (50 °F).
Service tip
The reversing pilot valves (52B)-1 (52B)-2 are not identical. If the pilot valves happened to be installed in the opposite
ports, the fan would operate in the wrong direction, i.e. no electrical signal would cause the motor operate in reverse.
If one of either of the pilot valves were replaced with the incorrect one, the fan would not rotate at all.
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LEIL15WHL1348HB 6
Fan drive — Reverse
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38 - Fan pump ( 38.5 cm³) 50 – Fan drive motor ( 33 cm³) 52B.2 – Reverse pilot control valve
39A – Hydraulic oil filter assembly 52 – Fan speed and reverser valve 52C – Fan speed control solenoid
48 – Oil cooler thermal bypass valve 52A – Fan drive pressure relief 52D – Fan reverse solenoid valve
49 - Hydraulic oil cooler 52B.1 – Forward pilot control valve
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Reverse fan control system - Remove

bucket to the ground. Stop the engine and apply the
parking brake.
LEIL15WHL1782AA 1
2. With the engine NOT running, pump the brake repeat-

edly to be sure the brake accumulators have no hy-
draulic pressure, then move the loader control lever
back and forth several times to release any hydraulic
pressure in the pilot control circuit.
4. Slowly loosen the filler cap on the hydraulic reservoir
to release the air pressure in the reservoir. Connect
a vacuum pump to the hydraulic reservoir, turn on the
pump.
LEIL15WHL0825AA 2
5. Loosen the four nuts (2), with related washers to re-

move the rear fan guard (1) from the cooling frame
door.
LEIL15WHL1290AB 3
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6. Mark the fan hub (1) and the fan blade (2).
LEIL15WHL1301AB 4
7. Loosen the six bolts (2), with related spring lock wash-
ers and washers. Remove the fan (1) from the ma-
chine.
LEIL15WHL1302AB 5
8. Remove the pin cotter (1) and the hexagonal slotted

nut (2).
9. Attach a puller to the fan hub (3) . Remove the fan hub
(3). Remove the washer (4).
LEIL15WHL1303AB 6
10. Disconnect the connector (2) from the speed sensor

(1) installed on the fan motor.
LEIL16WHL1530AB 7
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11. Disconnect the fan motor tubes (1) from the fan motor
(2).
LEIL16WHL1531AB 8
12. Loosen the two nuts (1), with related washers and
bolts to separate the fan motor (2) from the cooling
door frame.
LEIL16WHL1532AB 9
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Reverse fan control system - Install

1. Tighten the two nuts (1), with related washers and bolts
to install the fan motor (2) on the cooling door frame.
LEIL16WHL1532AB 1
2. Connect the fan motor tubes (1) to the fan motor (2).
LEIL16WHL1531AB 2
3. Connect the connector (2) to the speed sensor (1) in-

stalled on the fan drive motor.
LEIL16WHL1530AB 3
4. Place the fan hub (3) in the correct position on the fan
motor. Install the washer, the hexagonal slotted nut (2),
and the washer (4). Tighten the hexagonal slotted nut
(2) to a torque of 94 – 122 N·m (69 – 90 lb ft). Install
the pin cotter (1).
LEIL15WHL1303AB 4
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5. Tighten the six bolts (2), with related spring lock wash-
ers and washers to install the fan (1).
Apply a moderate amount of LOCTITE® 243™ and
LOCTITE® 7471™ PRIMER T™ to the rear fan six
mounting bolts (2).
LEIL15WHL1302AB 5
6. Install the four nuts (2), with related washers to install

the rear fan guard (1) on the cooling frame door.
LEIL15WHL1290AB 6
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Reverse fan control system - Test

The Wheel Loaders can be equipped with reversible
cooling fans. This reversible option can be set to au-
tomatically trigger the clearing of debris from the cool-
ing system elements aproximately every ½ hour of op-
eration. This feature also allows the operator to clear
debris from the cooling system elements as required
at any time by activating a reversing switch in the cab.
The auto reverse feature only activates at elevated en-
gine speed. In the auto mode, machine operating con-
ditions also control the fan speed. Adjusting the pres-
sure delivered to the hydraulic drive motor changes the
fan speed. In auto mode, the fan speed varies from a
minimum speed up to the 100% speed value entered
into the display memory for that model.
Lower fan speeds allow the machine to warm up faster
in cold conditions. Reduced speed also lowers the ma-
chine noise level as well as reduces the power required
to drive the fan. This can contribute to improved fuel
economy.
Use the following procedures to select the Fan Test pro-
cedure.
1. Park the machine on firm, level surface. Lower the
bucket to the ground. Turn the engine OFF. Apply the
parking brake.
2. The LCD multifunction display located above the multi-
function keypad is on and displays the main menu.
3. Press the corresponding key to access the Machine
Service screen.
LEIL16WHL2335AB 1
4. Use up or down arrow to select the Calibration Settings

item. Press the enter/confirm key to access the selec-
tion screen.
LEIL16WHL0874AA 2
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5. Use up or down arrow to select the Fan Test item.
LEIL16WHL0899AA 3
6. Use left or right arrow to select the Fan speed %. Press

the enter/confirm key to start the Fan Test.
LEIL16WHL0899AA 4
For 1021G, the fan speed with engine at full throttle

should be within the following range:
• Maximum fan speed at 100%: 1040 – 1090 RPM
For 1121G, the fan speed with engine at full throttle
should be within the following range:
LEIL16WHL0901AA 5
7. Press the enter/confirm key to terminate the test and

return to the main menu.
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Index
Engine - 10
Fan and drive - 414

Reverse fan control system - Dynamic description - Cooling fan system . . . . . . . . . . . . . . . . . . . . . . . 3
Reverse fan control system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Reverse fan control system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reverse fan control system - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Engine - 10
Aftercooler - 310

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Contents
Engine - 10
Aftercooler - 310
SERVICE
Aftercooler
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Engine - Aftercooler
Aftercooler - Service instruction

Pressure test
bucket to the ground. Put the transmission in neutral,
apply the parking brake. Turn off the engine.
2. Raise the engine hood. Install a pressure gauge into
the port on the compressor housing outlet elbow. Install
another pressure gauge into the intake manifold port.
Visual inspection
1. Have an assistant to start and run the engine at
2000 RPM. Record pressure readings for both gauges.
If the pressure difference is greater than 0.06 bar
(0.87 psi), inspect the cooler components for damaged
or missing parts.
2. Inspect the turbocharger flex hose for leaks or holes
and insure that the clamps are tightened.
LEIL17WHL0319AB 1
3. Inspect the flexible hose of the turbocharger top air

cooler outlet for leaks or holes and ensure that the
clamps are tightened.
LEIL17WHL0321AB 2
4. Inspect the flexible hose of the intercooler top tube for

leaks or holes and ensure that the clamps are tight-
ened.
LEIL17WHL0320AB 3
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5. Inspect the intake manifold flexible hose for leaks or

holes and insure that the clamps are tightened.
LEIL17WHL0322AB 4
6. Visually inspect the top of air cooler for damage or

leaks.
NOTE: if the leak source has not been located, remove and
test the air cooler. Refer to Aftercooler - Test (10.310).
LEIL15WHL1285AA 5
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Aftercooler - Remove
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
W0398A
1. Lower bucket to the ground and install transport/service

link into the locked position.
LEIL15WHL1782AA 1
2. Locate the timed disconnect switch (1) and the hood

raise switch (2) in the battery box.
Raise the hood and put the timed disconnect switch (1)
in the OFF position.
LEIL15WHL0663AA 2

the radiator cap and coolant drain plug (arrow) to drain
the engine coolant. Reinstall the drain plug and radiator
cap after the coolant has drained.
ume.
LEIL15WHL0719AB 3
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4. Loosen the V-band clamp (1). Remove the O-ring and

the air intake elbow (2) of the turbocharger.
Loosen the clamps (3). Remove the air intake tube (4)
of the turbocharger.
Cover the turbocharger inlet to prevent debris entry.
5. Remove the air intake tube (4) through the engine wall.
LEIL17WHL0260AB 4
6. Loosen the clamps (3) from the intercooler tube (4).

7. Remove the intercooler tube (4) through the engine
wall.
LEIL17WHL0259AB 5
8. Remove the two nuts (1), the two washers (2) and the
U-bolt (3) from bottom support plate (4) of the inter-
cooler mounting frame.
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9. Remove the two bolts (1), the washers (2), and the
springs (3) from the intercooler mounting plate (4).
Remove the two bolts (5) and the washers (6) from the
intercooler mounting plate (4).
Remove the air cooler from frame.
LEIL15WHL1281BB-01 7
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Aftercooler - Install
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
W0398A
1. Place the air cooler into position on the intercooler

mounting plate (4).
Install the two bolts (1) with related washers (2) and
springs (3).
Install the two bolts (5) with related washers (6).
LEIL15WHL1281BB-01 1
2. Install the U-bolt (3), the washers (2) and the nuts (1) on
the bottom support plate (4) of the intercooler mounting
frame.
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3. Install the V-band clamp (1) and a new O-ring to con-

nect the air intake elbow (2) to the turbocharger.
Tighten the V-band clamp (1) to a torque of 6.8 N·m
(5.02 lb ft).
Tighten the hose clamps (3) to a torque of 10.2 –
11.3 N·m (90 – 100 lb in) to install the air intake tube
(4) of the turbocharger.
4. Secure the air intake tube (4) to the air cooler tightening
the hose clamps (3) to 10.2 – 11.3 N·m (90 – 100 lb in).
LEIL17WHL0260AB 3
5. Tighten the hose clamps (3) to a torque of 10.2 –

11.3 N·m (90 – 100 lb in) to install the air intercooler
inlet tube (4) to the elbow hose (2).
6. Secure the intercooler inlet tube (4) to the air cooler
tightening the clamps (3) to 10.2 – 11.3 N·m (90 –
100 lb in).
LEIL17WHL0259AB 4

Turn the timed disconnect switch to the ON position.
8. Fill the cooling system with required amount.
LEIL15WHL0663AA 5
Pressure test
1. Install a pressure gauge to the port on the turbo com-
pressor outlet elbow. Install another pressure gauge
into the intake manifold port.
Have an assistant to start and run the engine at
2000 RPM.
Record pressure readings for both gauges. confirm
that the pressure difference is less than 0.06 bar
(0.87 psi).
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Aftercooler - Test
1. Check the core for leaks by closing off the outlet
tube (1) and attaching regulated air pressure 550 kPa
(80 psi) to the inlet tube (2). Submerge the aftercooler
in water and check for air leakage.
2. If leakage is detected replace the aftercooler.
LEIL15WHL1549AB 1
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Index
Engine - 10
Aftercooler - 310
Aftercooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Aftercooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Aftercooler - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Aftercooler - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Engine - 10
Engine lubrication system - 304

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Contents
Engine - 10
SERVICE
Crankcase ventilation system

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - Engine lubrication system
Crankcase ventilation system - Remove

1. Locate the crankcase breather filter under the hood on
the engine, on the left-hand side of the machine.
2. Lower bucket to the ground and install transport/service
link into the locked position.
LEIL15WHL1782AA 1

the switch (2) in the battery box.
Raise the engine hood and put the timed disconnect
LEIL15WHL0663AA 2

LEIL15WHL0658AB 3
5. Remove the side body panel (2) from the left-hand side
of the engine compartment moving the latch (1).
LEIL15WHL0659AB 4
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6. Locate the crankcase breather filter on the left-hand

side of the machine.
LEIL17WHL0323AB 5
7. Release the clips securing the crankcase breather

housing cover.
LEIL17WHL0324AB 6
8. Remove the filter element and replace with new ele-

ment.
NOTE: wear personal protection when using compressed
air.
LEIL15WHL1799AA 7
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Crankcase ventilation system - Install

1. Install the new filter element into the filter housing.
Make sure that the filter is correctly seated.
RCPH11WHL233AAH 1
2. Secure the crankcase breather housing cover with the

clips.
LEIL17WHL0324AB 2
3. Install the side body panel (2) on the left-hand side of

machine and secure the latch (1) (if equipped).
LEIL15WHL0659AB 3
4. Close the wide rear fender panel compartment or stan-

dard fender wheel well if equipped.
LEIL15WHL0658AB 4
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LEIL15WHL0663AA 5
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Index
Engine - 10

Crankcase ventilation system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Crankcase ventilation system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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CNH Industrial Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122
SERVICE - Technical Publications & Tools
PRINTED IN ITALY
© 2018 CNH Industrial Italia S.p.A. All rights reserved.
No part of the text or illustrations of this publication may be reproduced.
CNH Industrial Italia S.p.A reserves the right to make improvements in design and changes in specifications at
any time without notice and without incurring any obligation to install them on units previously sold. Specifications,
descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject
to change without notice.
Availability of some models and equipment builds varies according to the country in which the equipment is being
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48083742_EN 31/07/2018
EN
SERVICE MANUAL
Transmission

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21
Contents
Transmission - 21
[21.113] Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
[21.135] Powershift transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
[21.105] Powershift transmission hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3
[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4
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21
Transmission - 21
Powershift transmission - 113

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Contents
Transmission - 21
TECHNICAL DATA
Powershift transmission
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General specification Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General specification Clutch Plate Thicknesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DIAGNOSTIC
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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Transmission - Powershift transmission
Powershift transmission - Torque

Solenoid Housing Cover 7.5 N·m (66 lb in)
Solenoid Retainer Plate 5.5 N·m (49 lb in)
Valve Duct Plate 9.5 N·m (84 lb in)
Control Valve Test Plugs 6 N·m (53 lb in)
Transmission Housing Duct Plate (M10X1) 6 N·m (53 lb in)
Transmission Housing Duct Plate (M14X15) 40 N·m (30 lb ft)
Transmission Housing Duct Plate (M26X15) 80 N·m (59 lb ft)
Transmission Housing Duct Plate (M8/10.9) 23 N·m (17 lb ft)
Control Valve Mounting 12 N·m (106 lb in)
Transmission Pump Rotor Cover (M6/8.8) 9.5 N·m (84 lb in)
Transmission Pump Rotor Cover ((M8/8.8) 23 N·m (17 lb ft)
Hydraulic Pump Mounting Flange 125 N·m (92 lb ft)
K3/K4 Bearing Cover 46 N·m (34 lb ft)
KR/K2 Bearing Cover 46 N·m (34 lb ft)
Output Flange 46 N·m (34 lb ft)
Parking Brake Disc 125 N·m (92 lb ft)
Transmission Pump Retaining Flange 79 N·m (58 lb ft)
Input Shaft Clamping Plate 32 N·m (24 lb ft)
Front Input Shaft Bearing Cover 46 N·m (34 lb ft)
Converter Outlet Temperature Sensor 25 N·m (18 lb ft)
Converter Back Pressure Spring Plug 130 N·m (96 lb ft)
Converter Bell (M8/10.9) 34 N·m (25 lb ft)
Converter Bell (M12/10.9) 115 N·m (85 lb ft)
Converter Flex Plate 46 N·m (34 lb ft)
Coarse Filter (Suction Screen) Cover 23 N·m (17 lb ft)
Engine Speed Sensor 30 N·m (22 lb ft)
Output Speed Sensor 23 N·m (17 lb ft)
Transmission Breather 12 N·m (106 lb in)
Powershift transmission - General specification Pressures

Main pressure and clutch pressure 16 – 18 bar ( 232 – 261 psi)
Converter in pressure 8.5 bar (123 psi)
Pressure reduction for solenoids 9 bar (131 psi)
Converter out pressure 5 bar (73 psi) minimum
Lubrication pressure 0.2 – 1.2 bar ( 3 – 18 psi)
Minimum pump output (at 2000 rpm) 115 l/min (30 US gpm)
Transmission oil operating temperature 80 – 120 °C ( 176 – 248 °F)
Clutch KV 16 – 18 bar ( 232 – 261 psi)
Clutch KR 16 – 18 bar ( 232 – 261 psi)
Clutch K1 16 – 18 bar ( 232 – 261 psi)
Clutch K2 16 – 18 bar ( 232 – 261 psi)
Clutch K3 16 – 18 bar ( 232 – 261 psi)
Clutch K4 16 – 18 bar ( 232 – 261 psi)
Powershift transmission - General specification Clutch Plate

Thicknesses
K4 Clutch 2.2 – 2.4 mm (0.087 – 0.094 in)
K3 Clutch 2.2 – 2.4 mm (0.087 – 0.094 in)
K2 Clutch 2.2 – 2.4 mm (0.087 – 0.094 in)
KV Clutch 2.8 – 3.0 mm (0.110 – 0.118 in)
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K1 Clutch 2.2 – 2.4 mm (0.087 – 0.094 in)

KR Clutch 2.8 – 3.0 mm (0.110 – 0.118 in)
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Powershift transmission - Remove

Prior operation:
Ladder - Remove (90.118), Cab - Remove (90.150), Oil reservoir - Remove (35.300), Variable displacement
pump - Remove (35.106), Drive shaft - Remove - Center Drive Shaft (23.314), Drive shaft - Remove - Rear Drive
Shaft (23.314)
1. Drain the transmission.

2. Disconnect the transmission fill tube (1) from the trans-
mission.
NOTE: splash back shield located inside transmission fill
tube.
LEIL15WHL1007AB 1
3. Disconnect the park brake caliper line (1).
LEIL15WHL1008AB 2
4. Disconnect the transmission-to-cooler oil return line (1).

5. Disconnect the output speed sensor electrical connec-
tor (2).
LEIL15WHL1009AB 3
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6. Disconnect the redundant brake switch electrical con-

nectors (1), (2).
LEIL15WHL1010AB 4
7. Disconnect the valve body electrical connector (1).

8. Disconnect the torque converter output temperature
sender electrical connector (2).
9. Disconnect the transmission-to-cooler oil line (3).
LEIL15WHL1011AB 5
10. Disconnect the engine speed sensor electrical con-

nector (1).
LEIL15WHL1012AB 6
11. Disconnect the intermediate speed sensor electrical

connector (1).
12. Disconnect the turbine speed sensor electrical con-
nector (2).
LEIL15WHL1013AB 7
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13. Remove the wire harness P-clamps (2). Position the

wire harness (1) away from the transmission.
LEIL15WHL1014AB 8
14. Remove the transmission-to-transmission oil filter

lines (1).
LEIL15WHL1015AB 9
15. Attach lifting equipment to the transmission. Support

the transmission.
LEIL15WHL1016AA 10
16. Remove two transmission mounting bolts (1).
LEIL15WHL1017AB 11
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17. Remove the converter housing cover plate (1).
LEIL15WHL1018AB 12
18. Remove the flex plate bolts (1).
LEIL15WHL1019AB 13

19. Remove the cover (1). Remove the plug (2) to gain
access to the flywheel.
front) until one of the torque converter bolts is visible
through the hole, and remove the bolt. Continue turn-
ing the flywheel (clockwise) in 30° increments to ex-
pose each bolt, until all the twelve bolts are removed.
LEIL15WHL1502AB 14
21. Lift and support the engine and transmission approxi-

mately three inches.
LEIL15WHL1016AA 15
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22. Remove the bell housing bolts (1).
LEIL15WHL1020AB 16
23. Remove the transmission.
LEIL15WHL1021AA 17
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Powershift transmission - Disassemble

1. Attach the transmission to a suitable work stand.
2. Remove the plug (1) and drain the transmission oil.
Loosen the hexagon bolts (2) and remove the cover
(3).
LEIL15WHL1211AB 1
3. Wait that the oil drain from the hole (1) and remove the
coarse filter assembly (2).
RCPH11WHL221BAU 2
4. Remove all oil lines, the complete gear shift system,

and the duct plate.
RCPH11WHL220BAU 3
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5. Install the eyebolts 380001282 and using a suitable lift-

ing device to remove the torque converter and the flex-
plate.
RAPH12WEL0453AA 4
6. Remove the bolts and install two threaded forcing

screws into the holes and force the cover off.
RCPH11WHL208BAU 5
7. Install the CAS2268 puller and remove the oil supply

flange out of the converter bell.
RCPH11WHL209BAU 6
8. Remove the converter safety valve (1) if required.

NOTE: the converter safety valve is fixed with a slotted pin
(2).
RAPH12WEL0454AA 7
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9. Loosen the bolt connection. Install the eyebolts

380001282 and using a suitable lifting device with a
pry bar 381000059 to separate the converter bell from
the transmission.
RCPH11WHL210BAU 8
10. Remove the rectangle ring.
RAPH12WEL0456AA 9
11. Press the input shaft out of the spur gear bearing.
Remove the release bearing inner ring and the spur
gear.
RCPH11WHL212BAU 10
12. Press off the bearing inner ring from the spur gear.
RAPH12WEL0458AA 11
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13. Remove the converter back – up valve.
RAPH12WEL0459AA 12
14. Remove the inductive sensor for engine speed.
LEIL15WHL0994AB 13
Input shaft
15. Pull the complete input shaft out of the transmission
housing and the pump.
RCPH11WHL223BAU 14
16. Remove the rectangular ring.
RCPH11WHL225BAU 15
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17. Remove the spur gear from the shaft and remove the
snap ring from the shaft.
RCPH11WHL227BAU 16
18. Using the tool 380001289, pull off the bearing inner
ring from the spur gear.
RCPH11WHL224BAU 17
19. Secure the input shaft in a suitable clamping vice de-

vice. Loosen the cap screw and remove the clamping
plate.
RCPH11WHL226BAU 18
20. Using a three-armed puller, remove the bearing inner

ring and the driver from the shaft. Watch for shims
when removed.
NOTE: put a cap over the bolt hole before installing the
puller to protect the threads in the shaft. Support the puller
on the face-input shaft. Pay attention to the released shim.
RCPH11WHL228BAU 19
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21. Separate the bearing inner ring from the driver. Watch
for shims.
NOTE: if necessary snap out the V-rings.
RCPH11WHL229BAU 20
Transmission pump
22. Loosen the cam and the hexagon bolt (depending on
version) and separate the pump flange from the hous-
ing.
RAPH12WEL0460AA 21
23. Loosen the cap bolts. Install the CAS2268 puller on

the transmission pump and fasten to the transmission
pump.
NOTE: extracting is supported by slightly tapping onto the
transmission housing.
RAPH12WEL0461AA 22
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Remove bearing outer ring - K2, K3, and K4 power take-off

24. Using an internal extractor, pull out the bearing outer
ring from the bore.
RAPH12WEL0462AA 23
25. Loosen the cap bolts. Take off the pump cover and
remove the rotor set. Assemble the rotor set with the
chamfer on the tooth tip showing downward and in-
stall the housing cover again. Torque (M8) to 23 N·m
(17 lb ft), and torque (M6) to 9.5 N·m (84 lb in).
NOTE: if marks due to running-in are found on the pump
housing or the housing cover, the complete pump is to be
replaced
RAPH12WEL0463AA 24
Layshaft
26. Remove the sealing cover and loosen the hexagon
bolt.
RCPH11WHL239BAU 25
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27. Use a slide hammer and remove the idler shaft from
the housing bore and the layshaft bearings.
RCPH11WHL240BAU 26
Removal of inductive and speed sensors

28. Remove the inductive sensor for turbine speed (1) and
the inductive sensor for intermediate gear train speed
(2).
RCPH11WHL242BAU 27
29. Remove the output speed sensor (3).
RCPH11WHL244BAU 28
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Parking brake
30. On the transmission rear-side, unscrew the screw
cap.
NOTE: for work on the brake system, observe the instruc-
tions and specifications of the brake manufacturer.
RAPH12WEL0469AA 29
31. Loosen the counternut and unscrew the adjusting

screw in a clockwise direction until the brake disc is
released.
RAPH12WEL0470AA 30
32. Loosen the cap bolts and separate the complete

brake from the transmission housing. Remove the
lock plate. Loosen the hexagon bolts and separate
the output flange/brake disc from output shaft.
RAPH12WEL0471AA 31
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Removal of the clutches and layshaft

33. Loosen the hexagon bolts and expel the bearing cover
KV/K1 with a striker from the housing bore. Repeat
step to remove the bearing cover KR/K2 (arrow).
NOTE: mark the installation location of the bearing cover.
RAPH12WEL0472AA 32
34. Pull out the bearing cover K4/K3 with the forcing
screws from the housing bore.
RAPH12WEL0473AA 33
35. Using a three-armed puller, separate the bearing inner

ring from the bearing cover K4/K3.
RAPH12WEL0474AA 34
36. Loosen the bolt connection. Separate the housing

cover from the housing by equally tightening both forc-
ing screws (1) and (2) as well as the threaded spindle
(3).
RAPH12WEL0475AA 35
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37. Remove the output shaft from the output gear.
RAPH12WEL0476AA 36
38. Loosen the hexagon bolts. Remove the oil baffle. In-
stall the eyebolts 380001282 and using a suitable lift-
ing device to lift the output gear out of the transmission
housing.
RAPH12WEL0477AA 37
39. Using a three-armed puller, remove the bearing inner

ring from the output gear.
RAPH12WEL0478AA 38
40. Take the roller bearing out of the housing bore and
remove the oil baffle.
RAPH12WEL0479AA 39
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41. When removing multi-disc clutches, the removal order

of the single clutches must follow this sequence:
K4/K3 to → KR/K2 to → KV/K1.
NOTE: for removal of clutch K4/K3, lift the clutch KR/K2
slight and move it in direction of the noted arrow.
RAPH12WEL0671AA 40
42. The clutches K3/K4 (1), K2/KR (2) , and K1/KV (3) are
shown after removal.
RAPH12WEL0481AA 41
43. Remove the layshaft gear.
RAPH12WEL0482AA 42
Removal of the 2nd power take - off

44. Snap out the retaining ring and remove the shims.
RAPH12WEL0483AA 43
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45. Lift the output shaft with the pry bar set 381000059
until the bearing outer ring is released.
RCPH11WHL271BAU 44
46. Take the output shaft out of the housing.
RCPH11WHL268BAU 45
47. Using an internal extractor, pull the bearing outer ring

out of the housing bore.
RAPH12WEL0486AA 46
48. Using the tool 381000084, pull off the bearing inner
ring from the shaft. Press the opposite bearing inner
ring from the shaft.
NOTE: The shaft and the gear cannot be separated (shrink
fit).
NOTE: To disassemble the clutches K3/K4, KR/K2, KV/K1,
refer to Clutch - Disassemble (21.155).
RAPH12WEL0487AA 47
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Powershift transmission - Assemble

CAUTION
Hot area!
Use care when working near hot components. Wear protective gloves.
Failure to comply could result in minor or moderate injury.
C0034A
CAUTION
Eye injury hazard!
Wear protective goggles when using compressed air.
C0035A
Prior operation:
Powershift transmission - Disassemble (21.113)
Transmission assembly
1. This figure shows the installation view order of the sin-
gle power takes-off as follows:
1. 1st power take-off.
2. 2nd power take-off.
LEIL15WHL0995BB 1
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2nd power take-off

2. Cool the shaft to about 80 °C (176 °F), and heat the
gear to approximately 120 °C (248 °F) and install on the
shaft.
LEIL15WHL1022AA 2
3. Press the bearing inner ring in place. Press the oppo-

site bearing inner ring in place.
LEIL15WHL1023AA 3
4. Insert the bearing outer ring into the housing bore.
RAPH12WEL0337AA 4
5. Position the preassembled power take-off shaft in the

housing and insert the bearing outer ring.
LEIL15WHL0999AA 5
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6. Adjust the axial play — power take-off bearing to a max-

imum of 10 mm, to be adjusted with shim(s) and/or re-
taining ring.
RAPH12WEL0483AA 6
7. Rotate the transmission housing by 180°. Insert the

sealing disc with the concave side facng downwards
into the housing bore. Wet the contact face with
LOCTITE® 262™.
NOTE: do not damage the centric orifice bore ø 0.88 mm
when installing the sealing disc.
RAPH12WEL0670AA 7
Installation of layshaft gear, multi-disc clutches and output gear

8. The layshaft gear bearing single components shown
are: Bearing inner ring (1), Ring (2), and Layshaft gear
(3).
RAPH12WEL0338AA 8
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9. Position the layshaft gear assembly in the housing.

NOTE: Only when the clutches are installed, the idler shaft
can be mounted.
RAPH12WEL0339AA 9
10. Insert the bearing outer rings KV/K1, KR/K2 and

K3/K4 into the housing bores.
RAPH12WEL0340AA 10
11. Install the eyebolts 380001282 and position the clutch

KV/K1 with a lifting tackle.
RAPH12WEL0341AA 11
12. Install the eyebolts 380001282 and position the clutch

KR/K2.
RAPH12WEL0342AA 12
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13. Check the installation position of the layshaft gear and

correct as needed.
RAPH12WEL0343AA 13
14. Fasten the spur gear K3 with a proper fixture and eye-
bolt axially.
NOTE: the fastened spur gear prevents the clutch discs
from dislocating when the clutch is lifted in.
LEIL15WHL1024AB 14
15. Lift the clutch KR/K2 slightly, and move it in the direc-
tion of the shown arrow and position the clutch K3/K4.
Then remove the fixture.
RAPH12WEL0671AA 15
16. Insert the bearing outer ring into the housing bore.
RAPH12WEL0345AA 16
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17. Heat the bearing inner ring and install it.

NOTE: use safety gloves as the unit may be hot.
NOTE: observe that the installation position - collar (arrow)
faces toward the spur gear. Install the bearing inner ring
after cooling down and then press in place.
RAPH12WEL0346AA 17
18. Position the oil baffle.
RAPH12WEL0347AA 18
19. Connect the eyebolts 380001282 and install the out-

put gear with a lifting tackle.
RAPH12WEL0348AA 19
20. Position the upper oil baffle, and install the wash-
ers. Fasten both plates with LOCTITE® 243™ treated
hexagon bolts. Torque to 23 N·m (17 lb ft).
RAPH12WEL0349AA 20
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Pre-assembly and mounting of the housing cover

Depending on the transmission version, differences re-
garding single components and their installation posi-
tion are possible.
21. Install the sealing cover. Wet the sealing surface with
LOCTITE® 262™.
RAPH12WEL0350AA 21
22. Insert the O-ring into the annular groove of the cover
and fasten the cover using hexagon bolts. Wet the
threads of the hexagon bolts with LOCTITE® 574™.
Torque to 23 N·m (17 lb ft).
NOTE: observe the installation position of the cover.
RAPH12WEL0351AA 22
23. Wet the mounting face with sealing compound

LOCTITE® 574™. Using a lifting tackle, place the
housing cover on the transmission housing.
RAPH12WEL0352AA 23
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24. Install the cylindrical pins (1) and (2) and the slotted
pin (3). Fasten the housing cover with the hexagon
and the cap bolts. Torque to 46 N·m (34 lb ft).
RAPH12WEL0353AA 24
Adjust the bearing preload of the clutch K4/K3 = 0.0 – 0.05 mm

25. For installation of a new bearing cover (1) and (3), both
finished bores (2) have to be sealed with a plug (4).
The finished bores (1) and (3) are located opposite to
each other.
RAPH12WEL0672AA 25
RAPH12WEL0673AA 26
26. Housing dimension: Press equally on the bearing in-

ner ring and determine the Housing Dimension I from
the mounting face to the bearing inner ring. Then re-
move the bearing inner ring. (Dimension I e.g. ...
43.65 mm (1.7 in)).
NOTE: take several measuring points and determine the
mean value.
RAPH12WEL0674AA 27
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27. Cover dimension: Determine dimension II from the

mounting face until contact/bearing inner ring. (Di-
mension II e.g. ... 42.12 mm (1.7 in)).
RAPH12WEL0675AA 28
Dimension I 43.65 mm (1.7 in)

Dimension II — 42.12 mm (1.7 in)
Difference = 1.53 mm (0.1 in)
Bearing + 0.02 mm (0.0 in)
preload...e.g.
Resulting shim(s) s = 1.55 mm (0.1 in)
28. Put on the shim.
RAPH12WEL0354AA 29
29. Heat the bearing inner ring. Install the bearing inner
ring and press down after cooling.
NOTICE: hot. Wear protective gloves.
RAPH12WEL0355AA 30
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30. Grease the rectangular rings and centrally align them.
RAPH12WEL0356AA 31
31. Grease and install the O-ring. Heat the inner diameter
of the bearing cover (bearing seat) to 120 °C (248 °F)
with a blower, an oven or a induction heater.
NOTE: do not use a torch!
RAPH12WEL0357AA 32
32. Install two adjusting screws 381000131. Assemble

the bearing cover and evenly tighten it with hexagon
bolts. Torque to 46 N·m (34 lb ft).
NOTE: Observe the radial installation position.
RAPH12WEL0358AA 33
33. Check the function of both the clutches with com-

pressed air. Replace the rectangular rings if needed.
NOTE: In case of a decisive pressure loss, a possible
cause might be a breakage of one or several of the rect-
angular rings.
RAPH12WEL0359AA 34
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Adjust the bearing preload of the clutch KR/K2 = 0.0 – 0.05 mm

34. For installation of a new bearing cover (1) and (3), both
of the finished bores (2) have to be sealed with a plug
(4). Finished bores are located opposite to each other.
LEIL15WHL1025AB 35
LEIL15WHL1026AB 36
35. Install the two studs. Torque to 13 N·m (115 lb in).
RAPH12WEL0362AA 37
36. Install the bearing outer ring.

NOTICE: pay attention to exact contact.
RAPH12WEL0363AA 38
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37. Housing dimension: Determine dimension I from the

bearing outer ring to the mounting face. (Dimension I
e.g.... 16.13 mm (0.6 in)).
LEIL15WHL1027AA 39

contact/bearing outer ring to the mounting face. (Di-
mension II e.g. ... 17.75 mm (0.7 in)).
LEIL15WHL1028AA 40
Example:
Dimension II 17.75 mm (0.7 in)
Dimension I — 16.13 mm (0.6 in)
Bearing + 0.03 mm (0 in)
preload...e.g.
39. Place the shim with assembly grease into the cover.
Install the O-ring.
LEIL15WHL1029AA 41
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40. Grease and centrally align the rectangular rings.
LEIL15WHL1030AB 42
41. Pull the bearing cover evenly until contact is made.

RAPH12WEL0368AA 43
42. With compressed air, check the function of both of the

clutches. Replace the rectangular rings if needed.
NOTE: in case of a decisive pressure loss, a possible
cause might be a breakage of one or several of the rect-
angular rings.
LEIL15WHL1031AA 44
Adjusting the bearing preload of the clutch KV/K1 = 0.0 – 0.05 mm

43. For installation of a new bearing cover (1), both of the
finished bores (2) have to be sealed with a plug (4).
LEIL15WHL1032AB 45
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44. Put the bearing outer ring over the bearing inner ring.
45. Housing dimension: Press evenly on the bearing
outer ring and determine Dimension I from the mount-
ing face to the bearing outer ring. (Dimension I e.g.
... 52.67 mm (2.1 in)).
NOTE: take several measuring points and determine the
mean value.
RAPH12WEL0371AA 46
46. Put the ring with the chamfer facing downwards into
the bearing cover.
LEIL15WHL1033AA 47

mounting face to the ring. (Dimension II e.g. ...
50.75 mm (2.0 in)).
LEIL15WHL1034AA 48
Example:
Bearing preload + 0.03 mm (0.0 in)
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48. Put in the shim.
LEIL15WHL1035AA 49
49. Install the bearing outer ring (1). Assembly the O-ring
(2).
LEIL15WHL1036AB 50
50. Grease and centrally align the rectangular rings.
LEIL15WHL1037AB 51
51. Heat the bearing bore to 120 °C (248 °F) with a heat
gun, an oven or a induction heater.
LEIL15WHL1038AA 52
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52. Install the two adjusting screws 381000131 (1). Place

the bearing cover (2) over the adjusting bolts and fas-
ten with the hexagon bolts.
NOTE: observe the radial installation position.
LEIL15WHL1039AB 53
53. With compressed air, check the function of both of the

clutches. Replace the rectangular rings if needed.
NOTE: In case of a decisive pressure loss, a possible
cause might be the breakage of one or several of the
rectangular rings.
LEIL15WHL1040AA 54
Installation of the output shaft

54. Heat the inner diameter of the output gear to 120 °C
(248 °F) with a heat gun, an oven or a induction
heater.
LEIL15WHL1041AA 55
55. Insert the output shaft with the long gearing facing
downward.
LEIL15WHL1042AA 56
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56. Rotate the transmission housing into a ( 90°) vertical

position. Temporarily attach the output shaft axially to
the converter side with a mounting tool.
RAPH12WEL0382AA 57
57. Rotate the transmission housing 90° back.
RAPH12WEL0383AA 58
Adjust the axial play of the output bearing = 0.3 – 0.5 mm

58. Determine Dimension I from the plane face-housing
to the end face-output shaft. (Dimension I e.g. ...
66.90 mm (2.6 in).
LEIL15WHL1043AA 59
59. Measure Dimension II from the plane face-housing to

the contact of the face-ball bearing. (Dimension II e.g.
... 64.20 mm (2.5 in)).
LEIL15WHL1044AA 60
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Example:
Required axial play — 0.40 mm (0.0 in)
(0.3...0.5mm) e.g.
Resulting shim s = 2.30 mm (0.1 in).
60. Install the shim.
LEIL15WHL1045AA 61
61. Install the ball bearing.
LEIL15WHL1046AA 62
62. With the output flange, pull the ball bearing until con-
tact is made. Then remove the output flange.
LEIL15WHL1047AA 63
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63. Fasten the ball bearing with a retaining ring.
LEIL15WHL1048AA 64
64. Remove the converter-side mounting tool. Install the

shaft seal (1) with the sealing lip facing the oil sump.
Use a mounting tool or equivalent, to set the shaft
seal.
NOTE: depending on the version, different shaft seals can
be used.
NOTE: if the outer diameter is rubber coated. Wet it with
spirits.
NOTE: if the outer diameter is metallic, wet it with sealing
compound LOCTITE® 574™.
LEIL15WHL1049AB 65
Output flange-version with parking brake

65. Press on the screen sheet.
NOTE: the installation position of the screen sheet is iden-
tical with the output flange-standard version.
LEIL15WHL1050AB 66
66. Install the output flange-brake.

NOTE: installation of the output flange and the adjustment
of the gap size is identical with the standard version.
LEIL15WHL1051AA 67
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67. To mount the brake, remove the bolt cap and loosen
the locking nut. Unbolt the adjusting bolt counterclock-
wise until > 13.0 mm (0.5 in) of the brake disc shim
appears.
NOTE: for working on the brake system, the instructions
and the specifications of the brake manufacturer are
mandatory!
LEIL15WHL1052AB 68
68. Position the brake and fasten with the cap bolts.
Torque to 125 N·m (92.2 lb ft).
LEIL15WHL1171AA 69
69. Adjust the nominal clearance = 2.0 mm (0.1 in). Make

the pressure connection and apply the required re-
lease pressure = 150 bar (2175 psi) to the brake (the
cup spring set is preloaded). Fasten the adjusting bolt
in a clockwise direction until both of the brake lining
carriers contact the brake disc.
NOTE: the turning of the adjusting screw is not possible or
admissible any more without a higher application of force.
70. Then turn back the adjusting bolt counterclockwise by
4/5 turns. This turn equals the nominal clearance of
2.0 mm (0.1 in).
LEIL15WHL1172AA 70
71. Keep the adjusting screw positioned and secure it with

a lock nut.
LEIL15WHL1173AA 71
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72. Put a new O-ring into the bolt cap and grease it. Install
the bolt cap.
LEIL15WHL1174AA 72
Output flange (converter side)

73. With a mounting tool or equivalent, install the shaft
seal with the sealing lip facing the oil sump.
NOTE: depending on the version, different shaft seals can
be used.
NOTE: if the outer diameter is rubber-coated: wet with spir-
its.
NOTE: if the outer diameter is metallic: wet with sealing
compound LOCTITE® 574™.
LEIL15WHL1175AB 73
74. Press the screen sheet over the collar of the output
flange.
NOTE: observe the installation position.
LEIL15WHL1176AB 74
75. The image exhibits the screen sheet (1), and the out-
put flange (2).
LEIL15WHL1177AB 75
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76. Install the output flange until contact is made.

NOTE: securing of the output flange and the gap size set-
ting is identical with the output flange installation at the
transmission rear side.
LEIL15WHL1178AA 76
Installation of the idler shaft

77. Centrically align the layshaft gear and the single com-
ponents. Heat the layshaft gear to 120 °C (248 °F)
with a heat gun, an oven or a induction heater.
NOTE: Do not use a torch!
LEIL15WHL1179AA 77
78. Install the adjusting screw 381000131 .
LEIL15WHL1180AA 78
79. Install the idler shaft.
LEIL15WHL1181AA 79
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80. Remove the adjusting screw and fasten the axle with
a hexagon bolt. Torque to 46 N·m (40 lb ft).
NOTE: wet the thread of the hexagon bolt with LOCTITE®
243™.
LEIL15WHL1182AA 80
81. Insert the sealing covers with the concave side facing
downward, flush to the housing surface. Wet the con-
tact face with LOCTITE® 262™.
LEIL15WHL1183AB 81
Transmission pump
82. Press the needle sleeve with the reinforced coating
toward the press-in tool until.
LEIL15WHL1184AB 82
83. Locate the bearing outer ring.
RAPH12WEL0407AA 83
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84. Install the O-ring and grease it.
RAPH12WEL0408AA 84
85. Heat the housing bore to 120 °C (248 °F) with a heat
gun, an oven or a induction heater.
RAPH12WEL0409AA 85
86. Install two adjusting screws (1) and correctly place the
pump (2).
NOTE: observe the radial installation position.
LEIL15WHL1185AB 86
87. Put the O-ring into the annular groove of the pump
flange.
NOTE: depending on the transmission version, fastening
of the pump flange may differ.
LEIL15WHL1186AB 87
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88. Wet both cap bolts threads with LOCTITE® 574™. Fas-
ten the pump flange and the pump with the cap bolts
(1). Torque to 79 N·m (58.3 lb ft). Through the holes,
wet the threads with LOCTITE® 574™.
RAPH12WEL0412AA 88
89. Rotate the transmission housing by 180°. Snap the

V-rings into the recess of the driver (internal gearing).
Install the key (1).
RCPH11WHL420BAU 89
90. Install the shims (s = 2.0 mm (0.1 in)) and locate the
bearing inner ring.
RCPH11WHL421BAU 90
91. Install the shims (s = 2.0 mm (0.1 in)).
RCPH11WHL416BAU 91
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92. Install the driver with a clamping plate and fasten with
the cap bolt. Torque to 32 N·m (23.6 lb ft). Wet the
thread of the cap bolt with LOCTITE® 243™.
RCPH11WHL417BAU 92
93. Press down the bearing inner ring.
RCPH11WHL418BAU 93
94. Snap in the retaining ring (1) and install the input gear.
LEIL15WHL1187AB 94
95. Snap-in and lock the rectangular ring.
LEIL15WHL1188AB 95
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96. Install the pre-assembled input shaft.

NOTE: align the key to the keyway.
RCPH11WHL419BAU 96
Adjust the axial play of the input shaft bearing = 0.0 – 0.05 mm
97. Put on the gasket. Insert the bearing outer ring and
press evenly. To determine dimension I, measure
from the mounting face (gasket) to the bearing outer
ring. (Dimension I e.g. ... 128.5 mm (5.1 in)
NOTE: take several measurements to determine the mean
value.
LEIL15WHL1189AA 97
98. To measure Dimension II, measure from the mounting

face-converter bell to the mounting face-bearing outer
ring. (Dimension II e.g. ... 127.46 mm (5.0 in).
NOTE: take several measurements to determine the mean
value.
LEIL15WHL1190AA 98
Example:
Axial play — 0.04 mm (0.0 in)
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99. Insert the shim and the bearing inner ring.
RAPH12WEL0415AA 99
Input - converter bell

100. To install a new converter bell, the three finished
bores have to be sealed with the plugs.
LEIL15WHL1191AB 100
101. Locate the bearing outer ring in the housing bore and
the bearing inner ring.
RAPH12WEL0417AA 101
102. Install the spur gear positioning the long collar facing
upward.
RAPH12WEL0418AA 102
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103. Heat the spur gear bore to 120 °C (248 °F) with a
heat gun, an oven or a induction heater.
RAPH12WEL0419AA 103
104. Install the input shaft.
RAPH12WEL0420AA 104
105. Heat the bearing inner ring and install.

NOTICE: hot, wear protective gloves.
RAPH12WEL0421AA 105
106. Install the bearing outer ring.
RAPH12WEL0422AA 106
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107. Snap the rectangular ring into the angular groove of

the input shaft and lock it. Grease the rectangular
ring and centrally align it.
RAPH12WEL0423AA 107
108. Install the converter safety valve (1) and fasten it with
a slotted pin (2). Then flush mount the slotted pin
within the recessed area. Put the O-ring (3) into the
annular groove.
LEIL15WHL1192AB 108
109. Press the needle bearing with the reinforced coating

facing toward the press-in tool, into the bore of the
bearing cover until seated.
LEIL15WHL1193AB 109
110. Flush mount the shaft seal with the sealing lip facing
downward toward the oil sump. Wet the outer diam-
eter with spirit. Grease the sealing lip.
LEIL15WHL1194AB 110
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111. Heat the housing bore to 120 °C (248 °F) with a

blower, an oven or a induction heater.
NOTE: keep in direct time sequence to secure the precise
contact to the oil supply flange.
RAPH12WEL0427AA 111
112. Install the two adjusting screws 381000131 (1) and

insert the flange (2) for the oil supply. Observe the
radial installation position.
RAPH12WEL0428AA 112
113. Grease the O-ring and put it into the annular groove
of the bearing cover.
LEIL15WHL1195AB 113
114. Put on the bearing cover and fasten with the hexagon
RAPH12WEL0430AA 114
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115. Install the bolt plug (1). Torque to 150 N·m (110.6 lb
ft). Install the next bolt plug (2) and torque to 25 N·m
(18.4 lb ft). Lastly, install the temperature sensor (3)
and torque to 25 N·m (18.4 lb ft) followed with the
bolt plug (depending on the version) and torque to
35 N·m (25.8 lb ft).
NOTE: always install new O-rings.
RAPH12WEL0431AA 115
116. Install the slotted pin in the converter pressure

back-up valve.
LEIL15WHL1196AA 116
117. Insert the piston and the compression spring (1). In-
stall a new O-ring and a bolt plug. Torque to 130 N·m
(96 lb ft)
RAPH12WEL0433AA 117
118. Install the washers on the hexagon bolts. Fasten the

gasket and the cover plate (1) with bolts and torque
to 9.5 N·m (84 lb in).
RAPH12WEL0434AA 118
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119. Install the two adjusting screws and a gasket (1). Put
the O-ring into the annular groove (2).
LEIL15WHL1197AB 119
120. Connect the eyebolts 380001282 and install the con-

verter bell with a lifting tackle. Observe the radial in-
stallation position.
NOTE: slightly rotate the input shaft during the installation
to protect the teeth from damage.
RAPH12WEL0436AA 120
121. Fasten the converter bell with the hexagon bolts.

Torque the M8/10.9 to 34 N·m (25 lb ft) and the M12/
10.9 to 115 N·m (85 lb ft).
RAPH12WEL0437AA 121
122. Fasten the flexible plates with the hexagon bolts and
washers. Torque to 46 N·m (34 lb ft).
RAPH12WEL0438AA 122
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123. Install the rectangular ring into the annular groove

and lock it. Then grease the rectangular ring and
centrally align it.
RAPH12WEL0439AA 123
124. Connect the eyebolts 380001282 and attach the lift-

ing tackle to the converter.
RAPH12WEL0440AA 124
125. At a control dimension of < 43 mm (1.7 in), the exact

installation position of the converter is ensured.
LEIL15WHL1198AA 125
126. Temporarily attach the converter axially until the

transmission installation.
RAPH12WEL0442AA 126
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Coarse filter
127. Install the filter assembly (1) into the housing bore.
Oil the seal (2).
LEIL15WHL1199AB 127
128. Install a new O-ring (1). Fasten the cover with the
hexagon bolts and washers. Torque to 23 N·m
(17.0 lb ft).
LEIL15WHL1200AB 128
Inductive and speed sensors

129. Inductive (A) sensors installation positions.
(21). Inductive sensor for turbine speed
(47). Inductive sensor for intermediate gear train
speed
(48). Inductive sensor for engine speed
LEIL15WHL0996BB 129
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130. Speed (B) sensor installation position.

(34). Output speed sensor
LEIL15WHL0997BB 130
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131. The following image describes the installation and

setting of the inductive sensor for engine speed, the
inductive sensor for turbine speed, and the inductive
sensor for intermediate gear train speed. Observe
the different settings for dimension “X”.
RAPH12WEL0331AA 131
Inductive sensor for engine X = 0.5 +0.3 mm

speed
Inductive sensor for X = 0.5 +0.3 mm
turbine speed
Inductive sensor for X = 0.3 ±0.1 mm
intermediate gear train
speed
132. To adjust dimension “X” with shim rings, measure

Dimension I on the inductive sensor from the contact
face to the bolt-in face. (Dimension I e.g. ... 30. mm
(1.2 in).
RCPH11WHL443BAU 132
133. Turn the counting disc until one tooth tip is central to
the inductive sensor bore.
134. Turn the plug gauge until touching.
LEIL15WHL0998AA 133
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135. Find the anvil at the tooth tip and lock in place with a
threaded pin.
RAPH12WEL0334BA 134
136. Turn out the plug gauge and determine Dimension II.
(Dimension II e.g. ... 30.10 mm (1.2 in).
RCPH11WHL445BAU 135
Example A1
Dimension II 30.10 mm (1.2 in)
Dimension X (0.5 − 0.60 mm (0.02 in)
+0.3 mm)
Results in = 29.50 mm (1.2 in)
installation in
dimension A
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Example A2
Dimension I 30. mm (1.2 in)
Installation − 29.50 mm (1.2 in)
dimension A
Results in shim s = 0.50 mm (0.020 in)
ring(s)
137. Install the correct shim ring(s) (1) and wet the thread
(3) with LOCTITE® 574™.
138. Install the inductive sensor for engine speed (2).
Torque to 30 N·m (22.1 lb ft). Install the inductive
sensor for turbine speed and the inductive sensor
for intermediate gear train speed the same way.
NOTE: observe the different setting dimensions.
RCPH11WHL446BAU 136
139. Install the sensor output speed (34).
LEIL15WHL1201AB 137
Sensor output speed legend

1. Housing 34. Sensor output speed
2. Spur gear K3 X. Setting dimension. X = 1.0 +0.5 mm
3. Disc carrier
140. Sensor output speed (hall sensor)
RAPH12WEL0445AA 138
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141. To determine Dimension I, measure from the hous-

ing face to the spur gear K3. (Dimension I e.g. ...
39.7 mm (1.6 in)).
RCPH11WHL447BAU 139
142. Measure Dimension II from contact face to the

mounting face. (Dimension II e.g. ... 40 mm
(1.6 in)).
RCPH11WHL448BAU 140
Example B1
Dimension X (1.0 +0.5mm) − 1.20 mm (0.0 in)
Results in installation dimension = 38.5 mm (1.5 in)
Example B2
Dimension II 40 mm (1.6 in)
Installation dimension − 38.5 mm (1.5 in)
Results in Shim(s) s = 1.5 mm (0.1 in).
143. Install the three 0.50 mm shims (1) and grease the
O-ring (2).
RCPH11WHL449BAU 141
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144. Fasten the sensor output speed with a cap bolt.

RCPH11WHL450BAU 142
145. Insert new O-ring on the bolt plug (1) and install.
Torque to 145 N·m (107 lb ft). Insert the sealing cov-
ers (2) with the concave side facing downwards, flush
to housing recess. Wet contact face with LOCTITE®
262™.
NOTE: depending on the transmission version, differences
of the single components and their installation positions
may be possible.
RAPH12WEL0446AA 143
146. Flush mount the cap to the housing face and install
the breather. Torque to 12 N·m (106 lb in). Wet the
sealing surface of the cup with LOCTITE® 262™.
RAPH12WEL0449AA 144
147. Install the bolt plugs with new O-rings in (1) and (2).
Torque to 100 N·m (73.8 lb ft). Place a new O-ring
on the adapter (3) and install it. Torque to 145 N·m
(107 lb ft).
RAPH12WEL0450AA 145
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148. Install both of the fixing plates.
RAPH12WEL0451AA 146
149. Put a new O-ring on the bolt plug and install it. Torque
to 80 N·m (59 lb ft).
NOTE: prior to transmission operation, oil must be properly
filled.
RAPH12WEL0452AA 147
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Powershift transmission - Install

1. Carefully lower the transmission into the chassis.
LEIL15WHL1021AA 1
2. Install the bell housing bolts (1). Tighten the bell hous-
ing bolts (1) to a torque of 54 – 60 N·m (40 – 44 lb ft).
LEIL15WHL1020AB 2
NOTE: steps 3, 4 and 5 are related only to CASE CONSTRUCTION 1021G.

3. Install the flex plate bolts (1). Tighten the flex plate bolts
(1) to a torque of 33 – 41 N·m (24 – 30 lb ft).
LEIL15WHL1019AB 3
4. Apply DOW 732 RTV SILICONE CLEAR to the converter

housing cover plate (1).
5. Install the converter housing cover plate (1).
LEIL15WHL1018AB 4
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NOTE: step 6 is related only to CASE CONSTRUCTION 1121G.

front) until one of the torque converter bolts location is
visible through the hole, and install the bolt. Continue
turning the flywheel (clockwise) in 30 ° increments to
expose each bolt location, until all the twelve bolts are
installed.
Install the plug (2). Install the cover (1).
LEIL15WHL1502AB 5
7. Install two transmission mounting bolts (1). Tighten the

two transmission mounting bolts (1) to a torque of 929
– 1044 N·m (685 – 770 lb ft).
LEIL15WHL1017AB 6
8. Remove the lifting equipment (1) on the transmission.
LEIL15WHL1016AA 7
9. Install the transmission-to-transmission oil filter lines

(1).
LEIL15WHL1015AB 8
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10. Position the wire harness (1) as shown. Install the wire
harness P-clamps (2).
LEIL15WHL1014AB 9
11. Connect the engine speed sensor electrical connector

(1).
LEIL15WHL1012AB 10
12. Connect the intermediate speed sensor electrical con-

nector (1).
13. Connect the turbine speed sensor electrical connector
(2).
LEIL15WHL1013AB 11
14. Connect the valve body electrical connector (1).

15. Connect the torque converter output temperature
sender electrical connector (2).
16. Connect the transmission-to-cooler oil line (3).
LEIL15WHL1011AB 12
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17. Connect the redundant brake switch electrical con-

nectors (1), (2).
LEIL15WHL1010AB 13
18. Connect the transmission-to-cooler oil return line (1)

19. Connect the output speed sensor electrical connector
(2).
LEIL15WHL1009AB 14
20. Connect the park brake caliper line (1).
LEIL15WHL1008AB 15
21. Connect the transmission fill tube (1) to the transmis-

sion. Tighten the transmission fill tube bolts to a torque
of 16 – 33 N·m (12 – 24 lb ft).
NOTE: splashback shield located inside transmission fill
tube.
LEIL15WHL1007AB 16
22. Check and adjust all fluid levels.
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23. Bleed the parking brake caliper using the bleeder

screw (1).
LEIL15WHL1212AB 17
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Next operation:
Drive shaft - Install - Rear Drive Shaft (23.314), Drive shaft - Install - Center Drive Shaft (23.314), Variable
displacement pump - Install (35.106), Oil reservoir - Install (35.300) , Cab - Install (90.150), Ladder - Install
(90.118).
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Powershift transmission - Testing

Test N°1
Test Point Condition
Operate machine in normal operating conditions and observe:
A. Verify actual oil temperature at test point. Normal operating temperature can be 56 °C ( 100 °F) above
the ambient temperatures.
B. Use a stop watch to establish the exact length of time required to reach the overheating condition.
C. Observe engine temperature.
Check
Does the engine overheat? Which overheats first - engine or transmission?
Expected Result
Result
Other Action
Result
(Possible
Cause)
Test N°2
When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast
idle ( 1250 – 1450 RPM ).
Check
Expected Result
Result Oil temperature returns to Normal - establish length of time (2 to 3 minutes).
Action
1. Check oil level, type and grade is correct.
2. Check operator’s gear selection is correct for conditions.
3. Make sure brakes are fully released.
4. Check the engine full throttle and stall speeds are correct as specified.
Other Action
Result Oil temperature remains overheated.
(Possible 1. Check for dirty radiator - airflow restricted.
Cause) 2. Check for engine overheating problem.
3. Check for faulty oil temperature gauge and sender or switch.
Test N°3
Perform all the pressure and flow tests.
Expected Result
Result
Other Action
Result
(Possible
Cause)
Test N°4
Compare the pressure and flow test results to the specifications in Powershift transmission - General
specification (21.113) to determine if any circuits are not within specifications.
Expected Result
Result
Other Action
Result
(Possible
Cause)
Test N°5
Refer to Powershift transmission - Pressure test (21.113) to determine possible cause of any test
results not within specifications.
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Expected Result
Result
Other Action
Result
(Possible
Cause)
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Index
Transmission - 21

Powershift transmission - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Powershift transmission - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Powershift transmission - General specification Clutch Plate Thicknesses . . . . . . . . . . . . . . . . . . . . . 3
Powershift transmission - General specification Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powershift transmission - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Powershift transmission - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Powershift transmission - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Powershift transmission - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Transmission - 21
Powershift transmission external controls - 135

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Contents
Transmission - 21
SERVICE
Transmission control valve

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Transmission - Powershift transmission external controls
Transmission control valve - Disassemble

1. Using the socket spanner 380001296 to remove the
mounting bolts and remove the transmission control
valve body.
RCPH11WHL220BAU 1
2. Remove the hose lines from duct plate. Using the

socket spanner 380001297 to remove the mounting
bolts and the gasket from the transmission housing.
NOTE: Mark hose connections prior to disassembly.
RCPH11WHL222BAU 2
3. Mark the installation position of the wiring harness on

the valve block.
RCPH11WHL170BAU 3
4. Remove the bolts securing the duct plate and interme-

diate plate to the valve block. Remove the duct and the
intermediate plates.
RCPH11WHL171BAU 4
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5. Remove the wiring harness retaining clamp.
RCPH11WHL172BAU 5
6. Using the socket spanner 380001296 to remove the

bolts and the cover. Repeat the process for opposite
cover.
RCPH11WHL173BAU 6
7. Remove the wiring harness.
RCPH11WHL174BAU 7
8. Using the socket spanner 380001296 to remove the re-

taining plate bolts, the retaining plates and the pressure
solenoids.
RCPH11WHL175BAU 8
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9. Remove two bolts and temporarily install two adjusting

screws 380001276 bolts (housing is preloaded). Re-
move the remaining bolts.
RCPH11WHL176BAU 9
10. Separate the housing from the valve body by equally

loosening the adjusting screws 380001276.
RCPH11WHL177BAU 10
11. Remove the components.
RCPH11WHL178BAU 11
12. Remove the opposite side solenoids, the housing and

the components.
RCPH11WHL179BAU 12
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Transmission control valve - Assemble

NOTE: Apply clean engine oil (15W-40) to pistons and springs, orifices, new O-rings, and filter screens before as-
sembly.
1. Place the valve body on the bench with the orifices up.
RCPH11WHL180BAU 1
2. Install the vibration damper (1), pistons (2), the pres-

sure reducing valve (3) and other components in the
positions shown.
RCPH11WHL181BAU 2
3. Preload the compression springs of the pistons. Install

a 5 mm (0.20 in) diameter roll pin.
RCPH11WHL182BAU 3
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4. Install the adjusting screws 380001276, the gasket (1),

and the housing cover.
RCPH11WHL183BAU 4
5. Tighten the adjusting screws 380001276 equally until

the cover is flush on the valve body.
RCPH11WHL184BAU 5
6. Push the pistons down through the pressure controller

holes and remove the roll pins.
RCPH11WHL185BAU 6
7. Install the bolts and torque them using the socket span-
ner 380001296 in a criss cross patter to 7.5 N·m (66 lb
in).
RCPH11WHL186BAU 7
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8. Install the solenoids and secure them with the retaining

plates and the bolts. Torque the bolts to 5.5 N·m (49 lb
in).
NOTE: Install the retaining plate with the neck towards
the valve body, install the controllers with connectors as
shown.
RCPH11WHL187BAU 8
9. Install the vibration damper (1), the pistons (2), the

main pressure valve (3) and other components in posi-
tions shown.
RCPH11WHL188BAU 9
10. Preload the compression springs of the pistons and

install a 5 mm (0.20 in) diameter roll pin. Install the
adjusting screws 380001276, the gasket (1), and the
housing cover.
RCPH11WHL189BAU 10
11. Install the bolts and torque them, using the socket
spanner 380001296, in a criss cross pattern to
7.5 N·m (66 lb in).
RCPH11WHL186BAU 11
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12. Install the solenoids and secure them using the socket
spanner 380001296, with the retaining plates and the
bolts. Torque the bolts to 5.5 N·m (49 lb in).
NOTE: Install the retaining plate with the neck towards
valve body, install the controllers with connectors as
shown.
RCPH11WHL190BAU 12
13. Install the wiring harness with connector on side of the

valve body with marking made during disassembly.
Connect the wiring harness to the solenoids.
RCPH11WHL191BAU 13
14. Install the gasket, install the wiring harness plug in the
cover. Install the bolts and torque them in a criss cross
pattern to 7.5 N·m (66 lb in).
RCPH11WHL192BAU 14
15. Install the wiring harness retaining clamp.
RCPH11WHL193BAU 15
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16. Install the screens into the bores of the intermediate

plate towards the distribution plate.
RCPH11WHL194BAU 16
17. Install two adjusting screws 381000128. Place the

intermediate plate with the screens facing up.
RCPH11WHL195BAU 17
18. Install the distribution plate. Install the bolts and

torque them using the socket spanner 380001296 in
a criss cross pattern to 9.5 N·m (84 lb in).
RCPH11WHL196BAU 18
19. Install new O-rings on the plugs. Install the plugs and
torque to 6 N·m (53 lb in).
RCPH11WHL197BAU 19
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20. Preassemble the duct plate. Install the connection

pipes (1), (2), (3), and (4). Torque to 6 N·m (53 lb
in). Install the screw plugs (5) and (6) and torque to
40 N·m (30 lb ft).
NOTE: Always install new O-rings.
RCPH11WHL437BAU 20
21. Using a new O-ring, install the screw plug and torque
to 80 N·m (59 lb ft).
RCPH11WHL438BAU 21
22. Install two M8 adjusting screws 380001275 and a new

gasket (arrow).
RCPH11WHL439BAU 22
23. Install the duct plate and secure it equally using the
socket spanner 380001297 with bolts torqued to
23 N·m (17 lb ft).
RCPH11WHL440BAU 23
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24. Insert two M6 adjusting screws 381000128 and install

the gasket (arrow).
RCPH11WHL441BAU 24
25. Install valve block and using the socket spanner

380001296 to secure evenly using bolts (6 pieces M6
x 100 mm and 17 pieces M6 x 76 mm) torqued to
12 N·m (9 lb ft).
NOTE: Note positioning of M6 x 100 mm bolts (arrow).
NOTE: Install lines depending on transmission version.
Use markings made during disassembly.
RCPH11WHL442BAU 25
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Transmission control valve - Visual inspection

WARNING
Flying debris!
Compressed air can propel dirt, rust, etc. into the air. Wear eye and face protection when using com-
pressed air.
W0307A
1. Clean all metal parts in cleaning solvent.

2. Immerse end housing, valve housing, valve plate, and
distribution plate in cleaning solvent and agitate clean-
ing solvent. Use compressed air to remove foreign
matter from interior of housings and plates and to en-
sure that all bores are clear of foreign matter.
3. Use compressed air to ensure that orifices are clear of
foreign matter.
4. Check filter screens for blockage, rips or tears. Re-
place if any of these conditions are seen.
5. Inspect the plates, housings and covers for corrosion,
cracks, breaks, chipping or other damage. Check
bores in housings for deep scratches, gouges, and
other damage. Replace a housing or cover if any of
the above conditions are seen.
6. Check pressure regulators for cracks, breaks, or other
damage. Check connector contacts for looseness of
signs of corrosion. Replace a pressure regulator if any
of these conditions are seen. Check resistance of pres-
sure regulators using a multimeter. Replace a pressure
regulator if resistance is not 17 – 21 Ω.
7. Check wiring harness connectors for signs of breaks,
cracks, or other damage. Check contacts for foreign
matter or corrosion. Check harness wiring for signs
of broken or cracked insulation and broken or frayed
wiring at connection to the connectors. Replace wiring
harness if any of these conditions are seen.
8. Check springs for cracks, breaks, distortion, or signs
of permanent set. Replace a spring if any of these
conditions are seen.
9. Inspect pistons for cracks, breaks, chipping grooves, or
other damage. Replace if any of these conditions are
seen.
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Index
Transmission - 21

Transmission control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Transmission control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission control valve - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Transmission - 21
Powershift transmission hydraulic components - 105

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Contents
Transmission - 21
SERVICE
Transmission lubrication pump

Disassemble - Lubrication charge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assemble - Lubrication charge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Transmission - Powershift transmission hydraulic components
Transmission lubrication pump - Disassemble - Lubrication charge

pump
1. Remove the shaft from the pump. Do not lose shims
that may be on the shaft.
RCPH11WHL308BAU 1
2. Remove the cover from the pump. If necessary, drive

the needle bearing from the cover.
RCPH11WHL310BAU 2
3. Mark the gear set for assembly later and remove it from
the coupling with the square key.
RCPH11WHL309BAU 3
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4. Remove the snap ring, drive coupling, and bearing. If

necessary, remove the three rings inside the coupling.
RCPH11WHL311BAU 4
5. Remove the bearing.
LEIL15WHL1001AA 5
6. Measure from the pump housing to the surface of the

gears. If there is more than 0.05 mm (0.002 in) of end
play, replace the pump assembly.
NOTE: The pump housing, cover, and gear set are only
serviced as an assembly.
LEIL15WHL1002AA 6
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Transmission lubrication pump - Assemble - Lubrication charge

pump
LEIL15WHL1003FA 1
1. Install the three rings inside the coupling and the bear-
ing on the coupling. Install the coupling and snap ring.
RCPH11WHL311BAU 2
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2. Install the gear set into the housing with a square key.
RCPH11WHL309BAU 3
3. Install the needle bearing in the cover and the cover on

the pump housing.
RCPH11WHL310BAU 4
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4. Install the shaft with shim. Apply LOCTITE® 242® to

screw and tighten to a torque of 32 N·m (24 lb ft).
LEIL15WHL1004AA 5
LEIL15WHL1005BA 6
Charge pump diagram shown.
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Index
Transmission - 21

Transmission lubrication pump - Assemble - Lubrication charge pump . . . . . . . . . . . . . . . . . . . . . . . . 5
Transmission lubrication pump - Disassemble - Lubrication charge pump . . . . . . . . . . . . . . . . . . . . . . 3
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Transmission - 21
Powershift transmission internal components - 155

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Contents
Transmission - 21
SERVICE
Clutch
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Transmission - Powershift transmission internal components
Clutch - Disassemble
Disassemble of the Multi-Disc Clutch K3/K4
1. By means of the clamping ring fasten the clutch to the
assembly truck 380001282.
LEIL15WHL0852AA 1
2. Pull off the roller bearing from the disc carrier.
LEIL15WHL0853AA 2
3. Separate the spur gear K3 from the disc carrier.
LEIL15WHL0854AA 3
4. Use the tool 380001292 and pull off the bearing inner
ring from the disc carrier.
LEIL15WHL0855AA 4
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5. Squeeze out the snap ring.

Remove the end shim and the disc set K3.
LEIL15WHL0856AA 5
6. Rotate the disc carrier by 90°.

Loosen the slotted nut.
LEIL15WHL0857AA 6

Use the tool 380001289 and pull off the taper roller
bearing.
LEIL15WHL0858AA 7
8. Pull off the spur gear K4 from the disc carrier.
LEIL15WHL0859AA 8
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9. Remove the ring.
LEIL15WHL0860AA 9
10. Pull off the taper roller bearing.
LEIL15WHL0861AA 10

LEIL15WHL0862AA 11
12. Preload the compression spring by means of fixture.

Squeeze out the snap ring and the released single
components.
Remove the opposite single components (K3 side)
analogously.
LEIL15WHL0863AA 12
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13. Separate both pistons by means of compressed air

from the disc carrier.
LEIL15WHL0864AA 13
Disassemble of the Multi-Disc Clutch KR/K2

1. Fasten the clutch by means of clamping ring (arrow) on
the assembly truck.
LEIL15WHL0865AB 14

LEIL15WHL0866AA 15
3. Use the tool 380001292 and pull off the taper roller
bearing from the disc carrier.
LEIL15WHL0867AA 16
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4. Press off the spur gear K2 from the disc carrier.

NOTICE: Pay attention to released disc carrier.
LEIL15WHL0868AA 17
5. Fasten the disc carrier by means of clamping ring.

Use the tool 380001292 and pull off the taper roller
LEIL15WHL0869AA 18

Remove the end shim and disc set K2.
LEIL15WHL0870AA 19

LEIL15WHL0871AA 20
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LEIL15WHL0872AA 21
9. Fasten the spur gear KR by means of clamping ring

(arrow) and pull it from the disc carrier.
NOTE: Collar of the clamping ring must show upwards (to
the spur gear).
LEIL15WHL0873AB 22
10. Remove the ring.
LEIL15WHL0874AA 23

Remove the end shim and the disc set KR.
LEIL15WHL0875AA 24
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LEIL15WHL0876AA 25
Disassemble of the Multi-Disc Clutch KV/K1

1. Fasten the clutch by means of clamping ring to the as-
sembly truck.
LEIL15WHL0877AA 26
LEIL15WHL0878AA 27
3. Remove the shim.
LEIL15WHL0879AA 28
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4. Pull off the spur gear K1 from the disc carrier.
LEIL15WHL0880AA 29
5. Opposite figure shows the spur gear bearing K1.

Bearing (1) can only be obtained as complete part.
NOTICE: If it is necessary to remove the clutch-pack-sided
ball bearing (arrow), the complete bearing (1) has to be
removed.
LEIL15WHL0881AB 30
6. Take off the bush.
LEIL15WHL0882AA 31
7. Pull off the ball bearing from the disc carrier.
LEIL15WHL0883AA 32
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NOTE: Pay attention to released balls.
LEIL15WHL0884AA 33

LEIL15WHL0885AA 34

LEIL15WHL0886AA 35
LEIL15WHL0887AA 36
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11. Pull off the spur gear KV from the disc carrier.
LEIL15WHL0888AA 37
12. Remove the ring.
LEIL15WHL0889AA 38
Squeeze out the snap ring.
Remove the end shim and the disc set KV.
Remove both pistons.
LEIL15WHL0890AA 39
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Clutch - Assemble
Assemble of the Multi-Disc Clutch K4/K3
LEIL15WHL0891FB 1
1. Disc carrier (assembly) 4. Piston

2. Spur gear K4 5. Compression spring
3. Spur gear K3 6. Plug 2x
K4. Multi-disc clutch K4 7. Plug 1x
K3. Multi-disc clutch K3
NOTE: observe the installation position of the single components for the following assembly.
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1. Lift the disc carrier with the K4-side showing down-

wards into the clamping ring and fasten it.
Rotate the disc carrier by 180°.
NOTICE: to install new disc carriers the finished bores
have to be sealed with plugs.
Installation position, see arrow.
LEIL15WHL0892AB 2
LEIL15WHL0893AB 3
2. Flush-mount the drain valve (arrow) with the chamfer

showing downwards.
LEIL15WHL0894AB 4
3. Put both O-Rings scroll-free into the annular grooves

of the piston.
LEIL15WHL0895AB 5
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4. Oil the O-Rings and the piston contact surface.

Install the K3 piston equally until contact.
NOTE: observe the installation position of the piston.
LEIL15WHL0896AA 6
5. Install the spacer and the compression spring.
LEIL15WHL0897AA 7
6. Place the guide ring, with the chamfer (arrow) showing

upwards, over the compression spring and install the
snap ring.
LEIL15WHL0898AB 8
7. Lift the disc carrier out of the clamping ring. Preload

the compression spring by means of fixture and engage
the snap ring into the annular groove of the disc carrier
(arrow).
Install the drain valve, piston and compression spring
on the opposite side (Clutch K4) analogously.
Then lift the disc carrier with the K4-side showing down-
LEIL15WHL0899AB 9
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Disc Components K4
NOTE: below sketch or table shows the standard version as to the installation position of the single components.
LEIL15WHL0900FB 10
Pos. Description Quantity s (mm) Remarks

1 Disc carrier 1
2 Piston 1
3 Outer clutch disc 2 1.85 Coated on one side
4 Outer clutch disc 4 2.5 Coated on both sides
5 Inner clutch disc 2 4.0
7 Inner clutch disc 2 2.5 ... 4.0 optional
8 Snap ring 1 2.10 ... 3.10 optional
9 End shim 1
Number of friction surfaces: 10
Disc clearance: 2.2 – 2.4 mm (0.087 – 0.094 in)
NOTE: install the outer clutch discs (3) with uncoated side showing to the piston and the end shim respectively.
The respective clutch side can be seen on the length of the disc carrier.
K4 = Dimension X (short disc carrier side)
K3 = Dimension Y (long disc carrier side)
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Check disc clearance K4 = 2.2 – 2.4 mm (0.087 – 0.094 in)

NOTE: in order to ensure a perfect measuring result, the disc set is first of all to be installed without oil.
1. Install the disc set according to sketch or table.
LEIL15WHL0901AA 11
2. Install the end shim and fasten it by means of the snap

ring.
LEIL15WHL0902AA 12
3. Press on the end shim with approximately 10 kg

(22.0 lb) and set dial indicator to “Zero“.
Then press the end shim against the snap ring (up-
wards) and read the disc clearance on the dial indicator.
NOTE: if the required disc clearance differs, it has to be
corrected with the adequate inner clutch disc or/and snap
ring, see table / Pos. 7 and Pos. 8.
Upon setting of disc clearance, remove the disc set,
oil the clutch discs with CASE AKCELA NEXPLORE™
FLUID and reinstall them.
LEIL15WHL0903AB 13
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Preassemble and install the spur gear K4

1. Opposite figure shows the single components of the
spur gear K4.
1. Bearing inner ring
2. Bearing outer ring
3. Ring
4. Spur gear
LEIL15WHL0904AB 14
Locate both bearing outer rings (2) until contact.

2. Heat the bearing inner ring and install it until contact.
LEIL15WHL0905AA 15
3. Install the ring.
LEIL15WHL0906AA 16
4. Assemble the spur gear until all inner clutch discs are
located.
LEIL15WHL0907AA 17
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5. Heat the bearing inner ring (spur gear bearing) and lo-
cate it until contact.
NOTICE: use safety gloves.
LEIL15WHL0908AA 18
6. Heat the bearing inner ring (clutch bearing) and install

it until contact.
LEIL15WHL0909AA 19
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Clutch Components K3
LEIL15WHL0910FB 20

1 Disc carrier 1
2 Piston 1
9 End shim 1
NOTE: install the outer clutch discs (3) with uncoated side showing to the piston and end shim respectively.
K3 = Dimension Y (long disc carrier side)
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1. Install disc set according to sketch or table.
LEIL15WHL0911AA 21

ring.
LEIL15WHL0912AA 22

(22.0 lb) and set the dial indicator to “Zero“.
LEIL15WHL0913AB 23

LEIL15WHL0914AA 24
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5. Lift the disc carrier out of the clamping ring.

To ensure the exact locating of the single components,
preload the bearing with 10000 kg (22046.2 lb).
NOTICE: support on the lower as well as upper bearing
inner ring.
Use pressure pieces.
LEIL15WHL0915AA 25
6. Lift the disc carrier with the K4-side showing down-

Install the slotted nut.
NOTE: observe installation position of the slotted nut. Col-
lar (∅ 60 mm) must show to the bearing inner ring. Oil the
thread!
Tightening torque MA = 550 N·m (406 lb ft)
LEIL15WHL0916AA 26
7. Install the bearing outer ring into the spur gear K3 until
contact.
LEIL15WHL0917AA 27
located.
LEIL15WHL0918AA 28
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9. Heat the roller bearing and locate it until contact.

LEIL15WHL0919AA 29
10. Install the bearing inner ring.
LEIL15WHL0920AA 30
11. Check function of the clutches K3 and K4 by means

of compressed air.
NOTE: closing or opening of the clutches is clearly audible
when the single parts have been installed adequately.
LEIL15WHL0921AA 31
12. Snap-in and lock the rectangular rings.
LEIL15WHL0922AB 32
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Assemble of the Multi-Disc Clutch KR/K2
LEIL15WHL0923FB 33
1. Disc carrier 4. Piston

2. Spur gear KR 5. Compression spring
KR. Multi-disc clutch KR 7. Plug 1x
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1. Lift the disc carrier with the KR-side showing down-

Then rotate the disc carrier by 180°.
have to be sealed with plugs.
LEIL15WHL0924AB 34
LEIL15WHL0925AB 35

showing downwards.
LEIL15WHL0926AB 36

of the piston.
LEIL15WHL0927AB 37
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4. Oil the O-Rings and the piston contact surfaces.

Install K2 piston equally until contact.
LEIL15WHL0928AA 38
LEIL15WHL0929AA 39
6. Place the guide ring, with the chamfer (arrow) showing

upwards, over the compression spring and install the
snap ring.
LEIL15WHL0930AB 40

Preload the compression spring by means of fixture
and engage the snap ring into the annular groove of
the disc carrier (arrow).
on the opposite side (Clutch KR) analogously.
Then lift the disc carrier with the KR-side showing
downwards into the clamping ring and fasten it.
LEIL15WHL0931AB 41
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Disc Components KR
LEIL15WHL0932FB 42

1 Disc carrier 1
2 Piston 1
9 End shim 1
KR = Dimension Y (long disc carrier side)
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Check disc clearance KR = 2.8 – 3.0 mm (0.110 – 0.118 in)

LEIL15WHL0933AA 43

ring.
LEIL15WHL0934AA 44

NOTE: If the required disc clearance differs, it has to be
Upon setting of disc clearance, remove disc set, oil
clutch discs with CASE AKCELA NEXPLORE™
LEIL15WHL0935AB 45
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Preassemble and install spur gear KR

1. Opposite figure shows the single components of spur
gear KR.
1. Bearing inner ring (75 x 37 mm)
2. Ring
3. Spur gear
4. Bearing inner ring (75 x 41 mm)
LEIL15WHL0936AB 46
2. Heat the bearing inner ring (75 x 37 mm) and install it

until contact.
LEIL15WHL0937AA 47
located.
LEIL15WHL0938AA 48
LEIL15WHL0939AA 49
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5. Heat the bearing inner ring (75 x 41) and locate it until
contact.
LEIL15WHL0940AA 50
6. Heat the bearing inner ring (clutch bearing) and locate

it until contact.
LEIL15WHL0941AA 51
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Disc Components K2
LEIL15WHL0942FB 52

1 Disc carrier 1
2 Piston 1
9 End shim 1
KR = Dimension Y (long disc carrier side)
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LEIL15WHL0943AA 53

ring.
LEIL15WHL0944AA 54

ring.
LEIL15WHL0945AB 55
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Preassemble and install spur gear K2

1. Undercool gear (1) (approximately - 80 °C (176 °F))
and heat gear (2) (approximately 120 °C (248 °F)).
Engage the snap ring (arrow), preload it and join both
components by means of hydr. press until the snap ring
engages into the annular groove of gear (2).
LEIL15WHL0946AB 56
2. Opposite figure shows the single components of the

spur gear bearing.
2. Spur gear assembly
LEIL15WHL0947AB 57

LEIL15WHL0948AA 58
located.
LEIL15WHL0949AA 59
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5. Heat the bearing inner ring (spur gear bearing) and in-
stall it until contact.
LEIL15WHL0950AA 60

it until contact.
LEIL15WHL0951AA 61

inner ring.
Use pressure pieces.
LEIL15WHL0952AA 62
8. Lift the disc carrier into the clamping ring and fasten it.
K2-side:
NOTE: observe installation position of the slotted nut.
Chamfer must show to the bearing inner ring.
Oil the thread.
LEIL15WHL0953AA 63
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9. KR-side:
lar (∅ 76 mm) must show to the bearing inner ring.
Oil the thread.
LEIL15WHL0954AA 64
10. Check function of the clutches K3 and K4 by means

of compressed air.
Snap-in and lock the rectangular rings.
LEIL15WHL0955AB 65
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Assemble of the Multi-Disc Clutch KV/K1
LEIL15WHL0956FB 66
1. Disc carrier 4. Piston

2. Spur gear KV 5. Compression spring
KV. Multi-disc clutch KV 7. Plug 1x
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1. Lift the disc carrier with the KV-side showing down-

Then rotate the disc carrier by 180°.
have to be sealed with plugs!
LEIL15WHL0957AB 67
LEIL15WHL0958AB 68

showing downwards.
LEIL15WHL0959AB 69

of the piston.
LEIL15WHL0960AB 70
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4. Oil the O-Rings and the piston contact surfaces.

Install K1 piston equally until contact.
LEIL15WHL0961AA 71
LEIL15WHL0962AA 72
6. Place guide ring, with the chamfer (arrow) showing up-

wards, over the compression spring and install the snap
ring.
LEIL15WHL0963AB 73

Preload the compression spring by means of fixture
and engage the snap ring into the annular groove of
the disc carrier (arrow).
on the opposite side (Clutch KV) analogously.
Then lift the disc carrier with the KV-side showing
downwards into the clamping ring and fasten it.
LEIL15WHL0964AB 74
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Disc Components KV
LEIL15WHL0965FB 75

1 Disc carrier 1
2 Piston 1
9 End shim 1
The respective clutch side can be seen on the length and ∅ of the disc carrier respectively.
KV = Dimension Y (long disc carrier side and large ∅ respectively)
K1 = Dimension X (short disc carrier side and small ∅ respectively)
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Check disc clearance KV = 2.8 – 3.0 mm (0.110 – 0.118 in)

1. Install the disc set according to sketch or table.
LEIL15WHL0966AA 76

ring.
LEIL15WHL0967AA 77

LEIL15WHL0968AB 78
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Preassemble and install spur gear KV

gear KV.
2. Bearing outer ring
3. Ring
4. Spur gear
Install both bearing outer rings (2) until contact.
LEIL15WHL0969AB 79

LEIL15WHL0970AA 80
LEIL15WHL0971AA 81
located.
LEIL15WHL0972AA 82
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5. Heat the bearing inner ring (spur gear bearing) and lo-
cate it until contact.
LEIL15WHL0973AA 83

it until contact.
LEIL15WHL0974AA 84
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Disc Components K1
LEIL15WHL0975FB 85

1 Disc carrier 1
2 Piston 1
9 End shim 1
The respective clutch side can be seen on the length and ∅ of the disc carrier respectively.
K1 = Dimension X (short disc carrier side and small ∅ respectively)
KV = Dimension Y (long disc carrier side and large ∅ respectively)
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LEIL15WHL0976AA 86

ring.
LEIL15WHL0977AA 87

ring.
Upon setting of disc clearance, remove disc set, oil
clutch discs with CASE AKCELA NEXPLORE™
LEIL15WHL0978AB 88
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Preassemble and install spur gear K1

gear K1.
1. Ball bearing (assembly)
2. Snap ring
3. Spur gear
LEIL15WHL0979AB 89
NOTE: prior to installation of the single components, align

the disc set by means of the spur gear radially and center
it.
LEIL15WHL0980AA 90
2. Install the snap ring.
LEIL15WHL0981AA 91
3. Install the bush with collar (arrow) on face end showing

to the snap ring.
LEIL15WHL0982AB 92
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4. Press in the ball bearing until contact.

NOTE: Install the ball bearing with the lubricating groove
(arrow) showing downwards.
Put the press-in tool only to the bearing outer ring.
LEIL15WHL0983AB 93
5. Heat the second ball bearing and install it until contact.

NOTE: lubricating groove (arrow), must show upwards.
LEIL15WHL0984AB 94
6. Assemble the bush.
LEIL15WHL0985AA 95
7. Heat the spur gear to approximately 120 °C (248 °F)

and assemble it until all inner clutch discs are located.
LEIL15WHL0986AA 96
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8. Install shim s = 1.20 mm.
LEIL15WHL0987AA 97

LEIL15WHL0988AA 98

inner ring! Use pressure pieces.
LEIL15WHL0989AA 99
11. Lift the disc carrier into the clamping ring.

lar (∅ 60 mm) must show to the taper roller bearing.
Oil the thread.
Install the opposite slotted nut (KV-side) analogously.
LEIL15WHL0990AA 100
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12. Check function of the clutches KV and K1 by means

of compressed air.
LEIL15WHL0991AA 101
13. Snap-in and lock the rectangular rings.
LEIL15WHL0992AB 102
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Index
Transmission - 21

Clutch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Clutch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN ITALY
48083742_EN 31/07/2018
EN
SERVICE MANUAL
Four-Wheel Drive (4WD) system

48083742_EN 31/07/2018
23
Contents
Four-Wheel Drive (4WD) system - 23
[23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1
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23
Drive shaft - 314

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Contents
Drive shaft - 314
TECHNICAL DATA
Drive shaft
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Drive shaft
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Drive shaft
Remove - Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install - Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remove - Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install - Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove - Center bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install - Center Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remove - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Four-Wheel Drive (4WD) system - Drive shaft
Drive shaft - Torque

Center, Rear and Front Drive Shaft Bolts 136 – 149 N·m (100 – 110 lb ft)
Center Bearing Bolts 150 – 164 N·m (111 – 121 lb ft)
Lock Nut for Yoke on Front Drive Shaft 339 – 375 Nm ( 250 – 275 lb.ft)
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Drive shaft - Component identification
LEIL15WHL1202FB 1
1. Carrier bearing 5. Rear drive shaft

2. Front axle 6. Rear axle
3. Front drive shaft 7. Transmission
4. Center drive shaft
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Drive shaft - Remove - Front Drive Shaft

drive shaft (2) to the yoke (3) of the front drive shaft (4).
NOTICE: the bolts that fasten the center drive shaft to the
front drive shaft must be replaced when removed.
LEIL15WHL1203AB 1
2. Loosen and remove the lubrication hose (1) from the

carrier bearing (2).
LEIL15WHL1204AB 2
3. Loosen and remove the lock nut (1) which fastens the
yoke (2) to the front drive shaft and remove the yoke
(2).
NOTE: make an alignment mark on the yoke and the front
drive shaft to be sure that the yoke is installed correctly.
LEIL15WHL1205AB 3
4. Loosen and remove the bolts (1) that fasten the front
drive shaft (2) to the front axle.
LEIL15WHL1206AB 4
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5. Use a prybar to disengage the front drive shaft from

the front axle and remove the front drive shaft from the
machine.
NOTE: if necessary, use a brass hammer to drive the front
drive shaft out of the center bearing.
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Drive shaft - Install - Front Drive Shaft

1. Apply antiseize compound to the bearing area of the
front drive shaft.
2. Place the front drive shaft into position in the center
bearing of the machine.
3. Install the bolts (1) that fasten the front drive shaft (2)
to the front axle.
110 lb ft)
LEIL15WHL1206AB 1
4. Apply antiseize compound to the splines on the front

drive shaft.
5. Install the yoke (2) to the front drive shaft, making sure
the alignment marks made during removal are aligned.
NOTE: If a new front drive shaft has been installed, make
sure the yoke being installed is 90 ˚ to the yoke on the other
end of the front drive shaft.
6. Install the lock nut (1) and washer which fastens the
yoke (2) to the front drive shaft. Tighten the lock nut (1)
to a torque of 339 – 375 Nm ( 250 – 275 lb.ft).
LEIL15WHL1205AB 2
7. Tighten the bolts (3) that secure the carrier bearing to

the front chassis.
8. Install the lubrication hose (1) to the carrier bearing (2).
LEIL15WHL1204AB 3
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9. Install the bolts (1) that fasten the center drive shaft (2)
to the yoke (3) of the front drive shaft (4).
110 lb ft)
LEIL15WHL1203AB 4
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Drive shaft - Remove - Center Drive Shaft

to the front drive shaft must be replaced when removed.
LEIL15WHL1203AB 1
2. Use a prybar to disengage the center drive shaft from

the yoke of the front drive shaft.
to the transmission must be replaced when removed.
LEIL15WHL1207AB 2
4. Hold the center drive shaft and remove from the ma-
chine.
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Drive shaft - Install - Center Drive Shaft

1. Hold the center drive shaft (2) in position and install
the bolts (1) that fasten the center drive shaft (2) to the
transmission.
110 lb ft)
LEIL15WHL1207AB 1
110 lb ft)
LEIL15WHL1203AB 2
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Drive shaft - Remove - Center bearing

NOTICE: the bolts (1) that fasten the center drive shaft to
the front drive shaft must be replaced when removed.
LEIL15WHL1203AB 1
2. Loosen and remove the lubrication hose (1) from the

carrier bearing (2).
LEIL15WHL1204AB 2
3. Loosen and remove the lock nut (1) which fastens the
yoke (2) to the front drive shaft and remove the yoke
(2).
NOTE: make an alignment mark on the yoke and the front
drive shaft to be sure that the yoke is installed correctly.
LEIL15WHL1205AB 3
4. Use an acceptable puller and remove the yoke from the

end of the front drive shaft.
5. Remove any paint or rust from the rear of the front drive
shaft and apply WD-40® or similar oil to loosen any rust
between the inner race and the front drive shaft.
6. Loosen the set screws that secure the carrier bearing
to the front drive shaft.
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23.1 [23.314] / 11
7. Loosen and remove the bolts (1), washers and nuts that
fasten the bearing housing (2) to the front frame.
LEIL15WHL1208AB 4
8. Install two longer bolts, at least 3 inches, to hold the

bearing housing during removal. Use an acceptable
puller to remove the bearing housing from the front
drive shaft.
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Drive shaft - Install - Center Bearing

NOTE: The center bearing and the bearing housing are not serviced separately. If the center bearing is worn or
damaged or if the bearing housing is cracked, a new center bearing and bearing housing must be used.
1. Apply antiseize compound to the bearing area of the
front drive shaft.
2. Install the bearing housing so that the lubrication fitting
is at the top.
3. Apply LOCTITE® 242® to bolt threads. Install the bolts
(1), washers and nuts that fasten the bearing housing
(2) to the front frame.
121 lb ft)
LEIL15WHL1208AB 1
4. Turn the set screw down to the shaft and then back it
off 1/4 turn and lock it with the jam nut. Repeat the
procedure with the other set screw.
LEIL13WHL1074AA 2
5. Apply antiseize compound to the splines on the front

drive shaft.
6. Install the yoke (2) to the front drive shaft, making sure
the alignment marks made during removal are aligned.
7. Install the washer and lock nut (1) that fasten the yoke
(2) to the front drive shaft. Tighten the lock nut (1) to a
torque of 339 – 375 Nm ( 250 – 275 lb.ft).
LEIL15WHL1205AB 3
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23.1 [23.314] / 13
8. Install the lubrication hose (1) into the fitting on the

bearing housing (2).
LEIL15WHL1204AB 4
110 lb ft)
LEIL15WHL1203AB 5
10. Lubricate the carrier bearing with the grease.
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Drive shaft - Remove - Rear Drive Shaft

1. Loosen and remove the bolts (1) that fasten the rear
NOTICE: the bolts (1) that fasten the rear drive shaft (2) to
the transmission must be replaced when removed.
2. Use a prybar to disengage the rear drive shaft (2) from
the transmission.
drive shaft (2) to the rear axle.
the rear axle must be replaced when removed.
LEIL15WHL1209AB 1
4. Hold the rear drive shaft and remove from the machine.
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Drive shaft - Install - Rear Drive Shaft

1. Hold the rear drive shaft (2) into position and install the
bolts (3) that fasten the rear drive shaft (2) to the rear
axle.
110 lb ft)
2. Install the bolts (1) that fasten the rear drive shaft (2) to
the transmission.
110 lb ft)
LEIL15WHL1209AB 1
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Index
Drive shaft - 314

Drive shaft - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive shaft - Install - Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive shaft - Install - Center Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Drive shaft - Install - Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Drive shaft - Install - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drive shaft - Remove - Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Drive shaft - Remove - Center bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drive shaft - Remove - Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive shaft - Remove - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Drive shaft - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN ITALY
48083742_EN 31/07/2018
EN
SERVICE MANUAL
Front axle system

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25
Contents
Front axle system - 25
[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
[25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2
[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3
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25
Powered front axle - 100

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25.1 [25.100] / 1
Contents
TECHNICAL DATA
Powered front axle

Torque - Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque - Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Powered front axle

External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE
Powered front axle

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Filling Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Filling Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Front axle system - Powered front axle
Powered front axle - Torque - Model 3105 II

Outboard planetary drive bolts Initial: 200 N·m (148 lb ft)
Final: 500 N·m (369 lb ft)
Brake spring retainer cover 34 N·m (25 lb ft)
Axle wheel end screw plug 50 N·m (37 lb ft)
Axle brake tube 100 N·m (74 lb ft)
Brake tube fitting to wheel end fitting 36 N·m (27 lb ft)
Axle housing bolts 560 N·m (413 lb ft)
Input flange slotted nut 1200 N·m (885 lb ft)
Differential releasing housing cover bolts 185 N·m (136 lb ft)
Differential housing cover bolts 400 N·m (295 lb ft)
Powered front axle - Special tools

Pinion shaft seal installer CAS2841
Pinion locknut wrench CAS2842
Pinion clamping device 380001546
Pinion outer bearing cup installer 380100001
Powered front axle - Torque - Model 3115 II

Locknut securing planetary carrier 700 – 1000 N·m (516 – 738 lb ft)
Axle brake tube mount 36 N·m (27 lb ft)
Axle drive housing bolts 560 N·m (413 lb ft)
Bearing housing cylindrical screws 50 N·m (37 lb ft)
Differential case oil tube 100 N·m (74 lb ft)
Differential case oil tube mounting nut 100 N·m (74 lb ft)
Spider gear mount disk bolts 50 N·m (37 lb ft)
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Powered front axle - General specification

Front Axle Model MT-L3105II - Open Differential (only for 1021G version)
LEIL15WHL1219FA 1
OVERALL WIDTH 2476 mm (97 in)

DISTANCE FLANGE TO FLANGE 2314 mm (91 in)
WHEEL MOUNTING BOLT CIRCLE DIAMETER 500 mm (20 in)
WHEEL MOUNTING BOLTS 23 ( M22x1.5)
HUB RATIO 6:1
CROWN/PINION RATIO 4.11:1
OVERALL RATIO 24.67:1
CLOCKWISE INPUT ROTATION (FACING INPUT
–
FLANGE) FOR FORWARD TRAVEL
Lubrication capacity for axles 42.0 l (44.4 US qt)

Lubrication capacity for axles with axle cooler 45.7 l (48.3 US qt)
Sun Gear Shaft End Play 0.5 – 2.0 mm (0.02 – 0.08 in)
Drive Pinion Rolling Torque 1.5 – 4.0 N·m (13.3 – 35.4 lb in)
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Front Axle Model MT-L3115II - Open Differential
Front Axle Model MT-L3115II - Locking Differential
LEIL15WHL1220FA 2

HUB RATIO 6.353:1
OVERALL RATIO 27:1
Lubrication capacity for heavy duty axles 62.0 l (65.5 US qt)

Lubrication capacity for heavy duty axles with axle cooler 65.7 l (69.4 US qt)
Sun gear shaft end play 0.5 – 2.0 mm (0.02 – 0.08 in)
Drive pinion rolling torque 1.5 – 5.0 N·m (13 – 44 lb in)
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Powered front axle - External view

Model 3105 II
LEIL15WHL1213FB 1
(1) Washer (4) Nut

(2) Bolt (5) Front Axle
(3) Washer
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Powered front axle - External view

Model 3115 II
LEIL15WHL1214FB 1
(1) Washer (4) Nut

(2) Bolt (5) Front Axle
(3) Washer
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Powered front axle - Remove

1. Park the machine on level surface.
Apply the articulation lock.
BD03A040-01 1
2. Raise the bucket and have an assistant to install safety

strut. Lower loader arms slowly until safety strut is sup-
porting loader arms.
BD03A092-01 2
3. Stop engine. Actuate brake pedal several times to dis-

charge brake accumulators. Put key switch in ON po-
sition and move loader control lever back and forth at
least 30 times to release any pressure from hydraulic
circuit. Put key switch in OFF position.
4. Remove four bolts (1) securing front drive shaft (2) to
front axle.
NOTICE: the bolts that fasten the front drive shaft must be
replaced when removed.
5. Use a prybar and disengage the front drive shaft (2)
from the front axle.
LEIL15WHL1206AB 3
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6. Disconnect brake hose (1) from elbow (2). Remove

and discard O-ring face seal from elbow.
BD03A168-01 4
7. For machines with brake damping accumulators, dis-

connect brake line from elbow at axle connection. re-
move and discard O-ring face seal from elbow. To re-
move accumulator, also disconnect brake line and hose
from accumulator. Unbolt accumulator from machine
frame.
LEIL13WHL0569AB 5
8. If equipped, disconnect the differential lock hose.
LEIL13WHL0570AB 6
9. Using an acceptable hydraulic jack, raise one tire from

ground
10. Install an acceptable jack stand under machine.
BD01D392-01 7
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11. Repeat Step 9 to 10 to raise other front axle tire from

ground.
12. Use an acceptable jack to hold front axle.
BD01F297-01 8
13. Remove bolts and washers from front wheels . Re-

move both wheels from front axle.
LEIL15WHL1229AB 9
14. Remove 4 nuts (3) bolts (1), and 8 washers (2) from
each side securing front axle to machine.
LEIL15WHL1230AB 10
15. Carefully lower front axle and remove from under ma-
chine.
Next operation:
Differential - Remove Model 3105 II (25.102), Wheel hub - Remove Model 3105 II (25.108), Differential - Remove
Model 3115 II (25.102), Wheel hub - Remove Model 3115 II (25.108)
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Powered front axle - Install

1. Carefully move front axle under machine and raise
against mounting pads on machine.
2. Apply one drop of engine oil to threads prior to assem-
bly. Install four washers on the top side (2), four bolts
(1), four washers on the bottom side, and four nuts (3)
on each side of the axle to secure front axle to machine.
LEIL15WHL1230AB 1
3. Tighten bolts to a torque of 1520 – 1712 N·m (1121 –

1263 lb ft) in the sequence indicated.
A. Front side of machine
LEIL13WHL0565FB 2
4. Install both wheels on front axle and secure using

washers and bolts.
LEIL15WHL1229AB 3
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5. Tighten bolts to a preliminary torque of 298 N·m (220 lb

ft) in sequence indicated; then tighten to a torque of 640
– 720 Nm ( 475 – 530 lb.ft) in same sequence.
6. Remove jack from front axle.
BD01F297-01 4
7. Using an acceptable hydraulic jack, raise axle

8. Remove jack stand from under machine.
BD01D392-01 5
9. Repeat Step 7 to 8 to remove other jack stand from

under machine.
10. Install a new O-ring face seal in elbow (1). Connect
brake hose (2) to elbow.
BD03A168-01 6
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11. For machines with brake damping accumulators, in-

stall a new O-ring face seal and connect brake line
to elbow at axle connection. If accumulator has been
removed, bolt accumulator to machine frame and con-
nect brake line and hose to accumulator.
LEIL13WHL0569AB 7
12. If equipped, connect differential lock hose.
LEIL13WHL0570AB 8
13. Secure the drive shaft (2) to the front axle using four
bolts (1).
Tighten bolts (1) to a torque of 136 – 149 N·m (100 –
110 lb ft).
LEIL15WHL1206AB 9
14. If necessary, fill axle with the specified gear lubricant.

See front axle filling.
15. Refer to Hydraulic service brakes - Bleed (33.202)
and bleed brakes.
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16. Start engine and raise bucket. Have an assistant to

remove the safety strut. Lower the bucket to ground
and stop the engine.
BD03A092-01 10
17. Put articulation lock in OPERATING position.
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Powered front axle - Filling Model 3105 II
RCPH11WHL143AAR 1
1. Brake bleeder 4. Oil filler hole

2. Bleeder 5. Oil drain hole (Axle casing)
3. Oil drain hole (Outputs)
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Powered front axle - Filling Model 3115 II
RCPH11WHL143AAR 1
1. Brake bleeder 4. Oil filler hole

2. Bleeder 5. Oil drain hole (Axle casing)
3. Oil drain hole (Outputs)
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Index

Powered front axle - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Powered front axle - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Powered front axle - Filling Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Powered front axle - Filling Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Powered front axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Powered front axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Powered front axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Powered front axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered front axle - Torque - Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered front axle - Torque - Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Front bevel gear set and differential - 102

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Contents
SERVICE
Bevel gear set and differential carrier

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Backlash Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Backlash Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Differential
Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Disassemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Remove Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Assemble Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Install Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Differential lock
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Front axle system - Front bevel gear set and differential
Bevel gear set and differential carrier - Check

Ideal tooth contact pattern
LEIL15WHL1223AA 1 LEIL15WHL1224AA 2
Coast side (concave) Drive side (convex)
Pinion distance must be increased
LEIL13WHL0577AA 3
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Pinion distance must be decreased
LEIL13WHL0580AA 6
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Bevel gear set and differential carrier - Backlash Model 3105 II

CAUTION
Burn hazard!
Always wear heat-resistant protective gloves when handling heated parts.
C0047A
Prior operation:
Differential - Assemble Model 3105 II (25.102)
1. Determine shim thickness to obtain correct gear con-

tact pattern. Read dimension I (arrow) from axle drive
housing. Dimension I e.g. 245.60 mm (9.67 in).
NOTE: If crown wheel or input pinion are damaged, both
parts must be replaced together. In case of an installation
of a complete new bevel gear set, pay attention to an iden-
tical mating number on input pinion and crown wheel.
NOTE: The following measuring procedures must be com-
pleted accurately. Inaccurate measurements lead to incor-
rect contact pattern requiring additional disassembly and
reassembly of input pinion and differential.
RCIL11WHL087BAF 1
2. Read pinion dimension (arrow), Dimension II. Dimen-

sion II e.g. 202.00 mm (7.95 in).
RCIL11WHL088BAF 2
3. Determine dimension III (bearing width). Dimension

III e.g. 42.60 mm (1.68 in). Calculation Example
“A”: Dimension I: 245.60 mm (9.67 in)Dimension II:
202.00 mm (7.95 in) Dimension III: 42.60 mm (1.68 in)
Difference = shim s = 1.00 mm (0.04 in).
RCIL11WHL089BAF 3
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4. Cool external bearing. With a driver tool, insert it into

axle drive housing until contact is made.
RCIL11WHL090BAF 4
5. Insert determined shim size e.g. s = 1.00 mm (0.04 in)

into housing.
RCIL11WHL091BAF 5
6. Cool internal bearing outer ring. Bring it into contact

position within housing hole using 380100001 Bearing
Cup Installer.
RCIL11WHL092BAF 6
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7. Heat tapered roller bearing. Insert it onto input pinion

until contact is made.
RCIL11WHL093BAF 7
8. Set rolling torque of input pinion bearing without shaft

seal at 1.5 – 4.0 N·m (13.3 – 35.4 lb in). Insert spacer
(e.g. s= 8.18 mm (0.32 in)).
NOTE: Based on experience, necessary rolling torque is
obtained when reusing the spacer removed during disas-
sembly e.g. s = 8.18 mm (0.32 in).
NOTE: A later check of rolling torque is needed.
RCIL11WHL094BAF 8
9. Insert preassembled input pinion into axle drive hous-

ing. Insert heated tapered roller bearing until contact is
made.
RCIL11WHL095BAF 9
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10. Press protection plate onto input flange (arrow) until

contact is made.
NOTE: Do not fit shaft seal until contact pattern has been
checked.
RCIL11WHL096BAF 10
11. Insert input flange and secure it with disk and slot-
ted nut. Torque to 1200 N·m (885 lb ft) using pin-
ion locknut wrench CAS2842 and clamping device
380001564.
NOTE: Temporarily mount slotted nut without Loctite.
While tightening, rotate input pinion several times in both
directions.
RCIL11WHL097BAF 11
12. Check rolling torque. It should be 1.5 – 4.0 N·m (13.3

– 35.4 lb in) without shaft seal.
NOTE: When installing new bearings try to achieve upper
value of rolling torque.
NOTE: In case of deviations from needed rolling torque,
correct with a corresponding spacer as specified in step 8.
For insufficient rolling torque - install thinner spacer ring.
Excessive rolling torque - install a thicker spacer ring.
RCIL11WHL098BAF 12
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25.2 [25.102] / 8
13. Determine required shims to set bearing rolling torque

(differential housing) and backlash (bevel gear set).
Select shims based on the read value (deviation/test
dimension) and corresponding specifications in f the
following table: (KRS - SET - RIGHT) (KRS = bevel
gear set): See the crown wheel rear side for devia-
tion. The test dimension “106” is stamped into the rear
side. If no + or - deviation is indicated, the value cor-
responds to actual value “0” in the table. Based on
this value, the required shims are allocated in the ta-
ble. Any + or - deviation of the test dimension caused
by production will be marked on the crown wheel rear
side (e.g. - 20 or - 10 or 10 or 20). Based on the de-
viation, the required shims are allocated in the table.
RCIL11WHL101BAF 13
14. 1 = Axle housing, 2 = Shim (crown wheel side), 3 =

Shim (differential carrier side) 4 = Axle housing
RCIL11WHL156BAF 14
Shims for differential in MT-L 3105 II axles

Crown wheel marking -20 -10 N/A 10
Deviation –0.2 -0.1 0 0.1
Shim diff. cage side 0.8 0.9 1.0 1.1
Shim thickness
Shim Crown wheel 1.2 1.1 1.0 0.9
side Shim thickness
15. Insert selected shim e.g. s = 1.0 mm (0.04 in) into

hole of axle housing and adjust bearing outer ring (ar-
row) until contact is obtained.
RCIL11WHL102BAF 15
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25.2 [25.102] / 9
16. Cover some drive and coast flanks of crown wheel

with marking ink. Insert premounted differential into
axle drive housing.
RCIL11WHL103BAF 16

row) until contact is made.
RCIL11WHL104BAF 17
18. Mount two locating pins and bring axle housing into
contact position with axle drive housing using a suit-
able lifting device. Temporarily attach axle housing
with hex bolts. Torque to 560 N·m (413 lb ft).
NOTE: Test mount axle housing without O-ring.
RCIL11WHL105BAF 18
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25.2 [25.102] / 10
19. Rotate input flange, in both directions several times,

to roll crown wheel over input pinion. Remove axle
housing and lift differential out of axle drive housing.
Compare obtained contact pattern with contact patter
examples at the beginning of this section.
NOTE: If a contact pattern deviation exists, a measuring
error was made during shim size determination. This must
be corrected.
RCIL11WHL107BAF 19
Next operation:
Differential - Install Model 3105 II (25.102) .
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Bevel gear set and differential carrier - Backlash Model 3115 II

CAUTION
Burn hazard!
C0047A
Prior operation:
Differential - Assemble Model 3115 II (25.102) Differential lock - Assemble Model 3115 II (25.102)
Reassembly axle drive housing

RCPH11WHL577BAU 1

sion II e.g. 265.00 mm (10.4 in).
RCPH11WHL578BAU 2
3. Determine dimension III (bearing width). See following

table for dimension determination procedure.
RCIL11WHL089BAF 3
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Calculation Example A
Dimension I 331.25 mm
Dimension II — 265.00 mm
Dimension III — 63.60 mm
Dimension = shim s = 2.60 mm
Reassembly of input pinion

4. Undercool the external bearing outer ring and insert it
into the axle drive housing until contact is obtained.
RCIL11WHL090BAF 4

into housing hole.
RCPH11WHL581BAU 5
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6. Undercool the internal bearing outer ring. and bring

it into contact position in the housing hole using the
assembly fixture (S).
RCIL11WHL092BAF 6

until contact is obtained.
RCIL11WHL093BAF 7

(e.g. s= 7.13 mm (0.3 in) ).
NOTE: According to our experience the necessary rolling
torque is obtained when reusing the spacer which has been
removed during disassembly (e.g.: s = 7.13 mm (0.3 in))!
A later check of the rolling torque however is absolutely
necessary!
RCIL11WHL094BAF 8
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9. Insert the preassembled input pinion into axle drive

housing. Insert the heated tapered roller bearing un-
til contact is obtained.
RCPH11WHL585BAU 9

contact is obtained.
checked.
RCIL11WHL096BAF 10
11. Insert input flange and use the wrench 380002318 to

fix it by means of disk and slotted nut. Tightening
torque to 1200 N·m (885 lb ft).
NOTE: Preliminarily mount slotted nut without Locite!
NOTE: While tightening, rotate the input pinion several
times in both directions!
RCPH11WHL587BAU 11
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• Insufficient rolling torque — Install thinner spacer
ring.
• Excessive rolling torque — Install thicker spacer ring.
NOTE: When installing new bearings try to achieve the up-
per value of rolling torque.
NOTE: In case of deviations from the necessary rolling
torque, correct with a corresponding spacer as specified
in step 8 following specifications below:
RCPH11WHL588BAU 12
13. Mount threaded connection. Tightening torque to

100 N·m (885 lb in).
RCPH11WHL589BAU 13
14. Mount oil tube. Tightening torque to 100 N·m (885 lb

in).
RCPH11WHL590BAU 14
15. Grease O-rings (arrows) and insert them into the an-
nular groves of the piston.
NOTE: This step is for locking differential equipped axles
only!
RCPH11WHL591BAU 15
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16. Insert piston (arrow) into the bearing housing until con-
tact is obtained.
only!
RCPH11WHL592BAU 16
Determination of shims for setting bearing rolling torque (differential housing) and back-
lash (bevel gear set)
17. Determine the required shims on the basis of the read
value (deviation/test dimension) and the correspond-
ing specifications of the table below: )KRS — SET —
RIGHT) (KRS = bevel gear set).
The test dimension „108“ is stamped into the crown
wheel rear side. If no + or – deviation is indicated,
this value corresponds to the actual value “O” in the
following table. Any + or – deviation of the test dimen-
sion caused by production will be marked on the crown
wheel rear side (e.g. - 20 or - 10 or 10 or 20). In accor-
dance with this deviation, the required shims are allo-
cated in the following table.
NOTE: Deviation see crown wheel rear side.
RCPH11WHL593BAU 17
18. Legend to sketch:

1. Bearing housing
2. Shim (crown wheel side)
3. Shim (diff. carrier side)
4. Axle drive housing
RCPH11WHL649BAU 18
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Shims for differential D /DL and DHL — 5000 in ZF axles MT — L 3115/3125

Crow wheel -30 -20 -10 0 10 20
making
Deviation -0.3 -0.2 -0.1 0 0.1 0.2
Shim 1.1 1.2 1.3 1.4 1.5 1.6
Diff. cage
side. Shim
thickness
Shim ZF-order 0730 300 842 0730 113 897 0730 113 868 0730 113 859 0730 113 869 0730 113 870
no.
Shim Crown 1.7 1.6 1.5 1.4 1.3 1.2
wheel
side. Shim
thickness
Shim ZF — 0730 300 926 0730 113 875 0730 113 874 0730 113 860 0730 113 873 0730 113872
order no.
19. Insert the determined shim (e.g. s= 1.4 mm (0.1 in)

into the hole of axle drive housing and reset until con-
tact with bearing outer ring is obtained.
RCPH11WHL594BAU 19
20. Cover some drive and coast flanks of the crown wheel
with marking ink. Then insert premounted differential
into axle drive housing.
RCPH11WHL595BAU 20
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21. Insert the determined shim (e.g. s = 1.4 mm (0.1 in))

into the bearing housing and reset the bearing outer
ring until contact is obtained.
RCPH11WHL596BAU 21
22. Place the premounted bearing housing onto the axle

drive housing by means of the lifting device.
NOTE: Preliminarily mount the bearing housing without
O-rings.
RCPH11WHL597BAU 22
23. Fix the bearing housing by means of cylindrical

screws (3x). Tightening torque (M12/10.9) to 50 N·m
(442.5 lb in).
RCPH11WHL598BAU 23
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Leak test of lock

24. Pressurize the lock (p= 1 bar (14.5 psi)), close shut-
off valve and remove air line.
NOTE: No noticeable pressure loss in allowed to occur
within 10 sec.
NOTE: Operation is only necessary for version with hy-
draulic differential lock!
RCPH11WHL599BAU 24
25. By rotating the input flange, roll crown wheel over in-
put pinion in both directions.
26. Then remove the bearing housing again and lift the
differential out of axle drive housing.
27. Compare the obtained contact pattern with contact
pattern examples at the beginning of this section.
NOTE: In case of any contact pattern deviation, a measur-
ing error was made during shim size determination. This
must be corrected.
RCPH11WHL600BAU 25
Next operation:
Differential - Install Model 3115 II (25.102)
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Differential - Remove Model 3105 II

Prior operation:
Powered front axle - Remove Model 3105 II/3115 II (25.100)
1. Use a suitable lifting device and attach axle to assembly

stand.
RCIL11WHL001BAF 1
2. Remove plug and drain oil from differential carrier.

NOTE: Use a suitable container for collection of oil and
abide by all local environmental laws for proper handling
and disposal.
RCIL11WHL002BAF 2
3. Remove plugs and drain oil from outputs.

and disposal.
RCIL11WHL003BAF 3
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4. Remove bleeder valves to avoid damage during output

and axle housing separation.
RCIL11WHL004BAF 4
5. Attach suitable lifting device to output assembly. Re-

move hex bolts and separate output assembly from
axle housing.
ATTENTION: Attach load carrying device with a wheel nut.
RCIL11WHL005BAF 5
6. Pull stub shaft and sun gear shaft from output.

NOTE: Watch for loose shim(s).
RCIL11WHL006BAF 6
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7. Secure axle housing with suitable lifting device and

loosen hex bolts. Separate axle housing from drive
housing.
NOTE: Be aware of possible release of differential.
RCIL11WHL024BAF 7
8. Loosen threaded connections and remove brake re-

lease tube.
RCIL11WHL025BAF 8
9. Remove screw neck.
RCIL11WHL026BAF 9
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10. Pull bearing outer ring and remove shim behind. Then
remove O-ring (arrow).
RCIL11WHL027BAF 10
11. Use a suitable lifting device and pull differential from

axle drive housing.
NOTE: Disassembly of differential is covered in a separate
section.
RCIL11WHL028BAF 11
12. Pull bearing outer ring (arrow) from housing and re-
move shim.
RCIL11WHL029BAF 12
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13. Heat slotted nut.

NOTE: Slotted nut is secured with LOCTITE® 262™.
RCIL11WHL032BAF 13
14. Remove slotted nut and shim using pinion locknut

wrench CAS2842 and clamping device 380001546.
RCIL11WHL033BAF 14
15. Pull input flange from pinion. Use a lever to remove

shaft seal.
RCIL11WHL034BAF 15
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16. Press input pinion from axle drive housing and remove
releasing tapered roller bearing.
RCIL11WHL035BAF 16
17. Remove spacer ring and pull tapered roller bearing

from input pinion.
RCIL11WHL036BAF 17
18. If needed, remove both bearing outer rings from axle

drive housing.
RCIL11WHL037BAF 18
Next operation:
Differential - Disassemble Model 3105 II (25.102)
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Differential - Disassemble Model 3105 II

Prior operation:
Differential - Remove Model 3105 II (25.102) .
1. Pull both tapered roller bearings from differential.
RCIL11WHL050BAF 1
2. Preload differential using a press. Remove hex bolts

and releasing housing cover.
RCIL11WHL051BAF 2
3. Preload differential using a press. Remove locking

bolts and housing cover.
RCIL11WHL052BAF 3
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4. Remove axle bevel gear with thrust washers from dif-

ferential housing.
RCIL11WHL053BAF 4
5. Force out both slotted pins.
RCIL11WHL054BAF 5
6. Force out both short differential axles. Remove releas-

ing spider gears with thrust washers from differential
housing.
RCIL11WHL055BAF 6
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7. Pull long differential axle. Remove releasing spider

gears with thrust washers from differential housing.
RCIL11WHL056BAF 7
8. Remove axle bevel gear and shim.
RCIL11WHL057BAF 8
9. Press crown wheel from differential carrier.
RCIL11WHL058BAF 9
Next operation:
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Differential - Assemble Model 3105 II

CAUTION
Burn hazard!
C0047A
Prior operation:
1. Mount locating pins and press heated crown wheel onto

differential housing until contact is made.
RCIL11WHL076BAF 1
2. Insert thrust washer into differential housing.
RCIL11WHL077BAF 2
3. Insert axle bevel gear.
RCIL11WHL078BAF 3
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4. Insert spider gears with thrust washers into differential

housing. Secure them with long spider shaft.
NOTE: Thrust washers must be positioned with tabs (ar-
row) located in recesses of differential housing.
RCIL11WHL079BAF 4

housing. Secure them with two short spider shafts.
NOTE: Thrust washers must be positioned with tabs (1)
located in recesses of differential housing. Pay attention
to radial installation position of spider shaft securing holes
(2).
RCIL11WHL080BAF 5
6. Secure short spider shafts with slotted pins.

NOTE: Flush mount slotted pins.
RCIL11WHL081BAF 6
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7. Mount second axle bevel gear.
RCIL11WHL082BAF 7
8. Secure thrust washers into housing cover with grease.
RCIL11WHL083BAF 8
9. Mount two adjusting bolts and insert housing cover un-

til contact with differential housing is obtained. Preload
differential using a press. Secure with new locking
RCIL11WHL084BAF 9
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10. Attach housing cover and preload differential with a

suitable press. Secure housing cover with hex bolts
and torque to 185 N·m (136 lb ft).
RCIL11WHL085BAF 10
11. Heat both tapered roller bearings and insert until con-
tact is made. Adjust tapered roller bearing after cool-
ing down.
RCIL11WHL086BAF 11
Next operation:
Bevel gear set and differential carrier - Backlash Model 3105 II (25.102) .
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Differential - Install Model 3105 II

Prior operation:
Bevel gear set and differential carrier - Backlash Model 3105 II (25.102)
1. After successful contact pattern check, reinsert differ-

ential into axle drive housing.
RCIL11WHL108BAF 1
2. Loosen slotted nut using pinion lock nut wrench

CAS2842 with 380001564 clamping device and pull
input flange from input pinion.
RCIL11WHL109BAF 2
3. Use pinion shaft seal installer CAS2841 to mount shaft

seal with seal lip facing oil chamber.
NOTE: Exact installation position of seal is obtained when
using specified tool.
NOTE: Wet outer diameter of shaft seal with mineral spirits
just before installation. Fill space between seal and dust lip
with grease.
RCIL11WHL110BAF 3
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4. Insert input flange and secure with disc and slotted nut
using pinion locknut wrench CAS2842 and clamp de-
vice 380001546. Torque to 1200 N·m (885 lb ft).
NOTE: Cover threads of slotted nut with LOCTITE® 262™.
RCIL11WHL111BAF 4
5. Grease O-ring (arrow) insert it into axle housing.
RCIL11WHL112BAF 5
6. Mount M20 locating pins. Use a suitable lifting de-

vice and bring axle housing into contact position with
axle drive housing. Secure axle housing with hex bolts.
NOTE: After assembling axle housing secure axle with
clamping brackets.
RCIL11WHL113BAF 6
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7. Mount fitting. Torque to 36 N·m (27 lb ft).
RCIL11WHL114BAF 7
8. Grease O-ring. Insert it into annular groove of brake

tube (arrow).
RCIL11WHL115BAF 8
9. Mount brake tube with threaded connection and hex nut

(arrow). Torque to 100 N·m (74 lb ft).
RCIL11WHL116BAF 9
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10. Install plug and new O-ring. Torque to 50 N·m (37 lb

ft).
RCIL11WHL117BAF 10
Next operation:
Wheel hub - Install Model 3105 II (25.108)
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CAUTION
Eye injury hazard!
C0035A
Prior operation:
Disassembly output and brake

1. Fix axle to suitable stand.
RCPH11WHL485BAU 1
2. Loosen screw plugs (3x), see Figures 2 and 3 and drain

oil from axle.
RCPH11WHL486BAU 2
RCPH11WHL487BAU 3
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3. Remove bleeder valve (arrow).

NOTE: To avoid any damage, the breather valve must be
removed when separating the output.
RCPH11WHL488BAU 4
4. Secure the output with the lifting device (S) and loosen
hexagon screws. Then separate the output assembly
from the axle housing
NOTE: Fix the load carrying device (S) with a wheel nut.
RCPH11WHL489BAU 5
5. Pull stub shaft and sun gear shaft.

NOTE: Pay attention to potentially releasing shim(s)
RCPH11WHL490BAU 6
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Disassembly axle housing

6. Secure axle housing with lifting device and loosen hex
screws. Then separate the axle housing from drive
housing.
RCPH11WHL507BAU 7

leasing brake tube.
RCPH11WHL508BAU 8
8. Loosen both screw necks.
RCPH11WHL509BAU 9
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Disassembly axle drive housing

9. Secure axle drive housing with the lifting device (S) and
loosen the hexagon screws.
10. Separate the axle drive housing from the axle housing.
RCPH11WHL510BAU 10
11. Fix axle drive housing to a suitable stand.
RCPH11WHL511BAU 11
12. Loosen cylindrical screws and lift the releasing bear-

ing housing with the lifting device.
RCPH11WHL512BAU 12
13. Pull bearing outer ring (arrow) out of the bearing hole
and remove the shim behind.
RCPH11WHL513BAU 13
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14. Press the piston out of the bearing housing by means

of compressed air.
NOTE: Operation is only necessary for the version with
hydraulic differential lock!
RCPH11WHL514BAU 14
15. Lift differential out of the axle drive housing with the
lifting device.
NOTE: Disassembly of the various differentials are located
in the Disassembly multi-disk section of this manual.
RCPH11WHL515BAU 15
16. Pull the bearing outer ring (arrow) out of the bearing
hole and remove the shim behind.
RCPH11WHL516BAU 16
17. Heat slotted nut by means of hot-air blower.

RCPH11WHL517BAU 17
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18. Loosen the slotted nut and remove the shim behind.
RCPH11WHL518BAU 18
19. Pull input flange from the input pinion. Use a lever
to lift the shaft seal ring behind, out of the axle drive
housing.
RCPH11WHL519BAU 19
20. Use a two-armed puller to press the input pinion out

of the axle drive housing and remove the releasing
tapered roller bearing.
RCPH11WHL520BAU 20
21. Remove the spacer ring and pull the tapered roller
bearing from the input pinion.
RCPH11WHL521BAU 21
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22. Loosen the threaded connection and remove the re-

leasing oil tube.
RCPH11WHL522BAU 22
23. If necessary, pull the internal bearing outer ring out of

the axle driving housing and remove shim behind.
RCPH11WHL523BAU 23
24. If necessary, pull the external bearing ring out of the

axle drive housing.
RCPH11WHL524BAU 24
Next operation:
Differential - Disassemble Model 3115 II (25.102) Differential lock - Disassemble Model 3115 II (25.102)
48083742_EN 31/07/2018
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Prior operation:
Differential - Remove Model 3115 II (25.102)
Disassembly differential D-5000

RCPH11WHL526BAU 1
2. Preload the differential by means of the press and

loosen the locking screws.
RCPH11WHL527BAU 2
3. Lift the differential cover from the differential housing by

means of the lifting device.
RCPH11WHL528BAU 3
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4. Loosen hexagon screws and remove the releasing

disk.
RCPH11WHL531BAU 4
5. Remove the thrust washer and axle bevel gear from the
differential housing.
RCPH11WHL532BAU 5
6. Force out slotted pins (4x).
RCPH11WHL533BAU 6
7. Pull spider shafts (4x) and remove the releasing spi-

der gears with the thrust washers from the differential
housing.
RCPH11WHL534BAU 7
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8. Remove axle bevel gear and shims behind.
RCPH11WHL535BAU 8
9. Support the crown wheel and force out the differential

housing.
RCPH11WHL536BAU 9
Next operation:
48083742_EN 31/07/2018
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CAUTION
Burn hazard!
C0047A
Prior operation:
Assemble differential D-5000

1. Mount two adjusting screws (S) and press the heated
crown wheel onto the differential housing until contact
is obtained.
RCPH11WHL546BAU 1
2. Insert disk and thrust washer into differential housing.
RCIL11WHL077BAF 2
RCIL11WHL078BAF 3
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housing and fix them with the spider shafts.
(2).
RCPH11WHL549BAU 4
5. Fix spider shafts with slotted pins (2 pieces/hole).

NOTE: Press the slotted pins with 180º offset openings into
flush position.
RCPH11WHL550BAU 5
6. Mount second axle bevel gear and thrust washer.
RCPH11WHL551BAU 6
7. Mount disk and fix with hexagon screws.

• Tightening torque (M10/10.9) to 50 N·m (443 lb in).
RCPH11WHL552BAU 7
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8. Mount two adjusting screws (S) and insert the differen-

tial cover by means of the lifting device.
• (S) Adjusting screws (M16 x 1.5)
RCPH11WHL574BAU 8
9. Preload the differential by means of the press and bolt

with NEW locking screws.
• Tightening torque (M/16/12.9) to 400 N·m (3540 lb
in).
RCPH11WHL564BAU 9
tact is obtained.
NOTE: Adjust tapered roller bearing after cooling down.
RCPH11WHL565BAU 10
Next operation:
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Prior operation:
Bevel gear set and differential carrier - Backlash Model 3115 II (25.102)
1. After the contact pattern check, insert the differential

again into axle drive housing.
RCPH11WHL601BAU 1
Reassembly of shaft seal ring (steps 2 — 4)

2. Use the wrench 380002318 to loosen the slotted nut
and pull the input flange from the input pinion.
RCPH11WHL602BAU 2
3. Mount the shaft seal ring with the seal lip showing to
the oil chamber.
NOTE: The exact installation position of the shaft seal rings
is obtained when using the specified driver tool (S).
NOTE: Wet the outer diameter of the shaft seal ring with
spirit directly before installation and fill the space between
seal and dust lip with grease.
RCPH11WHL603BAU 3
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finally tighten by means of disk and slotted nut. Tight-
ening torque to 1200 N·m (885 lb ft).
NOTE: Cover the thread of the slotted nut with Locite (Type
no.: 262)!
RCPH11WHL604BAU 4
5. Grease O-ring (arrow) and insert it into the annular

grove of the bearing housing.
RCPH11WHL605BAU 5
6. Insert the bearing housing by means of the lifting device

and finally tighten it with cylindrical screws. Tightening
torque (M12/10.9) to 50 N·m (37 lb ft).
RCPH11WHL606BAU 6
7. Grease O-rings (arrows) and insert them on both sides

of the axle drive housing.
RCPH11WHL607BAU 7
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8. Mount two adjusting screws (S) and bring axle drive

housing in contact position with the axle housing by
using the lifting device.
9. Then fix the axle drive housing with hexagon screws.
Tightening torque (M20/10.9) to 560 N·m (413 lb ft)
• (S) Adjusting screws (M20/10.9).
• (S) Eye bolt (M20).
NOTE: After mounting the axle drive housing, unbolt the
support (S) until contact is obtained.
RCPH11WHL608BAU 8
Reassembly axle housing

10. Mount both fittings. Tightening torque to 36 N·m
(27 lb ft).
RCPH11WHL609BAU 9
11. Mount brake tube. Tightening torque to 100 N·m

(74 lb ft).
RCPH11WHL610BAU 10
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12. Mount two adjusting screws (S) and bring the axle
housing into contact position with the axle drive hous-
ing by using the lifting device.
13. Then fix the housing by means of hexagon screws.
Tightening torque (M20/10.9) to 560 N·m (413 lb ft).
• (S) Adjusting screws (M20)
NOTE: After assembling the axle housing, secure the axle
with clamping brackets (S)!
RCPH11WHL611BAU 11
Next operation:
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Differential lock - Disassemble Model 3115 II

Prior operation:
Disassembly multi-disk differential lock DHL-5000

1. Remove axial roller cage (arrow).
RCPH11WHL525BAU 1
2. Pull both tapered roller bearing from the differential.
RCPH11WHL526BAU 2

RCPH11WHL527BAU 3
48083742_EN 31/07/2018
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RCPH11WHL528BAU 4
5. Preload the compression spring by means of the press

and disengage the retaining ring.
6. Then pull the sliding sleeve out of the differential cover
and remove the releasing compression springs.
RCPH11WHL529BAU 5
7. Remove single parts.

1. Disk
2. Pressure piece
3. Cage
4. Lever (15x)
5. Disk carrier
6. Disk package
RCPH11WHL530BAU 6

disk.
RCPH11WHL531BAU 7
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9. Remove thrust washer and axle bevel gear from the

RCPH11WHL532BAU 8
RCPH11WHL533BAU 9
housing.
RCPH11WHL534BAU 10
12. Remove the axle bevel gears and the shims behind.
RCPH11WHL535BAU 11
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housing.
RCPH11WHL536BAU 12
Next operation:
Differential lock - Assemble Model 3115 II (25.102)
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Differential lock - Assemble Model 3115 II

CAUTION
Burn hazard!
C0047A
Prior operation:
Differential lock - Disassemble Model 3115 II (25.102)
Assemble multi-disk differential lock DHL-5000

is obtained.
RCPH11WHL546BAU 1
2. Insert disk and thrush washer into the differential hous-

ing.
RCPH11WHL547BAU 2
RCPH11WHL548BAU 3
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4. Insert spider gears with thrust washers into the differ-

ential housing and fix them with the spider shaft.
NOTE: Thrust washers must be positioned with the tabs
(see arrows (1) ) in the recesses of the differential housing.
NOTE: Pay attention to radial installation position of the
spider shafts (fixing holes, arrow (2) ).
RCPH11WHL549BAU 4
5. Fix spider shafts with slotted pins (2 piece/hole).

flush position.
RCPH11WHL550BAU 5
RCPH11WHL551BAU 6

• Tightening torque (M10/10.9) to 50 N·m (37 lb ft).
RCPH11WHL552BAU 7
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Setting of disk package

8. Premount single parts according to the adjacent
sketch.
Setting of disk package
1. = Differential cover.
2. = Pressure piece.
3. = Disk.
4. = Cage.
5. = Lever (15x).
6. = End plate.
7. = Outer disks (optional). RCPH11WHL647BAU 8
8. = Inner disks.
9. Preload disk package with an axial force of F = 7
t. Then check the setting dimension „A” = 15.5 mm
(0.6 in) ± 0.2 mm (0.008 in) from the mounting face
of the differential cover to the plane face of the outer
disk. (Also see sketch below).
NOTE: Any deviation form the specified setting dimension
must be corrected with a corresponding outer disk!
RCPH11WHL553BAU 9
10. Legend to sketch

• A = Setting dimension = 15.5 mm (0.6 in) ± 0.2 mm
(0.008 in).
RCPH11WHL648BAU 10
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11. Engage the snap ring (see arrow) into the annular
groove of the disk carrier.
RCPH11WHL554BAU 11
12. Insert the premounted disk carrier onto the axle bevel
gear.
RCPH11WHL555BAU 12
13. Mount outer and inner disks.

NOTE: For the number of disks and disk arrangement
please refer to the relating spare parts list.
NOTE: Pay attention to the radial installation position of the
disk package, as shown on the adjacent figure.
RCPH11WHL556BAU 13
14. Insert end plate.
RCPH11WHL557BAU 14
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15. Mount cage and lever (15x).
RCPH11WHL558BAU 15
16. Insert pressure piece (see arrow) and install disk.
RCPH11WHL559BAU 16
17. Insert compression springs (6x) into the differential

cover.
RCPH11WHL560BAU 17
18. Insert sliding sleeve.
RCPH11WHL561BAU 18
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19. Preload the compression springs by means of the

press and engage the retaining ring into the annual
grove of the sliding sleeve.
RCPH11WHL562BAU 19
20. Mount two adjusting screws (S) and insert the differ-
ential cover by means of the lifting device.
RCPH11WHL574BAU 20

• Tightening torque (M16/12.9).to 400 mm (15.7 in)
RCPH11WHL564BAU 21
tact is obtained.
RCPH11WHL565BAU 22
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23. Insert axial roller cage (see arrow).
RCPH11WHL566BAU 23
Locking differential axles.

24. Grease O-rings (see arrows) and insert them into the
annular grooves of the piston.
only.
RCPH11WHL591BAU 24
25. Insert piston (see arrow) into the bearing housing until
only.
RCPH11WHL592BAU 25
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Check operability of DHL

26. Build up pressure p = 20 bar (290 psi) max. and close
connection to high pressure pump via shut-off valve.
Lock on:
• When rotating the input flange, both outputs must
have the same direction of rotation.
Lock off:
• When rotating the input flange, one side holds or has
the opposite direction of rotation.
ATTENTION: This procedure MUST be completed after
axle assembly, prior to axle installation!
NOTE: Prior to putting the axle into operation, fill it with RCPH11WHL645BAU 26
oil according to the related lubrication and maintenance
instructions.
Next operation:
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Index

Bevel gear set and differential carrier - Backlash Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bevel gear set and differential carrier - Backlash Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bevel gear set and differential carrier - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Differential - Assemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Differential - Disassemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Differential - Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Differential - Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Differential lock - Assemble Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Differential lock - Disassemble Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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Final drive hub, steering knuckles, and shafts - 108

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Contents
SERVICE
Wheel hub
Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Visual inspection Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Remove Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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Front axle system - Final drive hub, steering knuckles, and shafts
Wheel hub - Remove Model 3105 II

Prior operation:

stand.
RCIL11WHL001BAF 1

and disposal.
RCIL11WHL002BAF 2

and disposal.
RCIL11WHL003BAF 3
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RCIL11WHL004BAF 4
5. Attach appropriate lifting device to output assembly.

Remove hex bolts and separate output from axle hous-
ing.
RCIL11WHL005BAF 5

RCIL11WHL006BAF 6
Next operation:
Wheel hub - Disassemble Model 3105 II (25.108)
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Wheel hub - Disassemble Model 3105 II

Prior operation:
Wheel hub - Remove Model 3105 II (25.108)
1. Attach output assembly to suitable work stand.
RCIL11WHL007BAF 1
2. Use a lever to remove output shaft cover.
RCIL11WHL008BAF 2
3. Remove locking bolts and releasing cover.
RCIL11WHL009BAF 3
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4. Use a puller and press planetary carrier from profile of

output shaft.
RCIL11WHL010BAF 4
5. Use a suitable lifting device. Lift planetary carrier out

of brake housing.
RCIL11WHL011BAF 5
6. Pull tapered roller bearing from planetary carrier.
RCIL11WHL012BAF 6
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7. Remove retaining rings.
RCIL11WHL013BAF 7
8. Pull off planetary gears.
RCIL11WHL014BAF 8
9. Lift end plate out of brake housing.
RCIL11WHL015BAF 9
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10. Lift disk package out of brake housing.
RCIL11WHL016BAF 10
11. Remove hex bolts, releasing cover and cup spring.
RCIL11WHL017BAF 11
12. Mount bleeder valve and use compressed air to re-

move piston from brake housing.
RCIL11WHL018BAF 12
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13. If needed, remove guide ring, back-up rings and

grooved rings from annular grooves of brake housing
(see arrows).
RCIL11WHL019BAF 13
14. 1. Brake housing

2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
7. Metal face seal
8. Output shaft
RCIL11WHL153BAF 14
15. Use a suitable lifting device. Lift brake housing from

output shaft.
RCIL11WHL020BAF 15
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16. Use levers to remove slide ring seal from brake hous-
ing. If needed, remove both bearing outer rings.
RCIL11WHL021BAF 16
17. Use levers to remove slide ring seal from output shaft.
RCIL11WHL022BAF 17
18. Pull tapered roller bearing from output shaft.
RCIL11WHL023BAF 18
Next operation:
Wheel hub - Visual inspection Model 3105 II (25.108)
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Wheel hub - Visual inspection Model 3105 II

Prior operation:
NOTICE: Do not use compressed air to dry bearings. Allow bearings to air dry.
1. Clean all parts except friction plates in brake disc pack
using cleaning solvent. WEAR FACE PROTECTION
WHEN USING COMPRESSED AIR. Use compressed
air to clear passages in planetary ring gear and brake
housing.
2. Inspect bearing rollers for pitting, scoring, deforma-
tion, or other damage. Check inner face and bear-
ing cage for deformation, dents, and other damage.
Check associated bearing cups for scratches, grooves,
or cracks. Check bearings for rough spots or binding
by holding bearing and rotating. If bearing binds or ac-
tion is not smooth, replace the bearing.
3. Inspect bearing cups for pitting, scoring, cracks, or
seen.
NOTE: If a bearing or bearing cup requires replacement,
the associated part must also be replaced.
4. Check planetary ring gear, planetary gears, and plan-
etary carrier gear teeth for cracks, breaks, chipping, or
other damage. Replace the part if any of these condi-
tions are seen. Check planetary carrier shaft splines for
broken, cracked, or twisted condition. Replace if nec-
essary.
5. Check wheel end shaft for cracked, broken, or twisted
splines. Replace if any of these conditions are seen.
Next operation:
Wheel hub - Assemble Model 3105 II (25.108)
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Wheel hub - Assemble Model 3105 II

CAUTION
Burn hazard!
C0047A
Prior operation:
1. Pull wheel stud into output shaft until contact is made.

NOTE: A special tool should be used for repairs when
exchanging individual wheel studs with a mounted output
shaft. On a new output shaft, mount wheel studs with a
press.
RCIL11WHL118BAF 1
2. Heat tapered roller bearing and place it onto output

shaft.
RCIL11WHL119BAF 2
3. Wet O-ring of slide ring seal and locating hole with min-
eral spirits. Snap new slide ring seal onto output shaft.
NOTE: For installation position of seal, see Step 9.
NOTE: Surface of slide ring seal must not have any
grooves, scratches or other damage. Make sure that
sealing surface is parallel to housing face. O-rings must
be mounted evenly into locating hole and must not bulge
out.
ATTENTION: Risk of injury - metal rings have extremely
sharp edges. Wear protective gloves.
RCIL11WHL120BAF 3
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4. Mount new slide ring seal onto brake housing.

NOTE: Surface of slide ring seal may not have any
out.
RCIL11WHL121BAF 4
5. Insert both bearing outer rings (arrows) into brake

housing.
RCIL11WHL122BAF 5
6. Use suitable lifting device and place premounted brake

housing on output shaft.
NOTE: Before clamping seal rings (slide ring seal) to in-
stallation dimension, clean sliding surfaces and apply an
oil film. A leather cloth soaked in oil is recommended for
this step.
RCIL11WHL123BAF 6
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7. Insert back-up rings and grooved rings into annular

grooves of brake housing (arrows).
NOTE: For installation position, see Step 9.
RCIL11WHL124BAF 7
8. Clean annular groove of brake housing with mineral

spirits. Insert guide ring into annular grove (see Step
9). Secure it with LOCTITE® 415™ at its ends (arrows).
NOTE: Full circumference of guide ring must be in an exact
contact position.
NOTE: Upon installation, orifice of guide ring must show
upwards - 12 o’clock position.
RCIL11WHL125BAF 8
9. 1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
7. Metal Face Seal
8. Output shaft
RCIL11WHL153BAF 9
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10. Flush-mount slotted pins into holes of piston.
RCIL11WHL126BAF 10
11. Insert piston into brake housing and install with dealer
fabricated fixing device until contact is made.
NOTE: Sufficiently oil seal surface of piston/back-up rings,
grooved rings and guide ring with SAE 10W oils.
RCIL11WHL127BAF 11
12. Insert disk and cup spring with convex side showing
upwards into piston.
RCIL11WHL128BAF 12
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13. Insert cover and secure it with hex bolts. Torque to

34 N·m (25 lb ft).
RCIL11WHL129BAF 13
14. Insert outer and inner disks.

NOTE: For number of disks and disk arrangement, refer to
related spare parts list.
RCIL11WHL130BAF 14
RCIL11WHL131BAF 15
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16. Press stop bolt (1) into planetary carrier (2).
RCIL11WHL158BAF 16
17. Insert cylindrical roller bearing into planetary gear. To

do this, press cylindrical roller bearing (1) through
packaging sleeve (2) until snap ring (3) engages into
annular groove of planetary gear (4).
NOTE: Use packaging sleeve to facilitate assembly.
RCIL11WHL132BAF 17
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18. Heat bearing inner rings. Insert premounted planetary

gears with large radius facing planetary carrier (down-
wards). Secure planetary gears with retaining rings.
NOTE: Adjust bearing inner rings after cooling.
RCIL11WHL133BAF 18
19. Heat tapered roller bearing. Install it on planetary car-

rier.
RCIL11WHL134BAF 19
20. Wet contact face of bearing inner ring (1) and profile
teeth (2) in output shaft with anti-corrosive agent.
RCIL11WHL135BAF 20
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21. Align disk package centrally and radially. Heat output

shaft. Use a suitable lifting device to insert planetary
carrier into teeth of output shaft.
RCIL11WHL136BAF 21
22. Bring planetary carrier with measuring disk and three

old locking bolts (removed during disassembly) into
contact position.
RCIL11WHL137BAF 22
23. Pivot output 90°.

NOTE: Torque locking bolts successively to 200 N·m
(148 lb ft). Then, retorque to 500 N·m (369 lb ft).
RCIL11WHL138BAF 23
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24. Install new O-ring (1) and cover. Wet contact face (2)
with TEROSTAT ® MS-9360.
NOTE: Curing period for TEROSTAT ® MS-9360 is greater
than 24-hours.
RCIL11WHL139BAF 24
25. Insert cover into output shaft until contact is made.
RCIL11WHL140BAF 25
Next operation:
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Wheel hub - Install Model 3105 II

Prior operation:
1. Set sun gear shaft axial play range to 0.5 – 2.0 mm

(0.02 – 0.08 in). Use a straight edge to determine di-
mension I, from mounting face of brake housing to front
face of stop bolt. Dimension I e.g. 40.80 mm (1.61 in).
RCIL11WHL141BAF 1
2. Insert stub shaft into teeth of axle bevel gear until con-
tact is made.
NOTE: Mount stub shaft with long teeth towards differen-
tial.
RCIL11WHL142BAF 2
3. Insert sun gear shaft until contact is made.
RCIL11WHL143BAF 3
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4. Using a straight edge, measure dimension II, from front

face of sun gear shaft to mounting surface of axle hous-
ing. Dimension II e.g. 38.20 mm (1.50 in). CALCU-
LATION EXAMPLE: Dimension I: 40.80 mm (1.61 in)
Dimension II: 38.20 mm (1.50 in) Difference: 2.60 mm
(0.10 in) Required axial play e.g.: 1.00 mm (0.04 in)
Difference = shim e.g.: s = 1.60 mm (0.06 in).
RCIL11WHL144BAF 4
5. Insert sun gear shaft into planetary carrier.
RCIL11WHL145BAF 5
6. Insert shim(s) e.g. s = 1.60 mm (0.06 in) with grease

into sun gear shaft.
RCIL11WHL146BAF 6
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7. Attach O-ring (arrow) with grease into countersink of

brake housing.
RCIL11WHL147BAF 7
8. Grease O-ring (arrow) and install it in axle housing.
RCIL11WHL148BAF 8
9. Mount adjusting bolts and use appropriate lifting de-

vice to bring output into contact position with axle hous-
ing. Secure output using hex bolts. Torque to 560 N·m
(413 lb ft).
NOTE: Attach load carrying device with wheel stud.
RCIL11WHL149BAF 9
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10. Mount bleeder valve (arrow).
RCIL11WHL150BAF 10
Next operation:
Brakes - Leakage test (33.202)
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Prior operation:
1. Fix axle to assembly cart.
RCPH11WHL485BAU 1
2. Loosen screw plugs (3x, see Figures 2 and 3) and drain

oil from axle.
RCPH11WHL486BAU 2
RCPH11WHL487BAU 3
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RCPH11WHL488BAU 4
from the axle housing.
RCPH11WHL489BAU 5

NOTE: Pay attention to potentially releasing shim(s).
RCPH11WHL490BAU 6
Next operation:
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CAUTION
Eye injury hazard!
C0035A
Prior operation:
1. Attach output to a suitable stand.
RCPH11WHL491BAU 1
RCIL11WHL008BAF 2
3. Loosen locking screws and remove the releasing cover.
RCPH11WHL493BAU 3
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4. Lift the planetary carrier out of the brake housing by

means of a lifting device.
RCPH11WHL494BAU 4
RCPH11WHL495BAU 5
6. Disingage retaining rings.
RCPH11WHL496BAU 6
RCPH11WHL497BAU 7
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RCPH11WHL498BAU 8
RCPH11WHL499BAU 9
10. Loosen hexagon screws, remove releasing disk and

cup spring.
RCPH11WHL500BAU 10
11. Mount bleeder valve and press piston out of the brake
housing by means of compressed air.
RCPH11WHL501BAU 11
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grooved rings out of the annular grooves of brake
housing (see arrows).
NOTE: For the installation position of the single parts refer
to the following sketch.
RCPH11WHL502BAU 12

1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
7. Slide ring seal
8. Output shaft
RCPH11WHL646BAU 13
14. Using a suitable lifting device, lift the brake housing

from output shaft.
RCPH11WHL503BAU 14
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ing. If needed, force out both bearing outer rings.
RCPH11WHL504BAU 15
16. Use lever to remove slide ring seal from output shaft.
RCPH11WHL505BAU 16
RCPH11WHL506BAU 17
Next operation:
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CAUTION
Flying debris!
pressed air.
C0049A
WARNING
Chemical hazard!
Always wear protective clothing and goggles when cleaning with solvents, acids, or alkaline chemical
agents. Always follow the chemical manufacturer's instructions.
W0180A
Prior operation:

using cleaning solvent. Use compressed air to clear
passages in planetary ring gear and brake housing.
ATTENTION: Do not use compressed air to dry bearings.
Allow bearings to air dry.
seen.
essary.
Next operation:
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CAUTION
Burn hazard!
C0047A
CAUTION
Sharp object hazard!
Wear gloves when handling worn discs.
C0006A
Prior operation:
1. Pull wheel stud into output shaft until contact is ob-

tained.
• (S) Wheel stud puller, basic tool
• (S) Insert (M22x1.5)
NOTE: Special tool (S) may only be used for repair solu-
tion when exchanging individual wheel studs with mounted
output shaft. When using a new output shaft, mount the
wheel studs with the press.
RCPH11WHL612BAU 1
2. Heat tapered roller bearing and insert it into the output

shaft until contact is obtained.
RCPH11WHL613BAU 2
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eral spirits.
4. Snap NEW slide ring seal (part 1) into output shaft.
5. Then mount NEW slide ring seal (part 2) accordingly
into the brake housing.
NOTE: For the installation position of the seal, please refer
to Legend Sketch in step 12.
NOTE: The surface of slide ring seal may not have any
grooves, scratches or other types of damage. Take care
that the sealing surface is parallel to the housing face.
RCPH11WHL614BAU 3
6. O-rings must be mounted evenly into the locating hole

and must not bulge out of the hole.
NOTE: Metal rings have extremely sharp edges. Wear pro-
tective gloves.
RCPH11WHL615BAU 4
7. Insert both bearing outer rings (arrows) into the brake

housing until contact is obtained.
RCIL11WHL122BAF 5
8. Insert the premounted brake housing by means of the

lifting device over the output shaft until contact is ob-
tained.
NOTE: Before clamping seal rings to installation dimen-
sion, clean sliding surfaces and apply an oil film. A leather
cloth soaked in oil is recommended for this step.
RCPH11WHL617BAU 6
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NOTE: For installation position, see refer to Legend Sketch
step 12.
RCIL11WHL124BAF 7

spirits.
11. Then insert the guide ring into annular grove (refer to
Legend Sketch in step 12) and fix it with LOCTITE®
415™ at its extremities (arrows).
NOTE: The full circumference of guide ring must be in an
exact contact position.
NOTE: Upon installation, the orifice of the guide ring must
show upwards - 12 o’clock position.
RCIL11WHL125BAF 8

1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
7. Slide ring seal
8. Output shaft
RCPH11WHL646BAU 9
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13. Insert the piston into the brake housing and carefully
install with the fixing device (S) until contract is ob-
tained.
grooved rings and guide ring ( SAE 10W oils to be used)!
RCPH11WHL620BAU 10
14. Insert cup spring into the piston with the convex side
showing upwards.
RCPH11WHL621BAU 11
15. Insert disk and fix it by means of hexagon screws.

RCPH11WHL622BAU 12

NOTE: For the number of disks and the disk arrangement
RCPH11WHL623BAU 13
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RCPH11WHL624BAU 14
Setting of installation dimension

Installation dimension 57.25 mm (2.25 in) ... 57.79 mm
(2.3 in).
18. Measure installation dimension from the mounting
face of the brake housing to the front face of the end
plate.
• Installation dimension e.g.: 57.50 mm (2.3 in).
NOTE: Any deviation from the necessary installation di-
mension must be corrected with an appropriate outer disk
(see spare parts list).
RCPH11WHL625BAU 15
19. Press stop bolt into the cover until contact is obtained.
20. Then insert the premounted cover into the planetary
carrier until contact is obtained.
Legend to sketch:
1. Stop bolt.
2. Cover.
3. Planetary carrier.
RCPH11WHL651BAU 16
21. Insert cylindrical roller bearing into planetary gear —

for this purpose press the cylindrical roller bearing
through packaging sleeve until the snap ring engages
into annular groove of planetary gear.
1. Cylindrical roller bearing.
2. Packaging sleeve.
3. Snap ring.
4. Planetary gear.
RCPH11WHL626BAU 17
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22. Heat bearing inner rings and insert the premounted

planetary gears with large radius facing planetary car-
rier (downwards) until contact is obtained.
23. Then fix planetary gears by means of retaining rings.
RCPH11WHL627BAU 18
24. Heat tapered roller bearing and install it on the plane-

tary carrier until contact is obtained.
RCPH11WHL628BAU 19
25. Wet front face (contact face bearing inner ring, arrow
1) and profile (teeth, arrow 2) in the output shaft with
anti-corrosive Anti-seize.
RCPH11WHL629BAU 20
26. Align disk package centrally and radially.

27. Then insert the planetary carrier by means of the lifting
device into the teeth of the output shaft until contact is
obtained.
RCPH11WHL630BAU 21
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28. Pivot output 90°. Insert disk and fix planetary carrier
NOTE: Tighten locking screws successively with a tight-
ening torque of 200 N·m (148 lb ft). Then retighten the
locking screws successively with a tightening torque of
750 N·m (553 lb ft).
RCPH11WHL631BAU 22
29. Install O-ring (see arrow) to the cover.
RCPH11WHL632BAU 23
30. Insert the cover into the output shaft until contact is
obtained.
RCPH11WHL633BAU 24
Next operation:
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Prior operation:
1. Set the axial play of the sun gear shaft 0.5 – 2.0 mm
(0.02 – 0.08 in). Determine dimension I, from mounting
face of brake housing to front face of stop bolt. Dimen-
sion I e.g. 58.60 mm (2.3 in).
• (S) Gauge blocks
• (S) Straightedge
RCPH11WHL634BAU 1
tact is obtained.
NOTE: Pay attention to the installation position; mount the
stub shaft with the long teeth showing to the differential.
RCPH11WHL635BAU 2
3. Insert sun gear shaft until contact is obtained.
RCPH11WHL636BAU 3
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4. Measure dimension II, from front face of sun gear shaft

to mounting surface of axle housing.
NOTE: Refer to following calculation example table for cal-
culation procedure.
• Dimension II e.g.: 56.60 mm (2.2 in)
RCPH11WHL637BAU 4
CALCULATION EXAMPLE:
Difference 2.00 mm
Required axial play e.g.: — 1.00 mm
Difference = shim e.g.: s = 1.00 mm
RCPH11WHL638BAU 5
6. Fix determined shim(s) e.g. s = 1.00 mm (0.04 in) with

grease into sun gear shaft.
RCPH11WHL639BAU 6
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7. Fix O-ring (arrow) with grease into countersink of brake

housing.
RCPH11WHL640BAU 7
RCPH11WHL641BAU 8
9. Mount two adjusting screws (S) and use appropriate

lifting device to bring output into contact position with
axle housing. Secure output using hex bolts. Torque to
560 N·m (413 lb ft).
10. Then fix the output by means of hexagon screws.
NOTE: Fix load carrying device (S) with wheel stud.
RCPH11WHL642BAU 9
11. Mount bleeder (arrow).
RCPH11WHL643BAU 10
Next operation:
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Brakes - Leakage test Model 3115 II (33.202)
48083742_EN 31/07/2018
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Index

Wheel hub - Assemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wheel hub - Disassemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wheel hub - Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Wheel hub - Install Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wheel hub - Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wheel hub - Visual inspection Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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PRINTED IN ITALY
48083742_EN 31/07/2018
EN
SERVICE MANUAL
Rear axle system

48083742_EN 31/07/2018
27
Contents
Rear axle system - 27
[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2
[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3
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27
Powered rear axle - 100

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27.1 [27.100] / 1
Contents
TECHNICAL DATA
Powered rear axle

Torque - Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Powered rear axle

External view - Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
External view - Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE
Powered rear axle

Remove - Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install - Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remove - Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install - Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filling - Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Filling - Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Rear axle system - Powered rear axle
Powered rear axle - Torque - Model 3105 II

Axle wheel end screw plug 50 N·m (37 lb ft)
Brake tube fitting to wheel end fitting 36 N·m (27 lb ft)
Axle housing bolts 560 N·m (413 lb ft)
Differential releasing housing cover bolts 185 N·m (136 lb ft)
Powered rear axle - Special tools

Pinion shaft seal installer CAS2841
Pinion locknut wrench CAS2842
Pinion clamping device 380001546
Pinion outer bearing cup installer 380100001
Powered rear axle - Torque Model 3115 II

Locknut securing planetary carrier 700 – 1000 N·m (516 – 738 lb ft)
Axle brake tube mount 36 N·m (27 lb ft)
Axle drive housing bolts 560 N·m (413 lb ft)
Bearing housing cylindrical screws 50 N·m (37 lb ft)
Differential case oil tube 100 N·m (74 lb ft)
Differential case oil tube mounting nut 100 N·m (74 lb ft)
Spider gear mount disk bolts 50 N·m (37 lb ft)
Powered rear axle - General specification

Rear Axle Model MT-L3105II - Open Differential
Only for 1021G
LEIL15WHL1221F 1
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27.1 [27.100] / 3

HUB RATIO 6:1
OVERALL RATIO 24.67:1
CLOCKWISE INPUT ROTATION (FACING INPUT
–
FLANGE) FOR FORWARD TRAVEL
Lubrication capacity for axles 42.0 l (44.4 US qt)

Lubrication capacity for axles with axle cooler 45.7 l (48.3 US qt)
Sun Gear Shaft End Play 0.5 – 2.0 mm (0.02 – 0.08 in)
Drive Pinion Rolling Torque 1.5 – 4.0 Nm (13.28 – 35.4 lb in)
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Rear Axle Model MT-L3115II - Open Differential
Only for 1121G
LEIL15WHL1222F 2

HUB RATIO 6.353:1
OVERALL RATIO 27:1
Lubrication capacity for heavy duty axles 62.0 l (65.5 US qt)

Lubrication capacity for heavy duty axles with axle cooler 65.7 l (69.4 US qt)
Sun gear shaft end play 0.5 – 2.0 mm (0.02 – 0.08 in)
Drive pinion rolling torque 1.5 – 5.0 N·m (13 – 44 lb in)
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Powered rear axle - External view - Model 3105 II
LEIL15WHL1215FB 1
(1) Bolt M22x170 (Quantity 8) (8) Trunnion

(2) Washer (9) Nut (Quantity 8)
(3) Trunnion (10) Washer
(4) Seal (11) Thrust washer
(5) Seal (12) Trunnion cover
(6) Rear axle (13) Spacer
(7) Seal (14) Thrust washer
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Powered rear axle - External view - Model 3115 II
LEIL15WHL1216FB 1
(1) Bolt M22x170 (Quantity 8) (8) Seal

(2) Washer (9) Trunnion
(3) Rear axle (10) Thrust washer
(4) Seal (11) Spacer
(5) Trunnion (12) Thrust washer
(6) Seal (13) Trunnion cover
(7) Trunnion bearing
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Powered rear axle - Remove - Model 3105 II

1. Park machine on a level surface; be sure to allow ad-
equate space at side of machine for removal of rear
axle. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from hydraulic
circuit.
2. Put articulation lock in LOCKED position.
3. Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting.
4. Remove the grease hoses from the rear axle trunnions.
LEIL15WHL1782AA 1
the transmission.
8. Hold the rear drive shaft and remove from the machine. LEIL15WHL1209AB 2
9. Tag and disconnect the brake (arrows) and oil cooler

lines from the rear axle. Install caps and plugs.
BD03A169-01 3
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27.1 [27.100] / 8

ground and install an acceptable jack stand under ma-
chine. Repeat this step for other tire.
BD01F299-01 4
11. Use an acceptable jack to hold rear axle.

12. Remove bolts and washers from rear wheels.
Remove both wheels from rear axle.
LEIL15WHL1229A 5
LEIL15WHL1215FB 6
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27.1 [27.100] / 9
13. Put acceptable lifting equipment (transmission jack)

under the rear axle and trunnions. The weight of the
axle is approximately 1279 kg (2819 lb).
14. Remove the self-locking nuts (9) from the bolts (1)
holding the trunnions (3) and (8) to the machine frame.
15. Remove the rear axle and trunnions from the machine.
Place the rear axle and trunnions onto blocks or suit-
able work bench.
16. Remove the front trunnion (3) from the rear axle (6).
17. Remove the seals (4) and (5) from the rear trunnion
(3).
18. Remove the cap screws and washers from the rear
cover (12) on the rear trunnion (8).
19. Remove the rear cover (12) from the rear trunnion (8).
20. Remove the thrust washer (11).
21. Remove the cap screws and washers that fasten the
spacer (13) to the rear axle (6).
22. Remove the spacer (13) and thrust washer (14).
23. Remove the rear trunnion (8) from the rear axle (6).
24. Remove the seal (7) from the rear trunnion (8).
Next operation:
Differential - Remove Model 3105 II (27.106),
Wheel hub - Remove Model 3105 II (27.120) .
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Powered rear axle - Install - Model 3105 II
Prior operation:
NOTE: replace the seals and bushings in the trunnions as required.
LEIL15WHL1215FB 1
1. Put the rear axle on blocks.

2. Install the seal (7) on the rear trunnion (8) so that lip of
the seal is directed outward, as showed in figure 2.
LEIL16WHL1569AB 2
3. Install the rear trunnion (8) to the rear axle (6). Ensure
bushing is properly positioned.
4. Install a thrust washer (14) and the spacer (13). Use
cap screws and hardened washers to fasten the spacer
(13) to the rear axle (6).
5. Tighten the cap screws to a torque of 285 – 320 Nm
(210 – 236 lb ft).
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27.1 [27.100] / 11
6. Install the other thrust washer (11). Fasten the rear

cover (12) to the rear trunnion (8) using washers and
cap screws.
7. Tighten the cap screws to a torque of 105 – 115 Nm (77
– 85 lb ft).
8. Install the seals (4) and (5) on the front trunnion (3) so
that lip seals are directed outward, as showed in figure
3.
LEIL16WHL1568AB 3
9. Install the front trunnion (3) to the rear axle (6). Ensure
trunnion is properly positioned for installation into ma-
chine chassis.
10. Using acceptable lifting equipment, slowly move the
rear axle (6) and trunnions (3) and (8) into position
under the rear chassis.
11. Install the bolts (1), hardened washers and nuts (9) to
fasten the trunnions (3) and (8) to the rear chassis.
12. Tighten the nuts to a torque of 651 – 732 Nm (480 –
540 lb ft).
13. Hold the rear drive shaft (2) into position and install
the bolts (3) that fasten the rear drive shaft (2) to the
rear axle.
110 lb ft).
LEIL15WHL1209AB 4
14. Install the bolts (1) that fasten the rear drive shaft (2)
to the transmission.
110 lb ft).
LEIL15WHL1229A 5
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27.1 [27.100] / 12
15. Install the rear wheels, hardened washers and nuts.

16. Torque the wheel nuts in the sequence shown to a
preliminary torque of 298 N·m (220 lb ft). Final torque
the wheel nuts to 640 – 720 Nm (472 – 531 lb ft) in the
same sequence.
LEIL15WHL1231AB 6
17. Lower the machine to the ground.

18. Connect the brake and axle cooler lines to the rear
axle.
19. Connect the grease hoses to the trunnions.
20. Pump grease into the rear trunnion (8) and into the
front trunnion (3) until the grease is extruded thru the
seal. Wait 30 min for sealant cure time (only for the
rear trunnion).
21. Fill axle with gear lubricant specified in Capacities.
22. See Powered rear axle - Filling (27.100) for oil fill
plug location.
and bleed brakes.
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27.1 [27.100] / 13
Powered rear axle - Remove - Model 3115 II

1. Park machine on a level surface; be sure to allow ad-
equate space at side of machine for removal of rear
axle. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from hydraulic
circuit.
2. Put articulation lock in LOCKED position.
3. Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting.
4. Remove the grease hoses from the rear axle trunnions.
LEIL15WHL1782AA 1
the transmission.
8. Hold the rear drive shaft and remove from the machine. LEIL15WHL1209AB 2
9. Tag and disconnect the brake (arrows) and oil cooler

lines from the rear axle. Install caps and plugs.
BD03A169-01 3
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27.1 [27.100] / 14

ground and install an acceptable jack stand under ma-
chine. Repeat this step for other tire.
BD01F299-01 4
11. Use an acceptable jack to hold rear axle.

12. Remove bolts and washers from rear wheels.
Remove both wheels from rear axle.
LEIL15WHL1229A 5
LEIL15WHL1216FB 6
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27.1 [27.100] / 15
13. Put acceptable lifting equipment (transmission jack)

under the rear axle and trunnions. The weight of the
axle is approximately 1720 kg (3792 lb).
14. Remove the self-locking nuts from the bolts (1) and
washers (2) holding the trunnions (5) and (9) to the
machine frame.
15. Remove the rear axle (3) and trunnions (5) and (9)
from the machine. Place the rear axle and trunnions
onto blocks or suitable work bench.
16. Remove the front trunnion (5) from the rear axle (3).
17. Remove the seals (4) and (6) from the rear trunnion
(5).
18. Remove the cap screws and washers from the rear
cover (13) on the rear trunnion (9).
19. Remove the rear cover (13) from the rear trunnion (9).
20. Remove the thrust washer (12).
21. Remove the cap screws and washers that fasten the
spacer (11).
22. Remove the spacer (11) and thrust washer (10).
23. Remove the rear trunnion (9) from the rear axle (3).
24. Unscrew the bolts and remove the trunnion bearing
(7).
25. Remove the seal (8) from the rear trunnion (9).
Next operation:
Differential - Remove Model 3115 II (25.102), Wheel hub - Remove Model 3115 II (25.108) .
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27.1 [27.100] / 16
Powered rear axle - Install - Model 3115 II
Prior operation:
Differential - Remove Model 3115 II (27.106),
NOTE: replace the seals and bushings in the trunnions as required.
LEIL15WHL1216FB 1
1. Put the rear axle on blocks.

2. Install the bearing trunnion (7). Use the bolts and wash-
ers to fasten the bearing trunnion (7) to the rear axle (3).
3. Install the seal (8) on the rear trunnion (9) so that lip of
the seal is directed outward, as showed in figure 2.
LEIL16WHL1569AB 2
4. Install the rear trunnion (9) to the rear axle (3). Ensure
bushing is properly positioned.
5. Install a thrust washer (10) and the spacer (11). Use
cap screws and hardened washers to fasten the spacer
(11) to the rear axle (3).
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27.1 [27.100] / 17
6. Tighten the cap screws to a torque of 285 – 320 N·m

(210 – 236 lb ft).
7. Install the other thrust washer (12). Fasten the rear
cover (13) to the rear trunnion (9) using washers and
cap screws.
8. Tighten the cap screws to a torque of 105 – 115 N·m
(77 – 85 lb ft).
9. Install the seals (4) and (6) on the front trunnion (5).
10. Install the seals (4) and (6) on the front trunnion (5)
so that lip seals are directed outward, as showed in
figure 3.
LEIL16WHL1568AB 3
11. Install the front trunnion (5) to the rear axle (3). Ensure
trunnion is properly positioned for installation into ma-
chine chassis.
12. Using acceptable lifting equipment, slowly move the
rear axle (3) and trunnions (5) and (9) into position
under the rear chassis.
13. Install the bolts (1), hardened washers (2) and nuts to
fasten the trunnions (5) and (9) to the rear chassis.
14.
15. Hold the rear drive shaft (2) into position and install
the bolts (3) that fasten the rear drive shaft (2) to the
rear axle.
110 lb ft).
LEIL15WHL1209AB 4
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27.1 [27.100] / 18
16. Install the bolts (1) that fasten the rear drive shaft (2)
to the transmission.
110 lb ft).
LEIL15WHL1229A 5
17. Install the rear wheels, hardened washers and nuts.

18. Torque the wheel nuts in the sequence shown to a
preliminary torque of 298 N·m (220 lb ft). Final torque
the wheel nuts to 640 – 720 Nm (472 – 531 lb ft) in the
same sequence.
LEIL15WHL1231AB 6
19. Lower the machine to the ground.

20. Connect the brake and axle cooler lines to the rear
axle.
21. Connect the grease hoses to the trunnions.
22. Pump grease into the rear trunnion (9) and into the
front trunnion (5) until the grease is extruded thru the
seal. Wait 30 min for sealant cure time (only for the
rear trunnion).
23. Fill axle with gear lubricant specified in “Consum-
ables” in this manual.
24. See Powered rear axle - Filling (27.100) for oil fill
plug location.
and bleed brakes.
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27.1 [27.100] / 19
Powered rear axle - Filling - Model 3105 II
LEIL15WHL1217FB 1
(1) Oil Drain hole ( axle casing) (4) Brake breather

(2) Oil drain hole (outputs) (5) Cooler connector
(3) Oil filling and oil level check hole (6) Brake line connector
1. Refer to Capacities for proper lubricant.
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27.1 [27.100] / 20
Powered rear axle - Filling - Model 3115 II
LEIL16WHL2472FB 1
(1) Oil Drain hole ( axle casing) (4) Brake breather

(2) Oil drain hole (outputs) (5) Breather connector
(3) Oil filling and oil level check hole (6) Brake line connector
1. Refer to Capacities for proper lubricant.
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Index

Powered rear axle - External view - Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Powered rear axle - External view - Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Powered rear axle - Filling - Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Powered rear axle - Filling - Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Powered rear axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered rear axle - Install - Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Powered rear axle - Install - Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Powered rear axle - Remove - Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Powered rear axle - Remove - Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Powered rear axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered rear axle - Torque - Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered rear axle - Torque Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Rear bevel gear set and differential - 106

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27.2 [27.106] / 1
Contents
SERVICE
Rear bevel gear set and differential

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Backlash Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Backlash Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Differential
Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Remove Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Install Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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27.2 [27.106] / 2
Rear axle system - Rear bevel gear set and differential
Rear bevel gear set and differential - Check

Ideal tooth contact pattern
Pinion distance must be increased
LEIL13WHL0577AA 3
48083742_EN 31/07/2018
27.2 [27.106] / 3
Pinion distance must be decreased
LEIL13WHL0580AA 6
48083742_EN 31/07/2018
27.2 [27.106] / 4
Rear bevel gear set and differential - Backlash Model 3105 II

CAUTION
Burn hazard!
C0047A
Prior operation:

RCIL11WHL087BAF 1

sion II e.g. 202.00 mm (7.95 in).
RCIL11WHL088BAF 2
3. Determine dimension III (bearing width). Dimension

III e.g. 42.60 mm (1.68 in). Calculation Example
“A”: Dimension I: 245.60 mm (9.67 in)Dimension II:
202.00 mm (7.95 in) Dimension III: 42.60 mm (1.68 in)
Difference = shim s = 1.00 mm (0.04 in).
RCIL11WHL089BAF 3
48083742_EN 31/07/2018
27.2 [27.106] / 5
4. Cool external bearing. With a driver tool, insert it into

axle drive housing until contact is made.
RCIL11WHL090BAF 4

into housing.
RCIL11WHL091BAF 5
6. Cool internal bearing outer ring. Bring it into contact

position within housing hole using 380100001 Bearing
Cup Installer.
RCIL11WHL092BAF 6
48083742_EN 31/07/2018
27.2 [27.106] / 6

until contact is made.
RCIL11WHL093BAF 7

(e.g. s= 8.18 mm (0.32 in)).
NOTE: Based on experience, necessary rolling torque is
obtained when reusing the spacer removed during disas-
sembly e.g. s = 8.18 mm (0.32 in).
NOTE: A later check of rolling torque is needed.
RCIL11WHL094BAF 8
9. Insert preassembled input pinion into axle drive hous-

ing. Insert heated tapered roller bearing until contact is
made.
RCIL11WHL095BAF 9
48083742_EN 31/07/2018
27.2 [27.106] / 7

contact is made.
checked.
RCIL11WHL096BAF 10
11. Insert input flange and secure it with disk and slot-
ted nut. Torque to 1200 N·m (885 lb ft) using pin-
ion locknut wrench CAS2842 and clamping device
380001564.
NOTE: Temporarily mount slotted nut without Loctite.
While tightening, rotate input pinion several times in both
directions.
RCIL11WHL097BAF 11

NOTE: When installing new bearings try to achieve upper
value of rolling torque.
NOTE: In case of deviations from needed rolling torque,
correct with a corresponding spacer as specified in step 8.
For insufficient rolling torque - install thinner spacer ring.
Excessive rolling torque - install a thicker spacer ring.
RCIL11WHL098BAF 12
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27.2 [27.106] / 8
13. Determine required shims to set bearing rolling torque

(differential housing) and backlash (bevel gear set).
Select shims based on the read value (deviation/test
dimension) and corresponding specifications in f the
following table: (KRS - SET - RIGHT) (KRS = bevel
gear set): See the crown wheel rear side for devia-
tion. The test dimension “106” is stamped into the rear
side. If no + or - deviation is indicated, the value cor-
responds to actual value “0” in the table. Based on
this value, the required shims are allocated in the ta-
ble. Any + or - deviation of the test dimension caused
by production will be marked on the crown wheel rear
side (e.g. - 20 or - 10 or 10 or 20). Based on the de-
viation, the required shims are allocated in the table.
RCIL11WHL101BAF 13
14. 1 = Axle housing, 2 = Shim (crown wheel side), 3 =

Shim (differential carrier side) 4 = Axle housing
RCIL11WHL156BAF 14
Shims for differential in MT-L 3105 II axles

Crown wheel marking -20 -10 N/A 10
Deviation –0.2 -0.1 0 0.1
Shim diff. cage side 0.8 0.9 1.0 1.1
Shim thickness
Shim Crown wheel 1.2 1.1 1.0 0.9
side Shim thickness

row) until contact is obtained.
RCIL11WHL102BAF 15
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27.2 [27.106] / 9
16. Cover some drive and coast flanks of crown wheel

with marking ink. Insert premounted differential into
axle drive housing.
RCIL11WHL103BAF 16

row) until contact is made.
RCIL11WHL104BAF 17
18. Mount two locating pins and bring axle housing into
contact position with axle drive housing using a suit-
able lifting device. Temporarily attach axle housing
with hex bolts. Torque to 560 N·m (413 lb ft).
NOTE: Test mount axle housing without O-ring.
RCIL11WHL105BAF 18
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19. Rotate input flange, in both directions several times,

to roll crown wheel over input pinion. Remove axle
housing and lift differential out of axle drive housing.
Compare obtained contact pattern with contact patter
examples at the beginning of this section.
NOTE: If a contact pattern deviation exists, a measuring
error was made during shim size determination. This must
be corrected.
RCIL11WHL107BAF 19
Next operation:
Differential - Install Model 3105 II (27.106).
48083742_EN 31/07/2018
27.2 [27.106] / 11
Rear bevel gear set and differential - Backlash Model 3115 II

CAUTION
Burn hazard!
C0047A
Prior operation:
Reassembly axle drive housing

RCPH11WHL577BAU 1

sion II e.g. 265.00 mm (10.4 in).
RCPH11WHL578BAU 2
3. Determine dimension III (bearing width). See following

table for dimension determination procedure.
RCIL11WHL089BAF 3
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27.2 [27.106] / 12
Calculation Example A
Dimension III — 63.60 mm
Dimension = shim s = 2.60 mm
Reassembly of input pinion

4. Undercool the external bearing outer ring and insert it
into the axle drive housing until contact is obtained.
RCIL11WHL090BAF 4

into housing hole.
RCPH11WHL581BAU 5
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27.2 [27.106] / 13
6. Undercool the internal bearing outer ring. and bring

it into contact position in the housing hole using the
assembly fixture (S).
RCIL11WHL092BAF 6

RCIL11WHL093BAF 7

(e.g. s= 7.13 mm (0.3 in) ).
NOTE: According to our experience the necessary rolling
torque is obtained when reusing the spacer which has been
removed during disassembly (e.g.: s = 7.13 mm (0.3 in))!
A later check of the rolling torque however is absolutely
necessary!
RCIL11WHL094BAF 8
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9. Insert the preassembled input pinion into axle drive

housing. Insert the heated tapered roller bearing un-
til contact is obtained.
RCPH11WHL585BAU 9

checked.
RCIL11WHL096BAF 10

fix it by means of disk and slotted nut. Tightening
torque to 1200 N·m (10620.9 lb in).
NOTE: Preliminarily mount slotted nut without Locite!
NOTE: While tightening, rotate the input pinion several
times in both directions!
RCPH11WHL587BAU 11
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• Insufficient rolling torque — Install thinner spacer
ring.
• Excessive rolling torque — Install thicker spacer ring.
NOTE: When installing new bearings try to achieve the up-
per value of rolling torque.
NOTE: In case of deviations from the necessary rolling
torque, correct with a corresponding spacer as specified
in step 8 following specifications below:
RCPH11WHL588BAU 12
13. Mount threaded connection. Tightening torque to

100 N·m (885 lb in).
RCPH11WHL589BAU 13
14. Mount oil tube. Tightening torque to 100 N·m (885 lb

in).
RCPH11WHL590BAU 14
15. Grease O-rings (arrows) and insert them into the an-
nular groves of the piston.
only!
RCPH11WHL591BAU 15
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27.2 [27.106] / 16
16. Insert piston (arrow) into the bearing housing until con-
tact is obtained.
only!
RCPH11WHL592BAU 16
Determination of shims for setting bearing rolling torque (differential housing) and back-
lash (bevel gear set)
17. Determine the required shims on the basis of the read
value (deviation/test dimension) and the correspond-
ing specifications of the table below: )KRS — SET —
RIGHT) (KRS = bevel gear set).
The test dimension „108“ is stamped into the crown
wheel rear side. If no + or – deviation is indicated,
this value corresponds to the actual value “O” in the
following table. Any + or – deviation of the test dimen-
sion caused by production will be marked on the crown
wheel rear side (e.g. - 20 or - 10 or 10 or 20). In accor-
dance with this deviation, the required shims are allo-
cated in the following table.
NOTE: Deviation see crown wheel rear side.
RCPH11WHL593BAU 17

1. Bearing housing
2. Shim (crown wheel side)
3. Shim (diff. carrier side)
4. Axle drive housing
RCPH11WHL649BAU 18
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27.2 [27.106] / 17
Shims for differential D /DL and DHL — 5000 in ZF axles MT — L 3115/3125

Crow wheel -30 -20 -10 0 10 20
making
Deviation -0.3 -0.2 -0.1 0 0.1 0.2
Shim 1.1 1.2 1.3 1.4 1.5 1.6
Diff. cage
side. Shim
thickness
Shim ZF-order 0730 300 842 0730 113 897 0730 113 868 0730 113 859 0730 113 869 0730 113 870
no.
Shim Crown 1.7 1.6 1.5 1.4 1.3 1.2
wheel
side. Shim
thickness
Shim ZF — 0730 300 926 0730 113 875 0730 113 874 0730 113 860 0730 113 873 0730 113872
order no.
19. Insert the determined shim (e.g. s= 1.4 mm (0.1 in)

into the hole of axle drive housing and reset until con-
tact with bearing outer ring is obtained.
RCPH11WHL594BAU 19
20. Cover some drive and coast flanks of the crown wheel
with marking ink. Then insert premounted differential
into axle drive housing.
RCPH11WHL595BAU 20
48083742_EN 31/07/2018
27.2 [27.106] / 18
21. Insert the determined shim (e.g. s = 1.4 mm (0.1 in))

into the bearing housing and reset the bearing outer
ring until contact is obtained.
RCPH11WHL596BAU 21
22. Place the premounted bearing housing onto the axle

drive housing by means of the lifting device.
NOTE: Preliminarily mount the bearing housing without
O-rings.
RCPH11WHL597BAU 22
23. Fix the bearing housing by means of cylindrical screws

(3x). Tightening torque (M12/10.9) to 50 N·m (37 lb
ft).
RCPH11WHL598BAU 23
24. By rotating the input flange, roll crown wheel over in-
put pinion in both directions.
25. Then remove the bearing housing again and lift the
differential out of axle drive housing.
26. Compare the obtained contact pattern with contact
pattern examples at the beginning of this section.
NOTE: In case of any contact pattern deviation, a measur-
ing error was made during shim size determination. This
must be corrected.
RCPH11WHL600BAU 24
Next operation:
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Prior operation:
Powered rear axle - Remove Model 3105 II/3115 II (27.100)

stand.
RCIL11WHL001BAF 1

and disposal.
RCIL11WHL002BAF 2

and disposal.
RCIL11WHL003BAF 3
48083742_EN 31/07/2018
27.2 [27.106] / 21

RCIL11WHL004BAF 4
5. Attach suitable lifting device to output assembly. Re-

move hex bolts and separate output assembly from
axle housing.
RCIL11WHL005BAF 5

RCIL11WHL006BAF 6
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27.2 [27.106] / 22
7. Secure axle housing with suitable lifting device and

loosen hex bolts. Separate axle housing from drive
housing.
NOTE: Be aware of possible release of differential.
RCIL11WHL024BAF 7

lease tube.
RCIL11WHL025BAF 8
RCIL11WHL026BAF 9
48083742_EN 31/07/2018
27.2 [27.106] / 23
RCIL11WHL027BAF 10
11. Use a suitable lifting device and pull differential from

axle drive housing.
NOTE: Disassembly of differential is covered in a separate
section.
RCIL11WHL028BAF 11
12. Pull bearing outer ring (arrow) from housing and re-
move shim.
RCIL11WHL029BAF 12
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27.2 [27.106] / 24
13. Heat slotted nut.

RCIL11WHL032BAF 13
14. Remove slotted nut and shim using pinion locknut

wrench CAS2842 and clamping device 380001546.
RCIL11WHL033BAF 14
15. Pull input flange from pinion. Use a lever to remove

shaft seal.
RCIL11WHL034BAF 15
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27.2 [27.106] / 25
16. Press input pinion from axle drive housing and remove
releasing tapered roller bearing.
RCIL11WHL035BAF 16
17. Remove spacer ring and pull tapered roller bearing

from input pinion.
RCIL11WHL036BAF 17
18. If needed, remove both bearing outer rings from axle

drive housing.
RCIL11WHL037BAF 18
Next operation:
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27.2 [27.106] / 26

Prior operation:
Differential - Remove Model 3105 II (27.106) .
RCIL11WHL050BAF 1
2. Preload differential using a press. Remove hex bolts

and releasing housing cover.
RCIL11WHL051BAF 2
3. Preload differential using a press. Remove locking

bolts and housing cover.
RCIL11WHL052BAF 3
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4. Remove axle bevel gear with thrust washers from dif-

ferential housing.
RCIL11WHL053BAF 4
5. Force out both slotted pins.
RCIL11WHL054BAF 5
6. Force out both short differential axles. Remove releas-

ing spider gears with thrust washers from differential
housing.
RCIL11WHL055BAF 6
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27.2 [27.106] / 28
7. Pull long differential axle. Remove releasing spider

gears with thrust washers from differential housing.
RCIL11WHL056BAF 7
8. Remove axle bevel gear and shim.
RCIL11WHL057BAF 8
9. Press crown wheel from differential carrier.
RCIL11WHL058BAF 9
Next operation:
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27.2 [27.106] / 29

CAUTION
Burn hazard!
C0047A
Prior operation:
1. Mount locating pins and press heated crown wheel onto

differential housing until contact is made.
RCIL11WHL076BAF 1
2. Insert thrust washer into differential housing.
RCIL11WHL077BAF 2
RCIL11WHL078BAF 3
48083742_EN 31/07/2018
27.2 [27.106] / 30

housing. Secure them with long spider shaft.
NOTE: Thrust washers must be positioned with tabs (ar-
row) located in recesses of differential housing.
RCIL11WHL079BAF 4

housing. Secure them with two short spider shafts.
(2).
RCIL11WHL080BAF 5
6. Secure short spider shafts with slotted pins.

NOTE: Flush mount slotted pins.
RCIL11WHL081BAF 6
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27.2 [27.106] / 31
7. Mount second axle bevel gear.
RCIL11WHL082BAF 7
8. Secure thrust washers into housing cover with grease.
RCIL11WHL083BAF 8
9. Mount two adjusting bolts and insert housing cover un-

til contact with differential housing is obtained. Preload
differential using a press. Secure with new locking
RCIL11WHL084BAF 9
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27.2 [27.106] / 32
10. Attach housing cover and preload differential with a

suitable press. Secure housing cover with hex bolts
and torque to 185 N·m (136 lb ft).
RCIL11WHL085BAF 10
tact is made. Adjust tapered roller bearing after cool-
ing down.
RCIL11WHL086BAF 11
Next operation:
Rear bevel gear set and differential - Backlash Model 3105 II (27.106).
48083742_EN 31/07/2018
27.2 [27.106] / 33

Prior operation:
Rear bevel gear set and differential - Backlash Model 3105 II (27.106)
1. After successful contact pattern check, reinsert differ-

ential into axle drive housing.
RCIL11WHL108BAF 1
2. Loosen slotted nut using pinion lock nut wrench

CAS2842 with 380001564 clamping device and pull
input flange from input pinion.
RCIL11WHL109BAF 2
3. Use pinion shaft seal installer CAS2841 to mount shaft

seal with seal lip facing oil chamber.
NOTE: Exact installation position of seal is obtained when
using specified tool.
NOTE: Wet outer diameter of shaft seal with mineral spirits
just before installation. Fill space between seal and dust lip
with grease.
RCIL11WHL110BAF 3
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27.2 [27.106] / 34
4. Insert input flange and secure with disc and slotted nut
using pinion locknut wrench CAS2842 and clamp de-
vice 380001546. Torque to 1200 N·m (885 lb ft).
NOTE: Cover threads of slotted nut with LOCTITE® 262™.
RCIL11WHL111BAF 4
RCIL11WHL112BAF 5

NOTE: After assembling axle housing secure axle with
clamping brackets.
RCIL11WHL113BAF 6
48083742_EN 31/07/2018
27.2 [27.106] / 35
RCIL11WHL114BAF 7

tube (arrow).
RCIL11WHL115BAF 8

RCIL11WHL116BAF 9
48083742_EN 31/07/2018
27.2 [27.106] / 36

ft).
RCIL11WHL117BAF 10
Next operation:
48083742_EN 31/07/2018
27.2 [27.106] / 37

CAUTION
Eye injury hazard!
C0035A
Prior operation:
Disassembly output and brake

1. Fix axle to suitable stand.
RCPH11WHL485BAU 1
2. Loosen screw plugs (3x), see Figures 2 and 3 and drain

oil from axle.
RCPH11WHL486BAU 2
RCPH11WHL487BAU 3
48083742_EN 31/07/2018
27.2 [27.106] / 38

RCPH11WHL488BAU 4
from the axle housing
RCPH11WHL489BAU 5

NOTE: Pay attention to potentially releasing shim(s)
RCPH11WHL490BAU 6
48083742_EN 31/07/2018
27.2 [27.106] / 39
Disassembly axle housing

6. Secure axle housing with lifting device and loosen hex
screws. Then separate the axle housing from drive
housing.
RCPH11WHL507BAU 7

leasing brake tube.
RCPH11WHL508BAU 8
RCPH11WHL509BAU 9
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27.2 [27.106] / 40
Disassembly axle drive housing

9. Secure axle drive housing with the lifting device (S) and
loosen the hexagon screws.
10. Separate the axle drive housing from the axle housing.
RCPH11WHL510BAU 10
11. Fix axle drive housing to a suitable stand.
RCPH11WHL511BAU 11
12. Loosen cylindrical screws and lift the releasing bear-

ing housing with the lifting device.
RCPH11WHL512BAU 12
13. Pull bearing outer ring (arrow) out of the bearing hole
and remove the shim behind.
RCPH11WHL513BAU 13
48083742_EN 31/07/2018
27.2 [27.106] / 41
14. Lift differential out of the axle drive housing with the
lifting device.
NOTE: Disassembly of the various differentials are located
in the Disassembly multi-disk section of this manual.
RCPH11WHL515BAU 14
15. Pull the bearing outer ring (arrow) out of the bearing
hole and remove the shim behind.
RCPH11WHL516BAU 15
16. Heat slotted nut by means of hot-air blower.

RCPH11WHL517BAU 16
17. Loosen the slotted nut and remove the shim behind.
RCPH11WHL518BAU 17
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27.2 [27.106] / 42
18. Pull input flange from the input pinion. Use a lever
to lift the shaft seal ring behind, out of the axle drive
housing.
RCPH11WHL519BAU 18
19. Use a two-armed puller to press the input pinion out

of the axle drive housing and remove the releasing
tapered roller bearing.
RCPH11WHL520BAU 19
20. Remove the spacer ring and pull the tapered roller
bearing from the input pinion.
RCPH11WHL521BAU 20
21. Loosen the threaded connection and remove the re-

leasing oil tube.
RCPH11WHL522BAU 21
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27.2 [27.106] / 43
22. If necessary, pull the internal bearing outer ring out of

the axle driving housing and remove shim behind.
RCPH11WHL523BAU 22
23. If necessary, pull the external bearing ring out of the

axle drive housing.
RCPH11WHL524BAU 23
Next operation:
48083742_EN 31/07/2018
27.2 [27.106] / 44

Prior operation:
Disassembly differential D-5000

RCPH11WHL526BAU 1

RCPH11WHL527BAU 2

RCPH11WHL528BAU 3
48083742_EN 31/07/2018
27.2 [27.106] / 45

disk.
RCPH11WHL531BAU 4
5. Remove the thrust washer and axle bevel gear from the
RCPH11WHL532BAU 5
RCPH11WHL533BAU 6

housing.
RCPH11WHL534BAU 7
48083742_EN 31/07/2018
27.2 [27.106] / 46
8. Remove axle bevel gear and shims behind.
RCPH11WHL535BAU 8

housing.
RCPH11WHL536BAU 9
Next operation:
48083742_EN 31/07/2018
27.2 [27.106] / 47

CAUTION
Burn hazard!
C0047A
Prior operation:
Assemble differential D-5000

is obtained.
RCPH11WHL546BAU 1
2. Insert disk and thrust washer into differential housing.
RCIL11WHL077BAF 2
RCIL11WHL078BAF 3
48083742_EN 31/07/2018
27.2 [27.106] / 48

housing and fix them with the spider shafts.
(2).
RCPH11WHL549BAU 4
5. Fix spider shafts with slotted pins (2 pieces/hole).

flush position.
RCPH11WHL550BAU 5
RCPH11WHL551BAU 6

• Tightening torque (M10/10.9) to 50 N·m (443 lb in).
RCPH11WHL552BAU 7
48083742_EN 31/07/2018
27.2 [27.106] / 49
8. Mount two adjusting screws (S) and insert the differen-

tial cover by means of the lifting device.
RCPH11WHL574BAU 8

• Tightening torque (M/16/12.9) to 400 N·m (3540 lb
in).
RCPH11WHL564BAU 9
tact is obtained.
RCPH11WHL565BAU 10
Next operation:
Rear bevel gear set and differential - Backlash Model 3115 II (27.106).
48083742_EN 31/07/2018
27.2 [27.106] / 50

Prior operation:
Rear bevel gear set and differential - Backlash Model 3115 II (27.106)
1. After the contact pattern check, insert the differential

again into axle drive housing.
RCPH11WHL601BAU 1
Reassembly of shaft seal ring (steps 2 — 4)

2. Use the wrench 380002318 to loosen the slotted nut
and pull the input flange from the input pinion.
RCPH11WHL602BAU 2
3. Mount the shaft seal ring with the seal lip showing to
the oil chamber.
NOTE: The exact installation position of the shaft seal rings
is obtained when using the specified driver tool (S).
NOTE: Wet the outer diameter of the shaft seal ring with
spirit directly before installation and fill the space between
seal and dust lip with grease.
RCPH11WHL603BAU 3
48083742_EN 31/07/2018
27.2 [27.106] / 51

finally tighten by means of disk and slotted nut. Tight-
ening torque to 1200 N·m (885 lb ft).
NOTE: Cover the thread of the slotted nut with Locite (Type
no.: 262)!
RCPH11WHL604BAU 4
5. Grease O-ring (arrow) and insert it into the annular

grove of the bearing housing.
RCPH11WHL605BAU 5
6. Insert the bearing housing by means of the lifting device

and finally tighten it with cylindrical screws. Tightening
torque (M12/10.9) to 50 N·m (37 lb ft).
RCPH11WHL606BAU 6
7. Grease O-rings (arrows) and insert them on both sides

of the axle drive housing.
RCPH11WHL607BAU 7
48083742_EN 31/07/2018
27.2 [27.106] / 52
8. Mount two adjusting screws (S) and bring axle drive

housing in contact position with the axle housing by
using the lifting device.
9. Then fix the axle drive housing with hexagon screws.
• (S) Adjusting screws (M20/10.9).
• (S) Eye bolt (M20).
NOTE: After mounting the axle drive housing, unbolt the
support (S) until contact is obtained.
RCPH11WHL608BAU 8
Reassembly axle housing

(27 lb ft).
RCPH11WHL609BAU 9

(74 lb ft).
RCPH11WHL610BAU 10
48083742_EN 31/07/2018
27.2 [27.106] / 53
NOTE: After assembling the axle housing, secure the axle
RCPH11WHL611BAU 11
Next operation:
48083742_EN 31/07/2018
27.2 [27.106] / 54
Index

Rear bevel gear set and differential - Backlash Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear bevel gear set and differential - Backlash Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rear bevel gear set and differential - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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27.2 [27.106] / 56
Planetary and final drives - 120

48083742_EN 31/07/2018
27.3 [27.120] / 1
Contents
SERVICE
Wheel hub
Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Remove Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
48083742_EN 31/07/2018
27.3 [27.120] / 2
Rear axle system - Planetary and final drives

Prior operation:

stand.
RCIL11WHL001BAF 1

and disposal.
RCIL11WHL002BAF 2

and disposal.
RCIL11WHL003BAF 3
48083742_EN 31/07/2018
27.3 [27.120] / 3

RCIL11WHL004BAF 4
5. Attach appropriate lifting device to output assembly.

Remove hex bolts and separate output from axle hous-
ing.
RCIL11WHL005BAF 5

RCIL11WHL006BAF 6
Next operation:
48083742_EN 31/07/2018
27.3 [27.120] / 4

Prior operation:
1. Attach output assembly to suitable work stand.
RCIL11WHL007BAF 1
RCIL11WHL008BAF 2
RCIL11WHL009BAF 3
48083742_EN 31/07/2018
27.3 [27.120] / 5
4. Use a puller and press planetary carrier from profile of

output shaft.
RCIL11WHL010BAF 4

of brake housing.
RCIL11WHL011BAF 5
RCIL11WHL012BAF 6
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RCIL11WHL013BAF 7
RCIL11WHL014BAF 8
RCIL11WHL015BAF 9
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RCIL11WHL016BAF 10
RCIL11WHL017BAF 11
12. Mount bleeder valve and use compressed air to re-

move piston from brake housing.
RCIL11WHL018BAF 12
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(see arrows).
RCIL11WHL019BAF 13
14. 1. Brake housing

2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
7. Metal face seal
8. Output shaft
RCIL11WHL153BAF 14
15. Use a suitable lifting device. Lift brake housing from

output shaft.
RCIL11WHL020BAF 15
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ing. If needed, remove both bearing outer rings.
RCIL11WHL021BAF 16
17. Use levers to remove slide ring seal from output shaft.
RCIL11WHL022BAF 17
RCIL11WHL023BAF 18
Next operation:
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Prior operation:
NOTICE: Do not use compressed air to dry bearings. Allow bearings to air dry.
using cleaning solvent. WEAR FACE PROTECTION
WHEN USING COMPRESSED AIR. Use compressed
air to clear passages in planetary ring gear and brake
housing.
seen.
essary.
Next operation:
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CAUTION
Burn hazard!
C0047A
Prior operation:
1. Pull wheel stud into output shaft until contact is made.

NOTE: A special tool should be used for repairs when
exchanging individual wheel studs with a mounted output
shaft. On a new output shaft, mount wheel studs with a
press.
RCIL11WHL118BAF 1
2. Heat tapered roller bearing and place it onto output

shaft.
RCIL11WHL119BAF 2
eral spirits. Snap new slide ring seal onto output shaft.
NOTE: Surface of slide ring seal must not have any
out.
RCIL11WHL120BAF 3
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4. Mount new slide ring seal onto brake housing.

NOTE: Surface of slide ring seal may not have any
out.
RCIL11WHL121BAF 4
5. Insert both bearing outer rings (arrows) into brake

housing.
RCIL11WHL122BAF 5
6. Use suitable lifting device and place premounted brake

housing on output shaft.
NOTE: Before clamping seal rings (slide ring seal) to in-
stallation dimension, clean sliding surfaces and apply an
oil film. A leather cloth soaked in oil is recommended for
this step.
RCIL11WHL123BAF 6
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NOTE: For installation position, see Step 9.
RCIL11WHL124BAF 7

spirits. Insert guide ring into annular grove (see Step
9). Secure it with LOCTITE® 415™ at its ends (arrows).
NOTE: Full circumference of guide ring must be in an exact
contact position.
NOTE: Upon installation, orifice of guide ring must show
upwards - 12 o’clock position.
RCIL11WHL125BAF 8
9. 1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
7. Metal Face Seal
8. Output shaft
RCIL11WHL153BAF 9
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RCIL11WHL126BAF 10
grooved rings and guide ring with SAE 10W oils.
RCIL11WHL127BAF 11
RCIL11WHL128BAF 12
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13. Insert cover and secure it with hex bolts. Torque to

34 N·m (25 lb ft).
RCIL11WHL129BAF 13

NOTE: For number of disks and disk arrangement, refer to
RCIL11WHL130BAF 14
RCIL11WHL131BAF 15
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RCIL11WHL158BAF 16
17. Insert cylindrical roller bearing into planetary gear. To

do this, press cylindrical roller bearing (1) through
packaging sleeve (2) until snap ring (3) engages into
annular groove of planetary gear (4).
RCIL11WHL132BAF 17
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18. Heat bearing inner rings. Insert premounted planetary

wards). Secure planetary gears with retaining rings.
RCIL11WHL133BAF 18

rier.
RCIL11WHL134BAF 19
20. Wet contact face of bearing inner ring (1) and profile
RCIL11WHL135BAF 20
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RCIL11WHL136BAF 21

contact position. Torque to 200 N·m (148 lb ft).
RCIL11WHL137BAF 22

NOTE: Torque locking bolts successively to 200 N·m
(148 lb ft). Then, retorque to 560 N·m (413 lb ft).
RCIL11WHL138BAF 23
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NOTE: Curing period for TEROSTAT ® MS-9360 is greater
than 24-hours.
RCIL11WHL139BAF 24
RCIL11WHL140BAF 25
Next operation:
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Prior operation:
1. Set sun gear shaft axial play range to 0.5 – 2.0 mm

(0.02 – 0.08 in). Use a straight edge to determine di-
mension I, from mounting face of brake housing to front
face of stop bolt. Dimension I e.g. 40.80 mm (1.61 in).
RCIL11WHL141BAF 1
tact is made.
NOTE: Mount stub shaft with long teeth towards differen-
tial.
RCIL11WHL142BAF 2
3. Insert sun gear shaft until contact is made.
RCIL11WHL143BAF 3
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4. Using a straight edge, measure dimension II, from front

face of sun gear shaft to mounting surface of axle hous-
ing. Dimension II e.g. 38.20 mm (1.50 in). CALCU-
LATION EXAMPLE: Dimension I: 40.80 mm (1.61 in)
Dimension II: 38.20 mm (1.50 in) Difference: 2.60 mm
(0.10 in) Required axial play e.g.: 1.00 mm (0.04 in)
Difference = shim e.g.: s = 1.60 mm (0.06 in).
RCIL11WHL144BAF 4
RCIL11WHL145BAF 5
6. Insert shim(s) e.g. s = 1.60 mm (0.06 in) with grease

into sun gear shaft.
RCIL11WHL146BAF 6
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7. Attach O-ring (arrow) with grease into countersink of

brake housing.
RCIL11WHL147BAF 7
RCIL11WHL148BAF 8
9. Mount adjusting bolts and use appropriate lifting de-

vice to bring output into contact position with axle hous-
ing. Secure output using hex bolts. Torque to 560 N·m
(413 lb ft).
NOTE: Attach load carrying device with wheel stud.
RCIL11WHL149BAF 9
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10. Mount bleeder valve (arrow).
RCIL11WHL150BAF 10
Next operation:
Brakes - Leakage test (33.202)
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Prior operation:
1. Fix axle to assembly truck.
RCPH11WHL485BAU 1
2. Loosen screw plugs (3x, see Figures 2 and 3) and drain

oil from axle.
RCPH11WHL486BAU 2
RCPH11WHL487BAU 3
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RCPH11WHL488BAU 4
from the axle housing.
RCPH11WHL489BAU 5

NOTE: Pay attention to potentially releasing shim(s).
RCPH11WHL490BAU 6
Next operation:
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CAUTION
Eye injury hazard!
C0035A
Prior operation:
1. Attach output to a suitable stand.
RCPH11WHL491BAU 1
RCIL11WHL008BAF 2
RCPH11WHL493BAU 3
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RCPH11WHL494BAU 4
RCPH11WHL495BAU 5
6. Disingage retaining rings.
RCPH11WHL496BAU 6
RCPH11WHL497BAU 7
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RCPH11WHL498BAU 8
RCPH11WHL499BAU 9
10. Loosen hexagon screws, remove releasing disk and

cup spring.
RCPH11WHL500BAU 10
RCPH11WHL501BAU 11
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NOTE: For the installation position of the single parts refer
RCPH11WHL502BAU 12

1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
7. Slide ring seal
8. Output shaft
RCPH11WHL646BAU 13
14. Using a suitable lifting device, lift the brake housing

from output shaft.
RCPH11WHL503BAU 14
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27.3 [27.120] / 30
ing. If needed, force out both bearing outer rings.
RCPH11WHL504BAU 15
16. Use lever to remove slide ring seal from output shaft.
RCPH11WHL505BAU 16
RCPH11WHL506BAU 17
Next operation:
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CAUTION
Flying debris!
pressed air.
C0049A
WARNING
Chemical hazard!
W0180A
Prior operation:

ATTENTION: Do not use compressed air to dry bearings.
Allow bearings to air dry.
seen.
essary.
Next operation:
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CAUTION
Burn hazard!
C0047A
CAUTION
Sharp object hazard!
Wear gloves when handling worn discs.
C0006A
Prior operation:
1. Pull wheel stud into output shaft until contact is ob-

tained.
• (S) Wheel stud puller, basic tool
• (S) Insert (M22x1.5)
NOTE: Special tool (S) may only be used for repair solu-
tion when exchanging individual wheel studs with mounted
output shaft. When using a new output shaft, mount the
wheel studs with the press.
RCPH11WHL612BAU 1
2. Heat tapered roller bearing and insert it into the output

shaft until contact is obtained.
RCPH11WHL613BAU 2
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27.3 [27.120] / 33
eral spirits.
4. Snap NEW slide ring seal (part 1) into output shaft.
5. Then mount NEW slide ring seal (part 2) accordingly
into the brake housing.
NOTE: For the installation position of the seal, please refer
to Legend Sketch in step 12.
NOTE: The surface of slide ring seal may not have any
grooves, scratches or other types of damage. Take care
that the sealing surface is parallel to the housing face.
RCPH11WHL614BAU 3
6. O-rings must be mounted evenly into the locating hole

and must not bulge out of the hole.
NOTE: Metal rings have extremely sharp edges. Wear pro-
tective gloves.
RCPH11WHL615BAU 4
7. Insert both bearing outer rings (arrows) into the brake

housing until contact is obtained.
RCIL11WHL122BAF 5
8. Insert the premounted brake housing by means of the

lifting device over the output shaft until contact is ob-
tained.
NOTE: Before clamping seal rings to installation dimen-
sion, clean sliding surfaces and apply an oil film. A leather
cloth soaked in oil is recommended for this step.
RCPH11WHL617BAU 6
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NOTE: For installation position, see refer to Legend Sketch
step 12.
RCIL11WHL124BAF 7

spirits.
11. Then insert the guide ring into annular grove (refer to
Legend Sketch in step 12) and fix it with LOCTITE®
415™ at its extremities (arrows).
NOTE: The full circumference of guide ring must be in an
exact contact position.
NOTE: Upon installation, the orifice of the guide ring must
show upwards - 12 o’clock position.
RCIL11WHL125BAF 8

1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
7. Slide ring seal
8. Output shaft
RCPH11WHL646BAU 9
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install with the fixing device (S) until contract is ob-
tained.
grooved rings and guide ring ( SAE 10W oils to be used)!
RCPH11WHL620BAU 10
14. Insert cup spring into the piston with the convex side
showing upwards.
RCPH11WHL621BAU 11

RCPH11WHL622BAU 12

NOTE: For the number of disks and the disk arrangement
RCPH11WHL623BAU 13
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27.3 [27.120] / 36
RCPH11WHL624BAU 14
Setting of installation dimension

Installation dimension 57.25 mm (2.25 in) ... 57.79 mm
(2.3 in).
18. Measure installation dimension from the mounting
face of the brake housing to the front face of the end
plate.
• Installation dimension e.g.: 57.50 mm (2.3 in).
NOTE: Any deviation from the necessary installation di-
mension must be corrected with an appropriate outer disk
RCPH11WHL625BAU 15
20. Then insert the premounted cover into the planetary
Legend to sketch:
1. Stop bolt.
2. Cover.
3. Planetary carrier.
RCPH11WHL651BAU 16
21. Insert cylindrical roller bearing into planetary gear —

for this purpose press the cylindrical roller bearing
through packaging sleeve until the snap ring engages
into annular groove of planetary gear.
1. Cylindrical roller bearing.
2. Packaging sleeve.
3. Snap ring.
4. Planetary gear.
RCPH11WHL626BAU 17
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22. Heat bearing inner rings and insert the premounted

planetary gears with large radius facing planetary car-
rier (downwards) until contact is obtained.
RCPH11WHL627BAU 18
24. Heat tapered roller bearing and install it on the plane-

tary carrier until contact is obtained.
RCPH11WHL628BAU 19
25. Wet front face (contact face bearing inner ring, arrow
1) and profile (teeth, arrow 2) in the output shaft with
anti-corrosive Anti-seize.
RCPH11WHL629BAU 20

27. Then insert the planetary carrier by means of the lifting
device into the teeth of the output shaft until contact is
obtained.
RCPH11WHL630BAU 21
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28. Pivot output 90°. Insert disk and fix planetary carrier
NOTE: Tighten locking screws successively with a tight-
ening torque of 200 N·m (148 lb ft). Then retighten the
locking screws successively with a tightening torque of
750 N·m (553 lb ft).
RCPH11WHL631BAU 22
29. Install O-ring (see arrow) to the cover.
RCPH11WHL632BAU 23
obtained.
RCPH11WHL633BAU 24
Next operation:
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Prior operation:
1. Set the axial play of the sun gear shaft 0.5 – 2.0 mm
(0.02 – 0.08 in). Determine dimension I, from mounting
face of brake housing to front face of stop bolt. Dimen-
sion I e.g. 58.60 mm (2.3 in).
• (S) Gauge blocks
RCPH11WHL634BAU 1
tact is obtained.
NOTE: Pay attention to the installation position; mount the
stub shaft with the long teeth showing to the differential.
RCPH11WHL635BAU 2
3. Insert sun gear shaft until contact is obtained.
RCPH11WHL636BAU 3
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4. Measure dimension II, from front face of sun gear shaft

to mounting surface of axle housing.
NOTE: Refer to following calculation example table for cal-
culation procedure.
• Dimension II e.g.: 56.60 mm (2.2 in)
RCPH11WHL637BAU 4
CALCULATION EXAMPLE:
Difference 2.00 mm
Required axial play e.g.: — 1.00 mm
Difference = shim e.g.: s = 1.00 mm
RCPH11WHL638BAU 5
6. Fix determined shim(s) e.g. s = 1.00 mm (0.04 in) with

grease into sun gear shaft.
RCPH11WHL639BAU 6
48083742_EN 31/07/2018
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7. Fix O-ring (arrow) with grease into countersink of brake

housing.
RCPH11WHL640BAU 7
RCPH11WHL641BAU 8
9. Mount two adjusting screws (S) and use appropriate

lifting device to bring output into contact position with
axle housing. Secure output using hex bolts. Torque to
560 N·m (4956 lb in).
10. Then fix the output by means of hexagon screws.
Tightening torque (M20/10.9) to 560 N·m (4956 lb in).
NOTE: Fix load carrying device (S) with wheel stud.
RCPH11WHL642BAU 9
11. Mount bleeder (arrow).
RCPH11WHL643BAU 10
Next operation:
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Brakes - Leakage test Model 3115 II (33.202)
48083742_EN 31/07/2018
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Index

Wheel hub - Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Wheel hub - Install Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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48083742_EN 31/07/2018
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PRINTED IN ITALY
48083742_EN 31/07/2018
EN
SERVICE MANUAL
Brakes and controls

48083742_EN 31/07/2018
33
Contents
Brakes and controls - 33
[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2
48083742_EN 31/07/2018
33
Hydraulic service brakes - 202

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33.1 [33.202] / 1
Contents
TECHNICAL DATA
Hydraulic service brakes

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake discs
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUNCTIONAL DATA

Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake pedal control valve
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake pump
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Check - Brake modulation pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Check - Service brake system performance (stored energy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Brakes
Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Brake pedal control valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Accumulator
48083742_EN 31/07/2018
33.1 [33.202] / 2
Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Brake discs
Disassemble Model 3105 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Visual inspection Model 3105 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Assemble Model 3105 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Disassemble Model 3115 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Visual inspection Model 3115 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Assemble Model 3115 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Brake lines
Remove Model 3105 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Install Model 3105 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Remove Model 3115 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Install Model 3115 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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Brakes and controls - Hydraulic service brakes
Hydraulic service brakes - General specification

Brake pump output 42 – 45 L/min at 172 bar
( 11 – 12 gpm at 2500 psi at 2000 rpm)
3.5 L nitrogen accumulator pre-charge pressure 70 bar (1015 psi)
Redundant Brake accumulator Pressure switches PRB1 and Rising < 91 bar (1319.5 psi),
PRB2 (normally closed) Falling 70 – 84 bar (1015 – 1218 psi)
Low Brake Pressure Warning Switch Alarm OFF < 138 bar (2001 psi) increasing
Alarm ON 115 – 129 bar (1668 – 1870 psi)
decreasing
Brake accumulator charging valve Cut-in pressure: 162 – 172 bar (2349 – 2494 psi)
Cut-out pressure: 195 – 201 bar (2828 – 2914 psi)
Brake lamp pressure switch (normally open) Closing setpoint 4.1 bar (59 psi)
NOTE: see hydraulic schematics for additional specifications.
Hydraulic service brakes - Special tools

380001737 Nitrogen charging kit used to check and
charge the accumulator with nitrogen.
A. Regulator
B. Valve
C. Valve
D. Valve
E. Gauge
F. Valve
LEIL13WHL1358AB 1
380001168 Accumulator charging adapter
G. Adapter
LEIL13WHL1230AB 2
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CAS10280 Flow meter
LEIL13WHL1199AA 3
380001740 Flow meter fitting kit
LEIL13WHL1200AA 4
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Brake discs - Service limits

NOTICE: a wear measurement on the multi-disc brake must be made at least once a year. Wear measurement should
also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking function is
impaired.
NOTE: the procedure in applicable for axle model 3105 II and 3115 II. The figures may differ slightly from your ma-
chine, the procedure is the same.
1. Perform the wear measurement on both wheel end
sides.
2. Remove the plug (see the arrow in figure), actuate
the brake and determine the dimension (A) using a
thickness gauge.
3. Replace the brake packs on both sides of the axle
if dimension (A) is:
○ less than or equal to 3.5 mm (0.138 in), for axle
model MT-L3105-II used with 1021G or 1021F front
standard and rear (standard and heavy duty) open
differential axles
○ less than or equal to 3.0 mm (0.118 in), for axle
model MT-L3115-II used with 1021G or 1021F front RCIL11WHL163BAF 1
heavy duty with differential lock axle and 1121G or
1121F front (both open and differential lock) and rear
open differential axles
4. Replace O-ring when installing the plug.
5. Tighten plug to a torque of 70 N·m (52 lb ft).
LEIL15WHL1132AB 2
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Hydraulic service brakes - Component localization

Standard axle
LEIL16WHL2719GB 1
1. Front axle 6. Front brake accumulator (rear axle)

2. Rear axle 7. Parking brake accumulator
3. Brake pump 8. Front brake damping accumulator
4. Brake pedal control valve 9. Rear brake damping accumulator
5. Rear brake accumulator (front axle) 10. Resounding filter
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Heavy duty axle
LEIL16WHL2720GB 2
1. Front axle 7. Brake accumulator

2. Rear axle 8. Front brake accumulator (rear axle)
3. Brake pump 9. Front brake damping accumulator
4. Brake pedal control valve 10. Parking brake accumulator
5. Rear brake damping accumulator 11. Resounding filter
6. Rear brake accumulator (front axle)
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Hydraulic service brakes - Component localization

LEIL16WHL2721GB 1
1. Front axle 7. Parking brake accumulator

2. Rear axle 8. Front brake damping accumulator
3. Brake pump 9. Rear brake damping accumulator
4. Brake pedal control valve 10. Brake accumulator
5. Rear brake accumulator (front axle) 11. Brake accumulator
6. Front brake accumulator (rear axle) 12. Resounding filter
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Brake pedal control valve - Component identification
LEIL16WHL1607GB 1
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1. Brake pedal control valve 14. Connector 10 mm

2. Front accumulator hose (to "R2" port of the brake 15.
Connector 6 mm
pedal control valve)
3. Parking brake hose (to "X" port of the brake 16.
Connector 12 mm
pedal control valve)
4. Front accumulator hose (to "R1" port of the brake 17. Tube assembly (brake pedal control valve to tank
pedal control valve) plated)
5. Discharge hose (to "B" port of the brake pedal 18.
O-ring
control valve)
6. Front brake hose (to "T1" port of the brake pedal 19.
Connector 16 mm
control valve)
7. Front brake hose (to "T2" port of the brake pedal 20.
Connector 12 mm
control valve)
8. Supply hose (from brake pump to "P" port of the 21.
Tee 16 mm
brake pedal control valve)
9. Return to tank hose (to "N" port of the brake 22.
Tee 12 mm
pedal control valve
10. Parking brake accumulator hose (to "R4" port of 23.
Front axle diagnostic coupler
brake pedal control valve)
11. Connector 12 mm 24. Rear axle diagnostic coupler
12. Connector 12 mm 25. Elbow 90°
13. Elbow 45°
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Brake pump - Component identification
LEIL16WHL2725GB 1
1. Brake pump 9. Bracket 17. Resounding filter

2. Mounting bolt, M14 x 35 10. Pressure hose 18. Hose (Brake pump to resonator)
3. Washer, 15.5 x 28 x 3 mm 11. Transmission 19. Nut
4. Suction hose 12. Hydraulic tank 20. Elbow 90°
5. Bolt, M12 x 35 13. Suction filter 21. Hose (Resonator to brake valve)
6. Washer, spring lock 12 mm 14. Tee 22. Attenuator hose
7. Semi-flange 15. Elbow 90°
8. O-ring 16. Elbow 90°
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Hydraulic service brakes - Test

1. Check the oil level in the hydraulic reservoir; add oil as
necessary.
2. Push and release the brake pedal valve many times
with the engine stopped to remove all hydraulic pres-
sure from the brake system until there is no pressure
on the pedal.
3. Install two 207 bar (3002 psi) pressure gauges (
CAS10280 and 380001740) to front and rear hydraulic
brake accumulator test ports.
4. Make sure that the pressure gauge hoses are long
enough so the gauges can be read while sitting in the
operator seat.
NOTE: the gauges can not be connected to the test ports
if hydraulic pressure remains in the system.
5. Start the engine. Run the engine at low idle while read-
ing the pressure gauges. The alarms (buzzer, master
warning light and brake pressure warning light) should
shut off when the accumulator with the lowest pres-
sure reaches 106 – 115 bar (1537 – 1668 psi), approx-
imately 40 seconds at any engine speed.
6. After the alarms stop, run the machine at high idle to
finish charging the accumulators. The pressure must
increase on both gauges until 195 – 201 bar (2827.5 –
2914.5 psi) is reached. This is the accumulator valve
cut-out pressure. It is normal for the pressure to drop
slightly once the cut-out pressure is reached.
7. With the engine running at high idle, push and re-
lease the brake pedal rapidly while reading the drop in
pressure on the gauges. The pressure drops may not
be equal, but as the lowest pressure reaches 162 –
172 bar (2349 – 2494 psi), the system pressure must
start to increase. This is the valve cut in pressure.
NOTE: the brake cut-in and cut-out pressures of the brake
system charge valve are factory preset and are not ad-
justable.
NOTE: if the pressure on one of the pressure gauges is
lower than specified, the problem can be a bad accumula-
tor valve.
8. Stop the engine. Turn the ignition switch to the ON po-
sition. Push and release the brake pedal valve several
times while reading the pressure on the gauges. Each
push and release of the brake pedal valve will result in
a slight drop in pressure, but not necessarily equal on
the two gauges.
9. As the lowest pressure reaches 106 – 115 bar (1537
– 1668 psi) the brake warning lamp and alarm buzzer
must actuate. If the warning lamp and alarm buzzer fail
to work, test the low brake pressure warning switches
and electrical circuit. If the warning lamp and alarm
buzzer actuate at a higher or lower pressure than spec-
ified, test the low brake pressure warning switches and
replace as needed.
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10. After the low brake pressure light activates, press the
brake pedal valve eight more times.
11. Record the readings on the pressure gauges. The
pressure gauges should read at 83 bar (1204 psi).
12. If the pressures are at 83 bar (1204 psi), the test is
complete.
13. If the pressures are not within the required specifica-
tions, perform the hydraulic brake system bleeding.
14. After bleeding the brake system, perform the hydraulic
brake system test.
15. Continue to slowly push and release the brake pedal
valve several times until the gauge pressure suddenly
drops to zero. The last pressure reading before the
drop to zero is the nitrogen charge pressure in the ac-
cumulator. Test the pressure in both accumulators. If
the pressure is at 70 bar (1015 psi), charge or replace
the accumulator(s).
NOTE: nominal temperature of 20 °C (68 °F), colder tem-
perature will reduce pressure, hotter temperature will in-
crease pressure.
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Hydraulic service brakes - Bleed

1. Check the level of hydraulic fluid in the reservoir. Add
fluid to the reservoir if necessary.
NOTE: if machine is equipped with quick-attached compo-
nents, disconnect them from machine prior to proceeding.
2. Raise loader arms and install the safety strut (1) for safe
access to the front axle bleed screws.
3. Apply the parking brake.
4. Keep the engine speed at high idle until both brake
accumulators are fully charged.
NOTE: this will be approximately 30 seconds after the low
brake pressure light goes out. LEIL13WHL1231AB 1
5. Stop the engine.

6. Pump the brake pedal valve until there is no hy-
draulic pressure in the brake system (approximately
20 pumps).
7. Remove the plastic and rubber caps from each wheel
end and slowly open all four bleed screws.
NOTE: attach a hose to the bleed screws to prevent spilling
any fluids.
8. Start the engine and run at low idle.
9. Push the brake pedal valve all the way down and slowly
release for one cycle.
10. Close all four wheel end bleed screws.
11. Fully depress the brake pedal valve three times in 5
second cycles.
12. With the brake pedal valve partially depressed, open
the bleed screw on the left-hand front axle. Hold the
brake pedal valve in position until the oil is clear (no
bubbles). Close the bleed screw.
13. Open the bleed screw on the right-hand front axle.
Repeat step 12.
14. Open the bleed screw on the left-hand rear axle. Re-
peat step 12.
15. Open the bleed screw on the right-hand rear axle. Re-
peat step 12.
16. Replace all bleed screws, caps and plugs.
17. Check the hydraulic fluid and add as necessary.
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Hydraulic service brakes - Check - Brake modulation pressure
LEIL16WHL1653FB 1
1. Front axle test port 3. Front brake accumulator test port

2. Rear axle test port 4. Rear brake accumulator test port
Brake modulation pressure test

1. Make sure the hydraulic accumulator cut-in and cut-out
pressures are correct.
2. Install the articulation lock before doing this test.
3. Stop the engine. Pump the brake pedal until there is
no pressure in the brake system.
4. Remove the cab skirts to gain access to the brake test
ports.
5. Connect two 207 bar (3002 psi) pressure gauges (
CAS10280 and 380001740) to the front brake test port
(1) and the rear brake test port (2).
CAS10280 and 380001740) to the front brake accu-
mulator test port (4) and the rear brake accumulator
test port (3).
7. Start the engine.
8. Operate the machine at low idle and watch the pressure
gauges on the brake accumulators until the gauges rise
above 170 bar (2465 psi).
9. Apply and hold the brakes for 10 – 15 s.
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10. Make a note of the pressure on the gauges for the

front and rear brakes.
11. The front brake pressure should read 80 – 87 bar
(1160 – 1262 psi). This is the modulation pressure
for the front axle.
12. The rear brake pressure should read 78 – 85 bar
(1131 – 1232 psi). This is the modulation pressure
for the rear axle
13. If the pressures are not within the specified range, it
will be necessary to adjust the modulation pressures.
Brake modulation pressure adjustment

NOTE: the adjusting bolt to adjust the modulation pressure is located under the cab, under the brake pedal valve.
1. Remove the tamp evident cover (1).
NOTE: replace the tamp evident cover (1) after the adjust-
ment of the brake modulation pressure.
2. Remove the locking bolt (2).
3. Turn the adjusting screw (3) to adjust the modulation
pressure.
NOTE: the rear brake modulation pressure cannot be ad-
justed separately from the front brake modulation pressure.
4. Repeat steps 5 through 11 of the Brake modulation
pressure test procedure.
5. Repeat these steps until the brake modulation pressure
is within the specified range.
LELI12WL30884BB 2
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Hydraulic service brakes - Check - Service brake system

performance (stored energy)
LEIL16WHL1653FB 1
1. Front axle test port 3. Front brake accumulator test port

2. Rear axle test port 4. Rear brake accumulator test port
NOTE: prior to doing this procedure make sure that the accumulator pressures are correct.
1. Check the level of the hydraulic fluid in the reservoir,
add as needed.
2. Install the articulation lock (1) before doing this test.
3. Remove the left-hand side cab skirt to gain access to
the brake accumulator test ports.
4. Pump the brake pedal until there is no hydraulic pres-
sure in the brake system (approximately 20 pumps).
CAS10280 and 380001740) to the test ports 3 and 4.
6. Start the engine and let idle until both the front and
rear accumulators 3 and 4 are fully charged. The ac-
cumulators are fully charged at 190 – 196 bar (2755 –
2842 psi).
LEIL16WHL1599AA 2
7. Stop the engine.
8. Push the brake pedal valve down slowly, allowing for
full piston actuation.
NOTE: depress the brake pedal valve at the rate of three
strokes per minute.
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9. Continue pressing the brake pedal valve down. The

low brake pressure light should activate when the pres-
sure reaches 106 – 115 bar (1537 – 1668 psi). After
the low brake pressure light activates, press the brake
pedal valve eight more times.
10. Record the readings on the pressure gauges. The
pressure gauges should read at 83 bar (1204 psi).
11. If the pressures are at 83 bar (1204 psi), the test is
complete.
12. If the pressures are not within the required specifica-
tions, then the brake system must be bled.
13. After bleeding the brake system, perform this proce-
dure again.
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Brakes - Leakage test

1. Before start the test, bleed the hydraulic system.
2. Connect a high pressure hand-pump to the brake con-
nection port.
3. Pressurize brakes temporarily five times, with a maxi-
mum pressure of 100 bar (1450 psi).
High-pressure test:
Build up test pressure: 100 bar (1450 psi) maxi-
mum.
Close the connection to the high pressure pump
via shut-off valve. A maximum pressure drop of
2% or 2 bar (29 psi) is permissible during a 5 min
test period.
Low-pressure test:
RCIL11WHL151BAF 1
Reduce test pressure p = 5 bar (73 psi) and close
the shut-off valve. No pressure drop is allowed
during a 5 min test period.
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Brake pedal control valve - Remove

loader bucket to the floor. Stop the engine.
2. Put blocks on both sides of each tire to prevent machine
movement.
3. Make sure the brake accumulators are completely dis-
charged. Push down and release the brake pedals sev-
eral times (at least 30).
4. Turn the timed disconnect switch to the OFF position.
5. Remove the cab skirts located under the cab.
6. To release the pressure on the parking brake accu-
mulator, the line at the accumulator must be SLOWLY
cracked open. A pan will be needed to catch the hy-
draulic oil.
7. Connect a drain hose to the quick disconnect couplings
in each brake circuit to release any pressure in the
brake circuit.
8. Clean the brake pedal control valve (1) and the lines.
9. Put identification tags on all electrical and hydraulic
lines that are connected to the brake pedal control
valve.
10. Disconnect all the electrical connectors from the brake
pedal control valve (1).
11. Connect a vacuum pump to the hydraulic reservoir.
Start the vacuum pump.
12. Disconnect the following hoses from the brake pedal
control valve:
• supply hose (2) from "P port;
• rear accumulator hose (3) from "R1" port;
• front accumulator hose (4) from "R2" port;
• parking brake accumulator hose (5) from "R4" port;
• parking brake hose (6) from "X" port;
• discharge hose (7) from "B" port;
• front brake hose (8) from "T1" port;
• rear brake hose (9) from "T2" port; LEIL16WHL1609AB 1
• return hose (10) from "N" port.
Install protective plugs on the disconnected hoses.
LEIL16WHL1610AB 2
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13. Remove the four bolts M8x16 (3), the four screws
M8x30 (2), the two nuts M8 (4), and the gasket (5).
Remove the plates (6) and (7). Remove the brake
pedal control valve (1).
LEIL18WHL0944AB 3
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Brake pedal control valve - Install

1. Position the brake pedal control valve (1) in the cab.
Position the plates (6), (7) and the gasket (5). Lock
with the two nuts M8 (4), the four screws M8x30 (2),
and the four bolts M8x12 (3).
LEIL18WHL0944AB 1
2. Remove the protective plugs from the hoses and con-

nect the following hoses:
• supply hose (2) to the "P port;
• rear accumulator hose (3) to the "R1" port;
• front accumulator hose (4) to the "R2" port;
• parking brake accumulator hose (5) to the "R4" port;
• parking brake hose (6) to the "X" port;
• discharge hose (7) to the "B" port;
• front brake hose (8) to the "T1" port;
• rear brake hose (9) to the "T2" port; LEIL16WHL1609AB 2
• return hose (10) to the "N" port.
3. Stop the vacuum pump and remove it.
4. Connect all the electrical connectors to the brake pedal
control valve (1).
6. Bleed the brake system.
7. Install the cab skirts.
8. Check the hydraulic reservoir oil level and add oil as
required.
LEIL16WHL1610AB 3
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Brake pump - Remove

Prior operation:
1. Connect a vacuum pump to the hydraulic oil tank.

2. Remove the four bolts (5) and washers (6) to separate
the two semi-flanges (7) from the brake pump (1).
3. Disconnect the suction hose (4) from the brake pump
(1). Discard the O-ring (8).
4. Disconnect the hose (brake pump to resonator) (18)
and attenuator hose (22). Plug the hoses and cap the
tee (14) and 90° elbow (15).
5. Disconnect the pressure hose (10). Plug the hose and
cap the 90° elbow (16).
LEIL16WHL2724BA 1
6. Attach a suitable lifting equipment to the brake pump

(1). Remove the two bolts (3) and washers (2).
Remove the brake pump (1).
LEIL16WHL1631AB 2
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Brake pump - Install

1. Lubricate and install a new O-ring of the brake pump.
2. Apply a small amount of CASE AKCELA MOLY
GREASE to coat the brake pump shaft spline.
RCPH11WHL057AAR 1
3. Attach a suitable lifting equipment to the brake pump

(1). Position the brake pump (1). Install the two bolts
(3) and washers (2). Tighten the bolts (3) to 149 –
170 N·m (110 – 125 lb ft).
LEIL16WHL1631AB 2
4. Unplug all the hoses and remove the cap from all el-
bows and tee.
5. Connect the pressure hose (10) to the brake pump (1)
through the 90° elbow (16).
6. Connect the hose (brake pump to resonator) (18) and
attenuator hose (22) to the brake pump (1) through the
tee (14) and 90° elbow (15).
7. Connect the suction hose (4) to the brake pump (1) by
installing a new O-ring (8), two semi-flanges (7), four
washers (6) and bolts (5).
Tighten the bolts (5) to 73 – 90 N·m (54 – 66 lb ft).
8. Stop the vacuum pump.
9. Bleed the hydraulic system.
10. Check the hydraulic oil level and add oil as required.
LEIL16WHL2724BA 3
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Brake pump - Flow test

1. Connect the flowmeter CAS10280 to the brake pump
as shown.
2. Make sure the load control of the flowmeter is open.
Start the engine. Run the engine at full throttle. Make
sure the oil is at operating temperature.
3. Measure the flow at 0 bar( 0 psi ). Record the flow
reading. Slowly close the load valve on the flowmeter
and read the flow at 170 bar ( 2500 psi ). Record the
flow reading.
4. Divide the flow reading at 170 bar ( 2500 psi) by the
reading at 0 bar ( 0 psi). Multiply the result by 100.
This is the percent efficiency of the pump. If the effi-
ciency of the pump is less than 85%, repair or replace
the pump.
NOTE: if unit is equipped with auxiliary steering a tee fitting
must be used instead of the straight connector (T).
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LELI12WL30887GB 1
1. BRAKE PUMP 4. FLOWMETER OUTLET HOSE

2. ELBOW 5. FILTER INLET MANIFOLD
3. FLOWMETER INLET HOSE 6. TRANSMISSION
48083742_EN 31/07/2018
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Accumulator - Discharging
1. Remove cover from accumulator charge port. Loosen
the Allen screw in the charge port.
NOTE: do not turn the Allen screw more than 1/8 of a turn
or gas will escape uncontrolled.
2. Install adapter 380001168 on accumulator, use the
380001737 nitrogen charging kit to discharge the
accumulator. The tool must be disconnected from the
nitrogen tank.
3. Close valves (B), (C) and (D).
4. Adjust the regulator (A) to the minimum pressure set-
ting by turning the knob counterclockwise.
LEIL13WHL1358AB 1
5. Turn the T-handle on valve (F) fully out.
6. Connect valve (F) to the valve stem on the adapter.
7. Turn the T-handle inward on valve (F) to engage the
pin in the valve stem, open valve (G).
8. Open valve (D) and check the charge pressure on
gauge (E).
9. To discharge the accumulator, partially open valve (B).
The accumulator charge will bleed down through the
regulator.
10. Once the accumulator is fully discharged, disconnect
valve (F) from the valve stem and remove adapter. LEIL13WHL1230AB 2
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Accumulator - Remove

movement.
3. Make sure that the brake accumulators (1), the parking
brake accumulator (2), the rear brake damping accu-
mulator (3) and the front brake damping accumulator
(4) are completely discharged.
Push down and release the brake pedal several times
(at least 30).
Cycle the parking brake 20 times.
LEIL16WHL1654AB 1
LEIL16WHL1655AB 2
If the machine is equipped with heavy duty axles, the

brake accumulators are three as showed in figure 3.
LEIL16WHL1685AB 3

5. Remove the left-hand cab skirt located under the cab
to gain access to accumulators.
6. Remove the cover access to the brake accumulators
(1)
draulic oil.
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brake circuit.
9. Clean the brake accumulators (1), the parking brake
accumulator (2), the rear brake damping accumulator
(3), the front brake damping accumulator (4) and lines.
10. Put identification tags on the line that is connected to
the parking brake accumulator (2).
12. Remove the elbows (7) to disconnect the tubes (5) and
(6) from both brake accumulators (1).
13. Loosen the clamp studs (9) on the clamps (8).
14. Remove the accumulators (1).
15. Install protective plugs in the tubes (5) and (6).
NOTICE: If the machine is equipped with heavy duty axle
remove the three accumulators (1) showed in figure 3.
LEIL16WHL1656BB 4
16. Disconnect the hose (12) from the parking brake ac-
cumulator (2).
17. Remove the nut (11) and the washer (10).
Remove the parking brake accumulator (2).
18. Install a protective plug in the hose (12).
LEIL16WHL1657AB 5
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19. Disconnect the hose (15) from the rear damping ac-
cumulator (3).
20. Loosen the clamp stud (13) on the clamp (14).
21. Remove the damping accumulator (3).
LEIL16WHL1658AB 6
22. Disconnect the hose (18) from the front damping ac-
cumulator (4).
24. Remove the front damping accumulator (4).
LEIL16WHL1659AB 7
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Accumulator - Install
1. Install the accumulators (1) in the accumulators clamps

(8), do not tighten the clamps at this time.
2. Connect the front brake accumulator tube (5) and the
rear brake accumulator tube (6) to the elbows (7).
Connect the elbows (7) to brake accumulators (1) and
tighten them.
3. Tighten the accumulator clamp studs (9) to 17.0 N·m
(12.5 lb ft).
NOTICE: if the machine is equipped with heavy duty axles,
the brake accumulator are three.
LEIL16WHL1656BB 1
4. Install the parking brake accumulator (2) into the

bracket on the rear chassis.
5. Install the nut (11) and the washer (10). Tighten the nut
(11).
6. Connect the hose (12) to the parking brake accumula-
tor (2).
LEIL16WHL1657AB 2
7. Install the rear brake damping accumulator (3). Tighten

the clamp stud (13) on the clamp (14).
8. Connect the hose (18) to the front damping accumula-
tor (4).
LEIL16WHL1658AB 3
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10. Connect the hose (18) to the front damping accumu-
lator (4).
LEIL16WHL1659AB 4

12. Install the left-hand cab skirt.
13. Install the cover access to the brake accumulators (1).
16. Perform the Parking Brake Test Procedure.
required.
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Accumulator - Remove

movement.
3. Make sure that the brake accumulators (1), the parking
brake accumulator (2), the rear brake damping accu-
mulator (3) and the front brake damping accumulator
(4) are completely discharged.
Push down and release the brake pedal several times
(at least 30).
Cycle the parking brake 20 times.
LEIL16WHL1687BB 1
LEIL16WHL1655AB 2

5. Remove the left-hand cab skirt located under the cab
to gain access to accumulators.
6. Remove the cover access to the brake accumulators.
draulic oil.
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brake circuit.
9. Clean the brake accumulators (1), the parking brake
accumulator (2), the rear brake damping accumulator
(3), the front brake damping accumulator (4) and lines.
10. Put identification tags on the line that is connected to
the parking brake accumulator (2).
12. Remove the two elbows (7) and the two T-fittings (7a)
to disconnect the tubes (5), (5a), (6) and (6a) from the
four brake accumulators (1).
13. Loosen the four clamp studs (9) on the four clamps
(8).
14. Remove the four brake accumulators (1).
15. Install protective plugs in the tubes (5), (5a), (6) and
(6a).
LEIL16WHL1660BB 3
16. Disconnect the hose (12) from the parking brake ac-
cumulator (2).
17. Remove the nut (11) and the washer (10).
Remove the parking brake accumulator (2).
18. Install a protective plug in the hose (12).
LEIL16WHL1657AB 4
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19. Disconnect the hose (15) from the rear damping ac-
cumulator (3).
21. Remove the damping accumulator (3).
LEIL16WHL1658AB 5
22. Disconnect the hose (18) from the front damping ac-
cumulator (4).
24. Remove the front damping accumulator (4).
LEIL16WHL1659AB 6
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Accumulator - Install
1. Install the four accumulators (1) in the four accumula-

tors clamps (8), do not tighten the clamp studs (9) at
this time.
2. Connect the front brake accumulator tube (5) and the
rear brake accumulator tube (6) to the tee T-fittings
(7a).
Connect the front brake accumulator tube (5a) and the
rear brake accumulator tube (6a) to the elbows (7a).
Connect the two T-fittings (7a) and the two elbows (7)
to the four brake accumulators (1) and tighten them.
3. Tighten the accumulator clamp studs (9) to 17.0 N·m
(12.5 lb ft).
LEIL16WHL1660BB 1
4. Install the parking brake accumulator (2) into the

bracket on the rear chassis.
5. Install the nut (11) and the washer (10). Tighten the nut
(11).
6. Connect the hose (12) to the parking brake accumula-
tor (2).
LEIL16WHL1657AB 2

8. Connect the hose (18) to the front damping accumula-
tor (4).
LEIL16WHL1658AB 3
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10. Connect the hose (18) to the front damping accumu-
lator (4).
LEIL16WHL1659AB 4

12. Install the left-hand cab skirt.
13. Install the cover access to the brake accumulators (1).
16. Perform the Parking Brake Test Procedure.
required.
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Accumulator - Check
1. Make sure that the oil side of the accumulator is com-
pletely discharged by doing the following:
A. Stop the engine.
B. Push down and release the brake pedal several
times (at least 30) to release the pressure.
2. Connect a drain hose to the test connector in each
brake circuit to release any pressure in the brake cir-
cuit.
3. Close valves (B) and (C) on the nitrogen charging kit
380001737.
4. Turn the stem out of valve (F) until the stem stops.
5. Remove the cap from the accumulator. Loosen the
Allen screw in the charge port.
NOTE: do not turn the Allen screw more than 1/8 of a turn
or gas will escape uncontrolled.
6. Connect adapter 380001168 to accumulator.
7. Connect valve (F) to the adapter valve stem.
8. Make sure that valve (D) and (G) are open.
9. Turn the stem into valve (F) and read the pressure
gauge (E).
NOTE: see chart indicated in "Accumulator - Charge" for
pressure readings.
10. If the pressure is too low, charge the accumulator with
dry nitrogen.
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Accumulator - Charging
NOTE: check the pressure in the accumulator according to the instructions in Checking the Nitrogen Charge in the
Accumulator. Keep the nitrogen charging kit 380001737 connected to the accumulator.
1. Close (turn counterclockwise) valve (A) and open valve
(B). Close valves (C), (D), and (G).
2. Turn the stem out of valve (F) until the stem stops mov-
ing. Disconnect valve (F) from the adapter valve stem.
3. Connect the nitrogen charging kit to a dry nitrogen tank.
4. Slowly turn valve (A) clockwise and read gauge (E) until
the pressure is equal to charge pressure required for
accumulator being charged. Stop turning valve (A).
5. If the pressure increases above required pressure,
quickly open and close valve (D) and read gauge (E).
If the pressure is still too high, close valve (A) (turn
counterclockwise) a small amount and quickly open
and close valve (D). The pressure shown on gauge (E)
is the charge pressure.
6. Connect valve (F) to the adapter valve stem. Turn the
stem into valve (F) until the stem stops moving and
open valve (G) and (D) to charge the accumulator.
7. After the accumulator stops charging, turn the stem out
of valve (F) until the stem stops moving and close valve
(G).
8. Close valve (B) and disconnect the nitrogen charging
kit from the adapter valve stem, remove the adapter.
9. Torque the Allen screw to 20 N·m (15 lb ft), install the
cover on the accumulator valve stem.
TEMPERATURE CHARGE PRESSURE

10 °C (50 °F) 67.4 bar (977 psi)
13 °C (55 °F) 68.1 bar (987 psi)
16 °C (60 °F) 68.8 bar (998 psi)
18 °C (65 °F) 69.3 bar (1005 psi)
21 °C (70 °F) 70.0 bar (1015 psi)
24 °C (75 °F) 70.7 bar (1025 psi)
27 °C (80 °F) 71.4 bar (1036 psi)
29 °C (85 °F) 71.9 bar (1043 psi)
32 °C (90 °F) 72.6 bar (1053 psi)
35 °C (95 °F) 73.3 bar (1063 psi)
38 °C (100 °F) 74.0 bar (1073 psi)
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Brake discs - Disassemble Model 3105 II

CAUTION
Eye injury hazard!
C0035A
1. Attach output to suitable work stand.
RCIL11WHL007BAF 1
RCIL11WHL008BAF 2
RCIL11WHL009BAF 3
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4. Use a two-armed puller, press planetary carrier from

profile of output shaft.
RCIL11WHL010BAF 4

of brake housing.
RCIL11WHL011BAF 5
RCIL11WHL012BAF 6
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RCIL11WHL013BAF 7
RCIL11WHL014BAF 8
RCIL11WHL015BAF 9
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RCIL11WHL016BAF 10
RCIL11WHL017BAF 11
12. Mount bleeder valve. Use compressed air to remove

piston from brake housing.
RCIL11WHL018BAF 12
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(see arrows).
RCIL11WHL019BAF 13
14. Take note of the installation position of the following

items:
1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
7. Metal face seal (Heavy Duty Option) Combi seal
(Standard)
8. Output shaft
RCIL11WHL153BAF 14
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Brake discs - Visual inspection Model 3105 II

WARNING
Chemical hazard!
W0180A
CAUTION
Eye injury hazard!
C0035A

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Brake discs - Assemble Model 3105 II

CAUTION
Burn hazard!
C0047A
1. Installation position:
1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
7. Metal face seal (Heavy Duty Option) Combi seal
(Standard)
8. Output shaft
RCIL11WHL153BAF 1
RCIL11WHL126BAF 2
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NOTE: sufficiently oil seal surface of piston/back-up rings,
grooved rings and guide ring with W-10 oils.
RCIL11WHL127BAF 3

RCIL11WHL128BAF 4
5. Insert cover and secure it with hexagonal bolts. Torque

to 34 N·m (25 lb ft).
RCIL11WHL129BAF 5
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NOTE: for number of disks and disk arrangement, refer to
RCIL11WHL130BAF 6
RCIL11WHL131BAF 7
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RCIL11WHL158BAF 8
9. Heat bearing inner race. Insert premounted planetary

wards) until contact is made. Secure planetary gears
with retaining rings.
NOTE: adjust bearing inner rings after cooling.
RCIL11WHL133BAF 9
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rier until contact is made.
RCIL11WHL134BAF 10
11. Wet contact face of bearing inner race (1) and profile
RCIL11WHL135BAF 11

RCIL11WHL136BAF 12
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contact position. Torque to 200 N·m (148 lb ft).
RCIL11WHL137BAF 13
14. Pivot output 180° and measure gap width from the
output shaft to the planetary carrier — see next sketch.
Then remove locking bolts and measure disk again.
NOTE: gap width e.g.: 0.21 mm (0.01 in).
RCIL11WHL159BAF 14
15. Legend to Sketch:

1 = Planetary carrier
2 = Output shaft
X = Gap width
RCIL11WHL166BAF 15
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16. Select the cover (optional) based on the following ta-

ble.
NOTE: cover has an offset of 0.07 mm (0.003 in) on one
side and an offset of 0.13 mm (0.005 in) on the other side.
NOTE: offset of 0.13 mm (0.005 in) is visually marked with
an annular grove (arrow)!
RCIL11WHL165BAF 16
Determined gap Width (Delta) Offset to be used on the cover

0.30 – 0.24 mm (0.012 – 0.009 in) 0.13 mm (0.005 in)
0.239 – 0.18 mm (0.009 – 0.007 in) 0.07 mm (0.003 in)
0.179 – 0.10 mm (0.007 – 0.004 in) 0.0 mm (0.000 in)
17. Pivot output 90°. Insert the cover with the offset e.g.
0.07 mm (0.003 in) showing towards the planetary
carrier and tighten with new locking bolts.
NOTE: when using the cover with offset of 0.07 mm
(0.003 in), the groove (arrow step 16) must be visible
when the cover is installed.
NOTE: tighten locking bolts successively to a torque of
200 N·m (148 lb ft). Then, retighten successively to a
torque of 500 N·m (369 lb ft).
RCIL11WHL138BAF 17
NOTE: curing period for TEROSTAT ® MS-9360 is greater
than 24-hours.
RCIL11WHL139BAF 18
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RCIL11WHL140BAF 19
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Brake discs - Disassemble Model 3115 II

CAUTION
Eye injury hazard!
C0035A
1. Attach output to a suitable work stand.
RCPH11WHL491BAU 1
RCIL11WHL008BAF 2
RCPH11WHL493BAU 3
48083742_EN 31/07/2018
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RCPH11WHL494BAU 4
RCPH11WHL495BAU 5
6. Disengage retaining rings.
RCPH11WHL496BAU 6
RCPH11WHL497BAU 7
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RCPH11WHL498BAU 8
RCPH11WHL499BAU 9
10. Loosen hexagon screws, remove, releasing disk and

cup spring.
RCPH11WHL500BAU 10
RCPH11WHL501BAU 11
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NOTE: for the installation position of the single parts refer
RCPH11WHL502BAU 12
13. Take note of the installation position of the following

items:
1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
7. Slide ring seal
8. Output shaft
RCPH11WHL646BAU 13
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Brake discs - Visual inspection Model 3115 II

WARNING
Chemical hazard!
W0180A
CAUTION
Eye injury hazard!
C0035A

48083742_EN 31/07/2018
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Brake discs - Assemble Model 3115 II

CAUTION
Burn hazard!
C0047A
1. Installation position:
1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
7. Slide ring seal
8. Output shaft
RCPH11WHL646BAU 1

install with the fixing device (S) until contact is obtained.
NOTE: sufficiently oil seal surface of piston/back-up rings,
grooved rings and guide ring (W-10 oils to be used).
RCPH11WHL620BAU 2
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3. Insert cup spring into piston with the convex side show-
ing upwards.
RCPH11WHL621BAU 3

RCPH11WHL622BAU 4

NOTE: for number of disks and disk arrangement, refer to
RCPH11WHL623BAU 5
RCIL11WHL131BAF 6
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Setting of installation dimension 57.25 – 57.79 mm (2.25 – 2.28 in)

7. Measure installation dimension from the mounting face
of the brake housing to the front face of the end plate.
• Installation dimension e.g.: 57.5 mm (2.3 in) mm.
NOTE: any deviation from the necessary installation di-
mension must be corrected with an appropriate out disk
RCPH11WHL625BAU 7

9. Insert the premounted cover into the planetary carrier
1. Stop bolt
2. Cover
3. Planetary carrier
RCPH11WHL651BAU 8
10. Insert the cylindrical roller bearing into the planetary

gear. For this purpose, press the cylindrical roller
bearing through the packaging sleeve until the snap
ring engages into the annular groove of the planetary
gear.
1. Cylindrical roller bearing
2. Packaging sleeve
3. Snap ring
4. Planetary gear
NOTE: use packaging sleeve to facilitate assembly!
RCPH11WHL626BAU 9
11. Heat bearing inner ring. Insert premounted planetary

wards) until contact is obtained.
NOTE: adjust bearing inner rings after cooling down.
RCPH11WHL627BAU 10
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13. Heat tapered roller bearing and install it on planetary

RCPH11WHL628BAU 11
14. Wet front face (contact face bearing inner ring, (1))
and profile (teeth (2)) in output shaft with anti-corro-
sive agent Weicon anti-seize.
RCPH11WHL629BAU 12

16. Insert the planetary carrier by means of the lifting de-
vice into the teeth of the output shaft until contact is
obtained.
RCPH11WHL630BAU 13

18. Insert disk and fix planetary carrier with NEW locking
screws.
NOTE: tghten locking screws successively with a tighten-
ing torque of 200 N·m (1770 lb in).
RCPH11WHL631BAU 14
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19. Install O-ring (arrow) to the cover.
RCPH11WHL632BAU 15
obtained.
RCPH11WHL633BAU 16
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Brake lines - Remove Model 3105 II

1. Secure axle housing to suitable lifting device. Loosen

hex bolts. Separate axle housing from drive housing.
NOTE: be aware of possible release of differential.
RCIL11WHL024BAF 1

lease tube.
RCIL11WHL025BAF 2
RCIL11WHL026BAF 3
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RCIL11WHL027BAF 4
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Brake lines - Install Model 3105 II

RCIL11WHL112BAF 1

NOTE: after assembling axle housing secure axle with
clamping brackets.
RCIL11WHL113BAF 2
RCIL11WHL114BAF 3
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tube (arrow).
RCIL11WHL115BAF 4

RCIL11WHL116BAF 5

ft).
RCIL11WHL117BAF 6
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Brake lines - Remove Model 3115 II

1. Secure axle housing to suitable lifting device. Loosen

hexagon screws, then. separate axle housing from
drive housing.
RCPH11WHL507BAU 1
2. Loosen threaded connections and remove the releas-

ing brake tube.
RCPH11WHL508BAU 2
RCPH11WHL509BAU 3
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Brake lines - Install Model 3115 II


(319 lb in).
RCPH11WHL609BAU 1

(885 lb in)
RCPH11WHL610BAU 2

Tightening torque (M20/10.9) to 560 N·m (4956 lb in)
• (S) Adjusting screws (M20).
NOTE: after assembling the axle housing, secure the axle
RCPH11WHL611BAU 3
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Index

Accumulator - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Accumulator - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Accumulator - Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Accumulator - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Accumulator - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Accumulator - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Accumulator - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Brake discs - Assemble Model 3105 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Brake discs - Assemble Model 3115 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Brake discs - Disassemble Model 3105 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Brake discs - Disassemble Model 3115 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Brake discs - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake discs - Visual inspection Model 3105 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Brake discs - Visual inspection Model 3115 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Brake lines - Install Model 3105 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Brake lines - Install Model 3115 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Brake lines - Remove Model 3105 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Brake lines - Remove Model 3115 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Brake pedal control valve - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake pedal control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake pedal control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Brake pump - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake pump - Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Brake pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Brake pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Brakes - Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic service brakes - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic service brakes - Check - Brake modulation pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic service brakes - Check - Service brake system performance (stored energy) . . . . . . . . . . 18
Hydraulic service brakes - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic service brakes - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic service brakes - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Hydraulic service brakes - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic service brakes - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Parking brake or parking lock - 110

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Contents
TECHNICAL DATA
Parking brake or parking lock

SERVICE
Parking brake or parking lock

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Brakes and controls - Parking brake or parking lock
Parking brake or parking lock - General specification

Spring Applied Hydraulic Released (SAHR) sliding calliper FSG 110
LEIL16WHL1632FB 1
1. Housing 6. Piston
2. Pressure ring 7. Lining pad
3. Thrust bolt 8. Lining pad
4. Adjusting screw 9. Guiding bolt
5. Bank of cup spring
The two identical brake pads slide freely on the guide bolt (9), which is fastened in the housing (1). The guide bolts
are guided in an additional brake anchor plate (screwed onto the vehicle).
When the brake is actuated (closed), the brake generates a clamping force at the brake lining pads (7), (8), which
cause a tangential force/braking moment to be generated at the brake disk, the extent of which depends on the coef-
ficients of friction generated by the linings. The clamping force is generated by the bank of cup springs, during which
the piston (6) is moved together with the adjusting screw (4), the thrust bolt (3) and the brake pad towards the brake
disk.
When the brake pad comes into contact with the brake disk, the reaction force shifts the housing onto the guide bolts
until the brake pad is also pressed against the brake disk. The brake is released by complete pre-tensioning of the
bank of cup springs (5). During this process, through application of the necessary release pressure after overcoming
the cup spring force, the piston must move back until it comes to rest against the pressure ring. (2).
The clamping force is reduced by wear of the brake lining and the brake disc. The brake must then be re-adjusted.
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Parking brake or parking lock - Disassemble

1. Park the machine on a hard level surface and lower the
loader bucket to the ground.
2. Place the wheel chocks on each wheel to prevent the
machine movement.
3. Install the articulation lock.
4. Place the timed disconnect switch to the OFF position.
5. Pump the brake pedal several times (at least 30 times)
to discharge the accumulators.
LEIL15WHL1782AA 1
6. Loosen and remove the cover from the parking brake.
LEIL13WHL1237AB 2
7. Loosen the jam nut, turn the adjusting bolt counter-

clockwise until the brake pads are loose.
LEIL13WHL1238AB 3
8. Remove the retainer pin and the brake pin.
LEIL13WHL1239AB 4
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9. Remove the two brake pads from the parking brake

assembly.
LEIL13WHL1240AA 5
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Parking brake or parking lock - Inspect

1. Clean and inspect all parts for wear and damage.
2. Inspect the brake disc for wear and damage.
3. Replace all parts that are worn or damaged.
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Parking brake or parking lock - Assemble

1. Install the two brake pads in the parking brake assem-
bly.
LEIL13WHL1240AA 1
2. Install the brake pins and the retainer pins.

3. Place the timed disconnect switch to the ON position.
Start the machine and run the engine at low idle with
the bucket resting on the ground.
NOTE: it will be needed to have an assistant help for this
procedure. An operator must be present in the cab at all
times to apply the service brakes and shut down the ma-
chine in the event of mechanical failure.
4. Disengage the parking brake.
A. Place the parking brake rocker switch to the OFF
position.
B. Apply the service brake and put the machine into LEIL13WHL1239AB 2
gear.
C. The parking brake light on the cluster will turn off at
this time.
Place the transmission back into neutral before pro-
ceeding.
NOTE: the hydraulic pressure will not be applied to the
parking brake until the parking brake rocker switch is turned
off, the service brakes applied and the transmission is put
into gear.
5. Turn the adjusting bolt clockwise until both brake pads
contact the brake disc; turn the adjusting bolt counter-
clockwise one turn. Tighten the jam nut to secure the
adjusting bolt.
6. Install the cover on the parking brake.
7. Perform the Parking Brake Test Procedure as de-
scribed in this section.
8. Return the articulation lock to the operating position.
LEIL13WHL1238AB 3
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Parking brake or parking lock - Service instruction

Spring Applied Hydraulic Released (SAHR) sliding caliper FSG 88
LEIL16WHL1633FB 1
1. Thrust bolt 5. Locknut

2. Bank of cup springs 6. Piston
3. Adjusting screw P. Even surface
4. Screw cap S. Socket wrench
NOTE: all mounting and basic setting work must be carried

out when the brake is cold.
Basic setting regulation

1. Turn the adjusting screw (3) manually clockwise un-
til both brake pads make contact with the brake disk.
Then it is not longer possible to turn the adjusting screw
without exerting a major amount of force.
2. Turn the adjusting screw (3) counter-clockwise in order
to set the following rated clearances:
Type Adjusting screw Clearance

Minimum 1 mm
(0.04 in)
FSG 110 M20 Nominal clearance
2 mm (0.08 in)
Maximum 3 mm
(1.2 in)
3. Hold the adjusting screw (3) in position with a hexago-

nal socket wrench (S) and lock with lock nut (5).
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4. Mount the screw cap (4) and tighten as far as possible

manually.
5. Mount the pressure connection in accordance with the
instructions of the axle / gear manufacturer.
6. For bleeding the piston chamber use the socket span-
ner size 13 for the bleeding valve.
Adjusting the parking brake

NOTE: during this adjusting process, the parking brake
must be released and the bank of cup springs (2) must
be completely pre-tensioned.
1. Place the machine on flat ground and secure with wheel

chocks and articulation lock to minimize the risk of in-
jury.
2. Release the parking brake by using the required re-
lease pressure ( 150 bar).
3. Release the screw cap (4) and unscrew it.
4. Release the locknut (5) and turn the adjusting screw (3)
with a socket wrench (size 10) (S) manually clockwise
until the two brake pads make contact with the brake
disk.
5. Turn the adjusting screw (3) counter-clockwise and set
the clearance specified in the table above.
6. Hold the adjusting screw in position with the hexagonal
socket wrench and lock with the lock nut.
7. Mount the screw cap and tighten as far as possible
manually.
8. Actuate the brake valve several times and check the
braking efficiency of the parking brake on a slope.
Emergency release of the parking brake

NOTE: in the event of a failure in pressure supply the park-
ing brake can be released manually in the following way.

chocks and articulation lock.
2. Release the screw cap (4) and unscrew it.
3. Release the locknut (5) and turn the adjusting screw
(3) with socket wrench (size 10) (S) manually counter-
clockwise until the brake disc is free.
NOTICE: for emergency release a torque of 70 N·m is re-

quired.
4. Mount the locknut and the screw cap. Tighten the lock-
nut and the screw cap as far as possible manually (pro-
tection against dirt).
NOTICE: in this condition the machine has no parking

brake facility and thus must be protected from rolling away
by different means. The brake must be adjusted before
re-commissioning.
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Maintenance and replacement of the brake pads
LEIL16WHL1634FB 2
1. Piston S. Socket wrench

2. Adjusting screw S1. Screwdriver (tool)
3. Locknut P. Inside of the piston
4. Thrust bolt
The brake pads themselves are maintenance free. All that is required here is a check for damaged parts, as well as
inspection to ensure that the brake disk remains easy running.
The thickness of the brake lining must be visually inspected at regular intervals, which depend on vehicle usage,
but every six months at the latest. In the event of a minimal residual lining thickness. These intervals must be
reduced accordingly in order to avoid major damage to the brake or disk:
Once the minimum remaining lining thickness of 2 mm (0.1 in) per brake lining carrier is reached, the brake lining
carrier must be replaced in accordance with the following instructions.

2. Release the parking brake by application of the re-
quired release pressure.
3. Release the screw cap and unscrew it.
(2) with socket wrench (size 10) (S) manually clockwise
until it lies flush with the inside of the piston (P).
5. Press back the thrust bolt (4) using a suitable screw-
driver (S1) until it has contact with the piston (1).
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LEIL16WHL1635FB 3
1. Guide bolt 5. Castellated nut

2. Lining pad 6a. Safety splint
3. Lining pad 6b. Safety clip
4. Permanent magnet
6. Depending on the free space available, release one

of the two guide bolts (1), removing the safety splint
(6a), unscrewing the castellated nut (5) and pulling the
guide bolt (1) out of the brake anchor plate. Remove
the brake lining pads tangentially to the brake disk.
NOTICE: in the event of minimal clearance, it is not pos-

sible for space reasons to exchange the brake lining plate
in accordance with these instructions, the brake must be
removed completely. To do this, pull both guide bolts out
of the brake anchor plate.
NOTICE: check the pressure hose. If the pressure hose
is to short, it must be unscrewed to remove the brake.
Before the pressure hose can be released the brake must
be emergency released.
7. Exchange the brake pads and insert the guide bolts

into the brake anchor plate. If you have removed the
complete brake you have to amount the brake on both
guide bolt again, now.
8. Check if both permanent magnets (4) still have suffi-
cient magnetic force to hold the brake lining plates.
9. Should this not be the case, the permanent magnets (4)
must also be changed by using a suitable screwdriver.
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10. Secure the guide bolt (1) with the castellated nut (5),
the safety splint (6a) and the safety clip (6b).
NOTE: after mounting new brake lining plates or their re-

pair, the brake must be correctly set in accordance with
the “Adjusting the parking brake” procedure.
Replacing the seals
LEIL16WHL1636FB 4
1. Piston 7. Guide bolt

2. Adjusting screw 8. Thrust bolt
3. Locknut 9. Bank of the cup spring
4. Housing A. seal
5. Circlip B. Seal
6. Seal

2. Release the parking brake by application of the re-
quired release pressure ( 150 bar).
3. Release the screw cap and unscrew it.
(2) with socket wrench (size 10) manually in a counter-
clockwise direction until the adjuster screw (2) is flush
with the inner side of the piston.
5. Push back the thrust bolt (8) until it has contact with the
piston (1). Following actuate the hand brake valve. (no
pressure must be in the piston chamber). The bank of
cup springs (9) is now completely depressurized.
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6. Unscrew the pressure hose and remove the brake.

7. Release the circlip (5) and remove the pressure ring of
the housing (4).
NOTICE: install the seal rings according orientation

showed in details (A) and (B), otherwise leaks can occur.
NOTE: use a suitable mounting needle with rounded edge
to install the new seal rings.
8. Change all seals and mount the parts of the brake in

other way round order. By mounting the piston (1),
the sliding and sealing surfaces must be greased lightly
using lubricating grease.
The dust protection cap is fitted with a vulcanized-in
steel ring which is used to press it through the locating
hole.
In order to replace this you will need to lever it out with
a suitable tool and then replace with a fitting fixture by
pressing it into the housing (4).
The new dust protection cap must be pressed in with
the aid of a suitable mounting ring and screw clamps or
a lever press.
9. Install the parking brake onto the gearbox.
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Parking brake or parking lock - Test

1. While testing, the machine must be on a clear level
surface with the bucket in the travel position.
NOTICE: always know the location of all workers in your
area. Warn them before you start working the machine.
Always keep all other persons away from your area. Se-
rious injury or death can result if you do not follow these
instructions.
2. Start the machine. Move the transmission control lever
to neutral. Push the parking brake switch on the multi-
function keypad.
LEIL16WHL0936AA 1
3. The LCD multi-function display located above the mul-

tifunction keypad is on and displays the main menu.
4. Press the corresponding key to access the Machine
Service screen.
LEIL16WHL2335AB 2
5. Use up or down arrow to select the Calibration Settings

item. Press the enter/confirm key to access the selec-
tion screen.
LEIL16WHL0874AA 3
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6. Use up or down arrow to select the Park Brake Test

item.
7. The screen displays the two conditions to be satisfied
before starting the parking brake test.
8. The machine is already on with parking brake.
Place the transmission in 3rd gear forward to meet the
second condition needed for the test.
9. Press the enter/confirm key to start the parking brake
test.
LEIL16WHL0879AA 4
10. When the parking brake test is on, push the foot throt-
tle to increase the engine speed as suggested by the
screen.
11. If the machine moves, the test failed. The parking
brake must be adjusted (see procedures in this sec-
tion).
12. If the machine remains stationary, the test passed.
13. Reduce the engine speed to low idle. Return the
transmission to neutral.
14. Press the enter/confirm key to terminate the test.
LEIL16WHL0880AA 5
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Index

Parking brake or parking lock - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parking brake or parking lock - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parking brake or parking lock - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parking brake or parking lock - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Parking brake or parking lock - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Parking brake or parking lock - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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PRINTED IN ITALY
48083742_EN 31/07/2018
EN
SERVICE MANUAL
Hydraulic systems

48083742_EN 31/07/2018
35
Contents
Hydraulic systems - 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.752] Hydraulic fan drive cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9
48083742_EN 31/07/2018
35

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Contents
TECHNICAL DATA
Hydraulic systems
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Hydraulic systems
Hydraulic schematic frame 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic schematic frame 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Component localization - Test ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SERVICE
Hydraulic systems
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Service instruction - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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Hydraulic systems - Hydraulic systems
Hydraulic systems - Special tools

CAS10162A, Portable filter unit
LEIL13WHL1194AA 1
CAS10192, Vacuum pump
LEIL13WHL1195AA 2
CAS10508, Fitting kit
LEIL13WHL1196AA 3
CAS1904-1, Pressure fitting kit
LEIL13WHL1197AA 4
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CAS10280, Flowmeter
LEIL13WHL1199AA 5
380001740, Flowmeter fitting kit
LEIL13WHL1200AA 6
5870 287 007, Hand pump
LEIL13WHL1227AA 7
CAS1804, Pressure fitting kit
LEIL13WHL1228AA 8
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Hydraulic systems - Hydraulic schematic frame 01

Callout Description Callout Description

(1) Brake pumps, 18.5 cm³ and 38.5 cm³ (2) 100 mesh filter strainers
(3) Parking brake accumulator, 0.16 L (0.04 US (4) Brake dumping accumulator, 0.16 L (0.04 US
gal), 97 bar (1406 psi) precharge gal), 7 bar (102 psi) precharge
(5) Brake valve, 83 bar (1204 psi) (6) Orbitrol valve, 985 cm³/rev
(7) Steering cylinder (left-hand) (8) Steering cylinder (right-hand)
(9) Relief valve, 8 – 10 bar (116 – 145 psi) (10) Steering cylinder relief valve, 345 bar (5002 psi)
(11) Hydraulic shuttle tee (12) Two pumps tandem system
Pump 1: 100 cm³/rev (6.1 in³/rev), Cut-off:
280 bar (4060 psi), Delta 26 bar (377 psi)
Pump 2: 85 cm³/rev (5.2 in³/rev) , Cut-off:
(14) Steering priority valve (15) Check valve fitting
(16) Auxiliary steering control valve (optional) (17) Auxiliary steering pump, 11 cm³
(18) Hydraulic tank filter (19) Steering valve, 100 L/min (26.4 US gpm)
(20) Hydraulic shuttle tee valve (21) Cut-off valve
(22) Orifice (23) Control valve
(24) 2-function control valve (25) 3-function control valve
(26) 4-function control valve (27) 2 function main control valve
(28) 3 function main control valve (29) 4 functions (5 spools) main control valve
(30) Lift cylinder (31) Tilt cylinder (Z-bar)
(32) Tilt cylinder (XR) (36) Service brake accumulator, 3.5 L (0.92 US gal),
70 bar (1015 psi) precharge
(37) Axle cooler Motor-Pump-Pump combination, (38) Orifice
55 bar (798 psi) bypass
(39) Axle cooler (40) Axle oil filter
(41) Pressure relief valve, 97 bar (1400 psi) (42) Check valve (open differential)
(43) Check valve (front differential lock) (44) Transmission hydraulic oil cooler
(45) Thermal bypass valve (46) Fan drive hydraulic motor, 33 cm³
(47) Hydraulic tank strainer assembly (48) Hydraulic tank check valve, 0.28 bar (4.06 psi)
(49) Return filter (50) Accumulator, 3.78 L (1.00 US gal), 14.5 bar
(210.2 psi) precharge
(51) Ride control valve (52) Fan relief valve
(53) Fan speed and reverse control valve (54) Front axle (open differential)
(55) Rear axle (open differential) (56) Front axle (front differential lock)
(57) Rear axle (differential lock) (60) Pilot supply accumulator, 0.32 L (0.08 US gal),
13.8 bar (200.1 psi) precharge
(61) Attenuator hose (62) Resounding filter
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LEIL17WHL0948JB 1
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Hydraulic systems - Hydraulic schematic frame 01

Callout Description Callout Description

(1) Brake pumps, 18.5 cm³ and 38.5 cm³ (2) 100 mesh filter strainers
(3) Parking brake accumulator, 0.16 L (0.04 US (4) Brake dumping accumulator, 0.16 L (0.04 US
gal), 97 bar (1406 psi) precharge gal), 7 bar (102 psi) precharge
(5) Brake valve, 83 bar (1204 psi) (6) Orbitrol valve, 985 cm³/rev
(7) Steering cylinder (left-hand) (8) Steering cylinder (right-hand)
(9) Relief valve, 8 – 10 bar (116 – 145 psi) (10) Steering cylinder relief valve, 345 bar (5002 psi)
(11) Hydraulic shuttle tee (13) Two pumps tandem system
(14) Steering priority valve (15) Check valve fitting
(16) Auxiliary steering control valve (optional) (17) Auxiliary steering pump, 11 cm³
(18) Hydraulic tank filter (19) Steering valve, 100 L/min (26.4 US gpm)
(20) Hydraulic shuttle tee valve (21) Cut-off valve
(22) Orifice (23) Control valve
(24) 2-function control valve (25) 3-function control valve
(26) 4-function control valve (27) 2 function main control valve
(28) 3 function main control valve (29) 4 functions (5 spools) main control valve
(32) / (35) Tilt cylinder (XR) (33) Lift cylinder
(34) Tilt cylinder (Z-bar) (36) Service brake accumulator, 3.5 L (0.92 US gal),
70 bar (1015 psi) precharge
(37) Axle cooler Motor-Pump-Pump combination, (38) Orifice
55 bar (798 psi) bypass
(39) Axle cooler (40) Axle oil filter
(41) Pressure relief valve, 97 bar (1400 psi) (42) Check valve (open differential)
(43) Check valve (front differential lock) (44) Transmission hydraulic oil cooler
(45) Thermal bypass valve (46) Fan drive hydraulic motor, 33 cm³
(47) Hydraulic tank strainer assembly (48) Hydraulic tank check valve, 0.28 bar (4.06 psi)
(49) Return filter (50) Accumulator, 3.78 L (1.00 US gal), 14.5 bar
(210.2 psi) precharge
(51) Ride control valve (52) Fan relief valve
(53) Fan speed and reverse control valve (56) Front axle (front differential lock)
(58) Frontr axle (open differential) (59) Rear axle (open differential)
(60) Pilot supply accumulator, 0.32 L (0.08 US (61) Attenuator hose
gal), 13.8 bar (200.1 psi) precharge
(62) Resounding filter
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LEIL17WHL0949JB 1
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Hydraulic systems - Dynamic description

The Wheel Loaders use a combination of:
• Variable displacement Pressure and Flow Compensated (PFC) piston type pump
• Open-center gear type pump
The closed center variable PFC hydraulic system supplies the oil flow requirements for:
• Priority flow divider manifold
• Steering
• Loader controls
• Loader lift
• Loader bucket
• Loader auxiliary system
• Loader valve pilot controls / EH manifold
The open center gear pump hydraulic system supplies, oil flow to the brakes, cooling fan, and oil cooler.
In a closed center variable displacement PFC system oil flow is minimal unless there is a hydraulic demand. In an
open-center system, oil is constantly pumped through the system regardless of hydraulic demand. When problems
are present in more than one steering or loader hydraulic function, consider that the problem could be within the
variable PFC hydraulic pump control system.
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Hydraulic Oil Supply Components

A single variable Pressure and Flow Compensated (PFC) hydraulic system controls both the steering (24) and the
loader control (22) systems on the Wheel Loaders. When it appears that there are malfunctions in both the steering
and loader control circuits consider there may be problems with one or both of the two pump PFC pumps (33) (34).
Oil flows from the reservoir to the PFC piston pump. The large wheel loaders have two piston type PFC pumps. Both
pumps directly supply oil to the steering priority valve (35). The steering priority valve (35) first supplies oil to steering
(24) with any excess flow then available to the loader valve (22). On units equipped with two PFC pumps, each
body of the piston pump has a compensator flow control system to deliver only the oil flow required by the hydraulic
system. On units equipped with a single PFC pump, a single compensator flow control system delivers only the oil
flow required by the hydraulic system. This control system requires a feedback signal (LS signal) from the loader
control valve (22) and/or from the steering valve (24) to deliver the oil required by the system.
The steering priority valve assembly (35) is located at the outlet of the 2nd pump. The function of this valve is to first
supply oil to the steering control system (24). The steering control valve (24) is located at the base of the steering
column.
The loader valve is mounted at the rear of the front chassis and can be accessed through the articulation joint or the
access cover at the front of the chassis. As the oil enters the loader valve, it supplies oil to the EH manifold circuit and
to the loader control spools. A pilot pressure regulator limits the maximum pilot pressure available to the EH manifold.
The bucket and loader lift sections are both included in the mono-block assembly. If the machine is equipped with
optional auxiliary hydraulic controls, each additional section consists of a separate section block. Each active spool
throughout the loader control valve generates a load sense (LS) signal pressure.
The LS feedback signal system sends the highest operating pressure signal requirement back to the compensator
flow regulator spool at the piston pump. The loader LS, as well as the steering LS signals, pass through the LS
shuttle check valve (35B) in the steering priority valve (35). From the LS shuttle check valve (35B) the LS signal is
then connected to flow regulator spools (33A) (34A) of the PFC pump assembly (32). This signals the pump to deliver
only the quantity of oil required by the hydraulic system.
The smaller wheel loaders use one variable displacement PFC pump to deliver flow to the steering priority valve (35),
the steering control valve (24), the loader valve (22), and the EH manifold (16). Included later in this section is a
detailed functional explanation of a single PFC pump.
The larger wheel loaders use two variable PFC pumps (35) to deliver flow to the steering priority flow divider (35), the
steering control valve (24), the loader valve (22) and the EH manifold (16). On units equipped with two PFC hydraulic
pumps, the first pump (34) is the only pump to supply the flow required to operate any of the hydraulic circuits at lower
flow requirements until it reaches maximum delivery. The second pump (33) only begins to deliver flow when the total
hydraulic flow requirements exceed the maximum capability of the first pump (34). The second pump (33) is idling at
no flow delivery until the first pump (34) reaches maximum delivery.
Both of the PFC pumps are mounted as an assembly (32) to the transmission towards the front of the wheel loader.
The first pump (34) is located closest to the transmission. The second pump (33) is mounted to the back of the first
pump (34) and is furthest from the transmission. The priority flow divider (35) is mounted directly to the second pump
(33). The outlet line from the first pump (34) is directly connected to the priority flow divider (35).
Component Flow Chart Legend

16 – EH manifold 34 – First pump
22 – Loader valve 34A – First pump compensator flow regulator spool
22A – Bucket 34B – First pump compensator pressure regulator spool
22B – Arm 35 – Steering priority valve
22C – Auxiliary 35A – Steering priority spool
24 – Steering orbitrol control valve 35B – Load sense (LS) signal shuttle check valve
24A – Steering isolation check valve 35C – Second pump isolation check valve
33 – Second pump 35D – Differential pressure relief valve
33A – Second pump compensator flow regulator spool 35E – Steering relief valve
33B – Second pump compensator pressure regulator
spool
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RCPH11WHL035HAN 1
Component Flow Chart
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Each of the hydraulic pumps are controlled by a compensator. Each of the compensators have two spools. The flow
regulator spools ( (33A) (34A)) control the output flow of each pump. The pressure regulator spools ( (33B) (34B))
control the maximum pressure that the pumps are capable of delivering. In the wheel loader hydraulic system, these
valves are adjusted higher than the maximum pressure in any of the circuits. Because of this higher adjustment, the
pressure regulator spools do not function. If one or both of these pressure regulator spools are adjusted too low, the
specified steering or loader relief valve pressures might not be able to be reached.
The priority flow divider (35) has many functions which require numerous components. The components of the
steering priority flow divider consists of the following components:
• Steering priority spool (35A)
• Load sense shuttle check valve (35B)
• Second pump isolation check valve (35C)
• Differential pressure relief valve (35D)
• Steering relief valve (35E)
Steering is more critical to the operation of the machine so the steering priority spool (35A) is in the circuit to provide
oil to the steering control valve (24) first. The priority spool (35A) is spring loaded to send all of the oil that the steering
system requires. Between the steering priority valve (35) and the steering orbitrol control valve (24), the oil flows
through the steering isolation check valve (24A). Once the steering circuit (24) is satisfied, all of the excess supply oil
then becomes available to the loader hydraulic system.
Both PFC pumps ( (33) (34)) require a load sense (LS) signal from the either the steering or loader systems, whichever
requires a higher pressure. The PFC pumps do not deliver flow until a command LS signal is received, Once a load
sense (LS) signal is received, the PFC pumps deliver as much flow as is required to satisfy the required LS pressure.
The LS signals from both the steering control system and the loader system are connected to the steering priority
valve. The LS signal shuttle check valve (35B) shifts away from the highest LS signal towards the lower LS signal. The
higher LS signal is then sent to the flow regulator spools of both of the PFC pumps. The higher pressure adjustment
of the first pump flow regulator (34A) causes that pump to begin to deliver flow first. The flow regulator pressure of
the first pump (34A) must be adjusted to specification. The adjustment of the flow regulator pressure of second pump
(33A) is lower than the first pump. If one compensator is adjusted, the opposite compensator must also be checked
and adjusted. The first pump flow regulator pressure must 3 – 4 bar (44 – 58 psi) higher than the adjustment of the
second pump flow regulator. It is preferable to use the same gauge to make both of these adjustments.
The second pump isolation check valve (35C) prevents pressurizing the second pump (33) from the outlet of the first
pump (34). Until the first pump (34) reaches full delivery, the second pump (33) is idling. The isolation valve (35C)
protects the second pump (33).
If the PFC pump control system malfunctions the pumps might deliver more flow than the hydraulic systems require,
causing excessive pressure at the pump outlet. A differential pressure relief valve (35D) is installed in the steering
priority valve limits this excessive pressure. The differential pressure relief (35D) provides a connection between the
PFC pump outlet flow and tank. The differential pressure relief valve is spring biased to the closed position. Pump
outlet pressure is ported to the non spring end of differential pressure relief valve spool. Load sense (LS) pressure is
ported to the spring end of the spool. The differential pressure relief opens when the pump outlet pressure is about
40 bar (580 psi) higher than load sense (LS) pressure.
The maximum steering pressure is lower than the maximum loader pressure. To limit this pressure in the steering
system, a steering pressure relief valve (35E) is connected between the steering LS signal (35B) in the steering priority
valve (35) and tank. This steering relief valve (35E) limits the maximum LS signal from the steering system and hence
limits the maximum steering pressure. The maximum pressure in the loader circuit is regulated by the loader relief
LS control valve located in the loader valve.
If only one of the complete steering or all of the loader circuits are malfunctioning, a quick check is to operate both
steering and loader at the same time. If both systems then operate, the PFC pumps should be OK. If only one circuit
of the loader valve malfunctions, the problem is in the loader valve only. If either the steering or all of the loader circuits
malfunction and both systems function when operated at the same time. A possible problem is then the shuttle check
valve (35B) in the steering priority valve (35).
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The piston pumps used in the wheel loaders have variable displacement and are pressure and flow compensated
(PFC).
The smaller wheel loaders have a single PFC pump to supply the hydraulic systems.
The large wheel loaders use a two PFC pump tandem assembly to deliver the required flow. The two pump system
operates the same as the single pump system. The first pump delivers all of the flow when under low flow require-
ments. The second pump is idling at no flow until the first pump reaches maximum flow.
The counterbalance spring (1) pushes the piston pump swash plate (3) to deliver maximum flow until the control piston
(2) reduces the pump output to what is required to satisfy system requirements. When the engine is off, the swash
plate rests at the full displacement position as shown.
The flow control spool (FR2) monitors the load sensing (LS) signal from the loader control valve to control the piston
pump so that it only delivers the flow required by the system.
The pressure control spool (FR1) can regulate the maximum pressure that the piston pump will deliver. On the wheel
loaders, the pressure regulator spool (FR1) does not function. If the pump outlet pressure exceeds the pressure
control spool setting, the displacement, and therefore outlet flow, of the piston pump will be reduced to only that
which is required to maintain the maximum pressure. On the wheel loaders the pressure regulator spool is set much
higher than the maximum pressure control, (main relief valve) located within the loader valve. The pressure regulator
spool (FR1) is not functional within these pumps unless it was incorrectly adjusted to a pressure lower than the main
relief valve. If either the steering and loader systems operate well at lower pressures but cannot be adjusted to the
maximum specified relief valve pressure, the pressure regulator spool may have been incorrectly adjusted.
1 – Counterbalance spring FR1 – Pressure regulator spool

2 – Control piston FR2 – Flow regulator spool
3 – Swash plate LS – Load sense signal pressure
4 – Pump outlet pressure L – Drain flow to reservoir
5– Flow regulator spring
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RCPH11WHL038GAN 2
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LEIL16WHL2705FB 3
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System Function Overview

This section provides a detailed explanation of how the Pressure and Flow Compensated (PFC) pump compensator
controls the pump.
When the engine is off, the pressure regulator spool (FR1) and the flow regulator spool (FR2) are spring loaded to
the closed position. The counterbalance spring pushes the swash plate to the full flow position. At start-up, pump
output flow is available to the steering and loader valve. The steering and loader control systems are closed center
design. The oil supply from the PFC pumps are blocked with the controls in neutral. With all controls in neutral, the LS
pressure will be vented to tank pressure. Pump outlet pressure is internally ported to the non spring end of the flow
regulator spool (FR2). Pump outlet pressure pushes on the left end of the flow regulator spool (FR2) overcoming the
flow regulator spring (5). Pump outlet pressure is then ported through the flow regulator spools to the control piston
(2). The control piston (2) then pushed the swash plate towards minimum displacement. The pump then delivers only
the flow required to maintain the flow regulator spring (5) pressure.
The flow regulator spring (5) is adjustable. Typically this spring does not require adjustment. If adjustment is required,
use the table below for the specifications. The flow regulator pressure of the first pump (34A) must be adjusted
to specification. The adjustment of the flow regulator pressure of second pump (33A) is lower than the first pump.
If one compensator is adjusted, the opposite compensator must also be checked and adjusted. Measure both the
pump outlet pressure and the LS pressure for the pump. Adjust the flow regulator spool to the pressure differential
specification. DO NOT activate any of the controls while making the adjustment, as the gauge may be damaged.
It is preferable to have a shutoff valve at the gauge to protect it from overpressure. The first pump flow regulator
pressure must 3 – 4 bar (44 – 58 psi) higher than the adjustment of the second pump flow regulator. It is preferable
to use the same gauge to make both of these adjustments to assure accuracy. The pump outlet pressure would be
approximately 24 – 35 bar (348 – 508 psi).
Model Pump 1 Delta P Pump 2 Delta P

521G and 621G 22 – 25 bar (319 – 362 psi) Not applicable
721G and 821G 28 – 30 bar (406 – 435 psi) 24 – 26 bar (348 – 377 psi)
921G 24 – 26 bar (348 – 377 psi) 21 – 23 bar (305 – 334 psi)
1021G and 1121G 25 – 27 bar (362 – 392 psi) 21 – 23 bar (305 – 334 psi)
When the steering or loader control system is activated, pump output pressure is available to the control spools. When
the loader circuit is activated, oil flow across the spool causes a pressure drop (Delta P) between the (PFC) pump
outlet pressure (4) and the LS signal pressure (6) back to the pump compensator. Pump output flow is delivered to
the inlet of the loader control valve through the steering priority valve.
When the pump outlet pressure (4) is higher than the LS signal pressure (6) plus the spring force (5), the flow regulator
spool (FR2) will gradually shift to send pump outlet oil (4) to the control piston (2) to reduce the output of the pump.
The flow regulator spool (FR2) will remain in balance between the pump outlet pressure (4) on the left end and the LS
pressure (6) plus the spring force (5) on the right end of the spool. The control piston (2) will move the swash plate
(3) so that the flow from the pump will maintain the specified differential pressure (Delta P).
The pressure at which the flow control spool (2) shuts the pump down is adjustable. The flow control spool of the
second pump is to be adjusted approximately 4 bar (58 psi) lower than the flow regulator on the first pump. Any time
that the pump is at less than full displacement, the flow control spool (2) will maintain the Delta P. At less than full
flow delivery of the 1st pump, the difference between pump outlet pressure and the LS pressure (Delta P) will be the
higher pressure setting of the 1st pump compensator. When the 1st pump is at maximum flow, the difference between
pump outlet pressure and the LS pressure (Delta P) will be the lower pressure setting of the 2nd pump. If the load
in the bucket would require 138 bar (2000 psi) pump outlet pressure to raise the load, the signal pressure would be
138 bar (2000 psi) minus Delta P.
The maximum pressure available to loader hydraulic system is controlled by loader main relief valve located in the
loader valve (7). The loader main relief connects between the LS signal pressure and the tank passage in the loader
valve (7). When the LS signal pressure is restricted, the pump will not be able to deliver flow above that pressure. The
steering signal relief valve located in the steering priority valve limits the maximum pressure available to the signal
line from steering control circuit to the spring end of the piston pump flow control spool (FR2).
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RCPH11WHL046GAN 4
1 – Counterbalance spring 6– Load sense signal pressure

2 – Control piston 7 – Loader valve
3 – Swash plate LS – Load sense signal pressure
4 – Pump outlet pressure L – Output port
5 – Flow regulator spring S – Sump
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Hydraulic systems - Component localization - Test ports
LEIL16WHL1653FB 1
1. Front axle test port

2. Rear axle test port
3. Front brake accumulator test port
4. Rear brake accumulator test port
5. Steering priority valve test port (pump pressure – pump
2 (G2))
6. Steering priority valve test port (load limit – pump 1
(G1))
7. Steering load sense test port
LEIL16WHL1854AB 2
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8. Differential lock valve test port
LEIL15WHL0830AB 3
9. Pilot pressure supply test port
LEIL16WHL1860AB 4
NOTE: for 1021G model, see Hydraulic systems - Hydraulic schematic frame 01 (35.000) in this manual for more
information about the location of the test ports.
NOTE: for 1121G model, see Hydraulic systems - Hydraulic schematic frame 01 (35.000) in this manual for more
information about the location of the test ports.
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Hydraulic systems - Cleaning

Hydraulic system fluid contamination
Contamination in the hydraulic system is a major cause
of the malfunction of hydraulic components. Contami-
nation is any foreign material in the hydraulic oil. Con-
tamination can enter the hydraulic system in several
ways.
A. When you drain the oil or disconnect any line.
B. When you disassemble a component.
C. From normal wear of the hydraulic components.
D. From damaged or worn seals.
E. From a damaged component in the hydraulic sys-
tem.
All hydraulic systems operate with some contamination.
The design of the components in this hydraulic system
permits efficient operation with a small amount of con-
tamination. An increase in this amount of contamina-
tion can cause problems in the hydraulic system. The
following list includes some of these problems.
A. Cylinder rod seals leak.
B. Control valve spools do not return to neutral.
C. Movement of control valve spools is difficult.
D. Hydraulic oil becomes too hot.
E. Pump gears, housing, and other parts wear
rapidly.
F. Relief valves or check valves held open by dirt.
G. Quick failure of components that have been re-
paired.
H. Cycle times are slow; machine does not have
enough power.
If your machine has any of these problems, check the
hydraulic oil for contamination. See types of contamina-
tion below. If you find contamination, use the portable
filter CAS10162A to clean the hydraulic system.
There are two types of contamination, microscopic and
visible.
Microscopic contamination occurs when very fine par-
ticles of foreign material are in suspension in the hy-
draulic oil.
These particles are too small to see or feel. Microscopic
contamination can be found by identification of the fol-
lowing problems or by testing in a laboratory. Examples
of the problems:
A. Cylinder rod seal leak.
B. Control valve spools do not return to NEUTRAL.
C. The hydraulic system has a high operating temper-
ature.
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Visible contamination is foreign material that can be

found by sight, touch, or odor. Visible contamination
can cause a sudden failure of components. Examples
of visible contamination:
A. Particles of metal or dirt or plastic or rubber in the
oil.
B. Air in the oil.
C. The oil is dark and thick.
D. The oil has an odor of burned oil.
E. Water in the oil.
NOTE: the hydrostatic system uses a third port bypass filter
system. If the filter becomes plugged it bypasses back to
the reservoir to stop contamination from entering the hydro-
static system. Upon completion of cleaning the hydraulic
system replace the hydrostatic system filter.
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Cleaning the hydraulic system

1. Prepare the portable filter CAS10162A by doing the
following steps:
A. Remove all the hydraulic oil from the inlet and out-
let hoses for the portable filter CAS10162A.
B. Remove the filter element from the portable filter
CAS10162A.
C. Remove all hydraulic oil from the portable filter
CAS10162A.
D. Clean the inside of the housing for the filter ele-
ment.
2. You must know whether the contamination is micro-
scopic or visible.
3. If the contamination is microscopic:
A. Check the maintenance schedule for the machine
to learn if the hydraulic oil must be changed. If
needed, change the hydraulic oil. Change the hy-
draulic filter.
B. Do steps 6 through 35.
4. If the contamination is visible:
A. Change the hydraulic oil and hydraulic filter.
B. Do steps 5 through 35.
5. Check the amount of contamination in the hydraulic
system by doing the following steps:
A. Disassemble one cylinder in two different circuits.
Check for damage to seals, scoring of the cylinder
wall, etc. Repair the cylinders as necessary.
B. If, in your judgment, the damage to the cylinders
was caused by sever contamination and is not the
result of normal wear, it is necessary to remove,
clean and repair valves, pump, lines, cylinders, hy-
draulic reservoir, etc. in the hydraulic system.
6. Remove the breather from the reservoir and connect
the vacuum pump CAS10192 to the opening. Start the
vacuum pump CAS10192.
7. Loosen and remove the drain plug from the reservoir.
8. Using the properly fitting kit, install the valve in the hole
for the drain plug. Make sure that the valve is closed.
9. Stop the vacuum pump CAS10192.
10. Connect the inlet hose for the portable filter
CAS10162A to the valve that is installed in the hole
for the drain plug.
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11. Disconnect the vacuum pump CAS10192 from the hy-

draulic reservoir air breather hose. Remove the filler
cap.
12. Install the outlet hose for the portable filter
CAS10162A in the hydraulic reservoir filler neck.
13. Open the valve that is installed in the hole for the drain
plug.
14. Move the switch for the portable filter CAS10162A
to the ON position. Start and run the engine at
1500 RPM.
15. Run the portable filter CAS10162A for 10 minutes.
16. Continue to run the portable filter CAS10162A. In-
crease the engine speed to full throttle. Heat the oil to
operating temperature by doing the following steps:
1. Hold the loader control in the bucket roll-back po-
sition for five seconds.
2. Return the blade control lever in the NEUTRAL
position for five seconds.
3. Repeat steps 1 and 2 until the oil in the hydraulic
system is at operating temperature.
17. Continue to run the engine at full throttle. Continue to
run the portable filter CAS10162A.
18. Operate each hydraulic circuit to completely extend
and retract the cylinders. Continue to operate each
hydraulic circuit two times, one after the other for 45
minutes.
19. Decrease the engine speed to low idle.
20. Continue to run the portable filter CAS10162A for 10
minutes.
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21. Stop the portable filter CAS10162A.

22. Stop the engine.
23. Remove the hose from the hydraulic reservoir.
24. Close the valve that is installed in the hole for the drain
plug.
25. Disconnect the inlet hose for the portable filter
CAS10162A from the valve. Remove the outlet hose
from the reservoir filler neck and replace the filler cap.
26. Connect the vacuum pump CAS10192 to the breather
hose of the hydraulic reservoir.
27. Start the vacuum pump CAS10192.
28. Remove the valve from the hole for the drain plug.
29. Install the drain plug.
30. Stop and disconnect the vacuum pump CAS10192
from the opening in the reservoir and install the
breather.
31. Remove the hydraulic filter elements from the ma-
chine.
32. Install new hydraulic filter elements on the machine.
33. Start the engine. Check for oil leakage around the new
hydraulic filters.
35. Check the oil level in the hydraulic reservoir. Add oil
as required.
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Hydraulic systems - Decontaminating

DANGER
Crushing hazard!
Always install the safety lock before working under the raised attachment.
Failure to comply will result in death or serious injury.
D0075A
1. Start and run the engine at 1500 rpm (r/min).

2. Completely retract the cylinders of all attachments on
the machine. Stop the engine
NOTICE: if retracting the cylinder rods causes the attach-
ment to be raised, block the attachment in place before
proceeding to the next step.
NOTE: any attachment or part of an attachment that is
raised must be supported with acceptable equipment to
prevent the attachment from falling.
3. Move each control lever in both directions to release
pressure in the hydraulic circuits.
4. Loosen and remove the filler cap from the reservoir.
5. Drain the hydraulic oil from the reservoir.
A. The reservoir holds approximately 134 L (35.4 US
gal) of hydraulic oil.
B. Have available acceptable equipment to drain the
hydraulic oil.
C. Remove the drain cap from the remote drain.
LEIL15WHL1801AB 1
6. Apply brakes at least 30 times to drain oil from accu-

mulators.
7. Remove the hydraulic filter elements from the machine.
9. Install the drain cap in the remote drain.
10. Fill the hydraulic reservoir with 134 L (35.4 US gal) of
hydraulic fluid.
11. Disconnect the line from the OPEN end and CLOSED
end of each cylinder.
12. Be sure all control levers are in the NEUTRAL posi-
tion.
13. Start and run the engine at low idle.
NOTICE: check the oil level in the hydraulic reservoir fre-
quently while doing step 13. Have another person hold a
container under the hydraulic lines while you do step 13.
14. Slowly move each control lever in both directions until
oil begins to flow from the open line. Hold the control
lever in place until clean oil flows from the open line.
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16. Connect the system line to the CLOSED end of each
cylinder.
17. Connect a suitable drain line to the OPEN end of each
cylinder and place the other end in an acceptable con-
tainer for contaminated oil.
18. Start the engine and run the engine at low idle.
19. Slowly and completely extend all cylinders. As the pis-
ton rod comes in/out of the cylinder, oil will be pushed
out of the OPEN end of the cylinders.
NOTE: any attachment or part of an attachment that is
raised must be supported with acceptable equipment to
prevent the attachment from falling.
20. Support any attachments that will be in the RAISED
position.
22. Disconnect the drain lines and connect the system
lines to the cylinders.
23. Check the oil level in the hydraulic reservoir. Add oil
as required.
24. Install the filler cap on the reservoir.
25. Remove the hydraulic filter elements from the ma-
chine.
27. Start and run the engine at 1500 rpm(r/min) , operate
each hydraulic circuit to completely extend and retract
the cylinders.
28. Stop the engine and check for leaks. Check the oil
level in the hydraulic reservoir. Add oil as required.
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Hydraulic systems - Service instruction - Troubleshooting

N° Test Point Expected Result Other Result (Possible Cause)
1 Condition Result Action
Visually check the machine for YES NO
oil leakage and damaged or Action Fill the hydraulic reservoir with
missing parts. Repair or replace Heat the oil in the hydraulic the hydraulic oil.
any damaged or missing parts. system to operating temperature.
Check the oil level in the hydraulic Operate the machine to find which
reservoir. Is the oil level correct? circuits have problems.
Problems in All Circuits YES NO
Replace the return line hydraulic Action Do the flow meter test of the
filter. Do the stall test to see Clean or replace the oil. hydraulic pump.
if the engine is good. Check
for contaminated oil. Is the oil
contaminated?
Problem in All Loader Circuits YES NO
Check the pressure setting of the Adjust the limit pressure
limit pressure in the loader control
valve. Is the pressure setting
correct?
Problem in the Braking Circuit YES NO
Action
Check the braking circuit.
Problem in a Single Loader Circuit YES NO
Start and run the engine at full Action The loader control valve is
throttle. Operate the control for Go to test 6 damaged.
the bad circuit. Does the cylinder Repair the loader control valve.
move in both directions?
Check the cylinder piston packing. YES NO
Is the packing good? Action Repair the cylinder.
Go to test 7
Check and adjust the circuit relief YES NO
valves. Then check the operation Action Disassemble the loader control
of the circuit again. Does the The problem is repaired. valve and check for worn or
circuit work correctly? damaged pars.
Problem in the Steering Circuit YES NO
Check the steering circuit. Is the Action Repair the component as
steering circuit good? Do the Steering Pump Limit necessary.
Pressure Test and Adjustment
Problem in the Ride Control YES NO
Lift arms rapidly and continuously Action See the Ride Control Test
sink towards the ground. Check the manual bleed valve for Procedure.
the ride control accumulator to be
sure that it is closed.
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Index

Hydraulic systems - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hydraulic systems - Component localization - Test ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hydraulic systems - Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hydraulic systems - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic systems - Hydraulic schematic frame 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic systems - Hydraulic schematic frame 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic systems - Service instruction - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic systems - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Reservoir, cooler, and filters - 300

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Contents
SERVICE
Oil reservoir
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil cooler/Heat exchanger
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Thermal bypass valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Hydraulic systems - Reservoir, cooler, and filters
Oil reservoir - Remove

Prior operation:
Engine hood - Remove (90.105)
Ladder - Remove (90.118)
Cab - Remove (90.150)

bucket to the ground. Put the articulation lock in the
locked position.
LEIL15WHL1782AA 1
2. Push the hydraulic functions lock-out switch in the nor-

mal operation position.
LEIL16WHL1125AA 2
3. Move the loader hydraulic control handle to the raise

and lower position several times (about 30 times) in
order to release any hydraulic pressure in the lift circuit.
4. Move the loader control handle in and out of the tilt
position several times, this will relieve any pressure in
the pilot accumulator.
5. Release the pressure in the ride control accumulator
with the bleeder valve in the ride control valve.
6. Actuate brake pedal several times (about 30 times) to
discharge brake accumulators.
7. Slowly loosen the filler cap for hydraulic tank to release
air pressure in the hydraulic tank.
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8. Put the timed disconnect switch in the OFF position.
LEIL15WHL0663AA 3

the radiator cap and coolant drain plug (arrow) to drain
the engine coolant. Reinstall the drain plug and radiator
cap after the coolant has drained.
ume.
LEIL15WHL0719AB 4
10. Drain the hydraulic oil tank.
LEIL15WHL1801AB 5
11. Loosen the hose clamp (1) on the air intake hose un-
der the air inlet engine hood.
NOTICE: for clarity the engine hood compartment top
cover is not shown in the figure.
LEIL17WHL0327AB 6
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12. Remove the mounting bolts (arrows) from engine

compartment top cover (1).
gine compartment cover and exhaust stack. Carefully
remove the cover (1), the exhaust stack (2) and the
precleaner (3) as an assembly.
LEIL15WHL0679AB 7
14. Remove the P-clamps that secure the radiator vent

hose to the engine wall, support brackets and coolant
tank.
15. Remove the hydraulic oil lines (1) and the related fit-
tings.
LEIL15WHL0682AB 8
fix the exhaust pipe support bracket (1) from the hy-
draulic tank.
Remove the clamp saddle (5), U-bolt (6), washers and
nuts to separate the exhaust system pipe (4) from the
bracket (1).
LEIL17WHL0302AB 9
fix from the muffler the bracket (1) that supports the
check valve (2). Loosen the clamp (4) to disconnect
the aspirator engine hose from the muffler.
LEIL17WHL0300AB 10
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18. Remove the two washers and nuts (5) to unfix the air
intake bracket (1) from the hydraulic tank.
LEIL17WHL0270AB 11
LEIL17WHL0269AB 12
19. Attach a suitable lift equipment to the left-hand and

right-hand support brackets (1), (4).
Remove the hardware to unfix the left-hand and right-
hand support brackets (1), (4) from the hydraulic tank
and engine wall.
Move the exhaust system assembly (left-hand and
right-hand support brackets (1), (4), muffler supports
(2), muffler (3)) out of the machine.
out of the way during removal.
LEIL17WHL0304AB 13
20. Disconnect all electrical connector from relay. Re-

move the bolts and washers (2) to unfix the relay
support bracket (1) from the hydraulic tank. Remove
the P-clamps (3) that secure electrical wire to the hy-
draulic tank.
LEIL17WHL0332AB 14
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21. Disconnect the hydraulic fittings (2) and (3) from the
hydraulic oil supply tube (1).
LEIL17WHL0258AB 15
22. Loosen the two clamps to disconnect the hydraulic oil

return tube (2) from the lower hose (1).
LEIL17WHL0257AB 16
23. Remove the four bolts (2) and remove the hydraulic
oil return tube (1).
LEIL15WHL1294AB 17
24. Remove the three clamps (1). Remove the two

clamps (2). Disconnect the hose (3), the hose (4) and
the overflow hose (5) from the coolant tank.
25. Disconnect the fill hose (6) from the coolant tank.
LEIL15WHL1295AB 18
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26. Remove the supply hose (1) and tank drain hose (2).
RCPH11WHL005AAR 19
27. Remove the three hydraulic pump suction hoses (1).
RCPH11WHL006AAR 20
28. Remove the hydraulic pump case drain hose (2) and
the two pilot hoses (1).
RCPH11WHL007AAR 21
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29. Remove the four hydraulic oil tank mounting bolts (1),
washers (2), and poly-lock nuts (3).
RCPH11WHL008AAR 22
30. Attach lifting equipment to the hydraulic oil tank. Re-

move the hydraulic oil tank.
RCPH11WHL094AAR 23
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Oil reservoir - Install

1. Attach lifting equipment to the hydraulic oil tank. Lower
the hydraulic oil tank onto the chassis.
RCPH11WHL094AAR 1
2. Install the two hydraulic oil tank front mounting bolts (1).
Tighten the hydraulic oil tank front mounting bolts (1) to
a torque of 302 – 407 N·m (223 – 300 lb ft).
3. Install the two hydraulic oil tank rear mounting bolts (2),
washers (3), (4), and poly-lock nuts (5). Tighten the
hydraulic oil tank rear mounting bolts (2) to the torque
of 407 – 542 N·m (300 – 400 lb ft).
NOTICE: the hydraulic tank rear mounting bolts (2), wash-
ers (3), (4), and nuts (5) are designed to be torqued only
one time. Replace the rear mounting bolts (2), washers (3),
(4), and nuts (5) as required.
RCPH11WHL008AAR 2
4. Install the hydraulic pump case drain hose (2) and the
two pilot hoses (1) .
RCPH11WHL007AAR 3
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5. Install the three hydraulic pump suction hoses (1).

6. Tighten the split, half clamp flange bolts (2) to the
torque of 73 – 90 N·m (54 – 66 lb ft).
RCPH11WHL006AAR 4
7. Install supply hose (1) and tank drain hose (2).
RCPH11WHL005AAR 5
8. Connect the hose (3), the hose (4) and the overflow
hose (5) to the coolant tank. Install and the clamps (1)
and the clamps (2) to secure the hose (3), the hose (4)
and the overflow hose (5) to the coolant tank.
9. Connect the fill hose (6) to the coolant tank.
LEIL15WHL1295AB 6
10. Install the hydraulic oil return tube (2). Install and
tighten the four bolts (2) to secure the hydraulic oil re-
turn tube (2) to hydraulic oil filter.
LEIL15WHL1294AB 7
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11. Install the two P-clamps to secure the hydraulic oil

return tube (2) to the lower hose (1).
LEIL17WHL0257AB 8
12. Connect the hydraulic fittings (2) and (3) to the hy-
draulic oil return tube (1).
LEIL17WHL0258AB 9
13. Install the air intake bracket (1) to the hydraulic tank
with two washers and nuts (5).
14. Install and tighten the clamp (2) to air intake bracket
(1).
15. Connect the air intake upper hose (3) with clamp (4).
Torque the clamp to 4 – 4.5 N·m (3 – 3.3 lb ft).
LEIL17WHL0270AB 10
LEIL17WHL0269AB 11
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16. Install the relay support bracket (1) to the hydraulic

tank with bolts and washers (2). Connect all electri-
cal connectors. Secure the electrical wires to the hy-
draulic tank with P-clamps (3).
LEIL17WHL0332AB 12
17. Attach a suitable lifting to the exhaust system assem-

bly (left-hand and right-hand support brackets (1), (4),
muffler supports (2), muffler (3)). Move the assembly
into the correct position on the machine.
out of the way or positioned correctly for reconnecting.
18. Install the left-hand and right-hand support brackets
(1), (4) to the hydraulic tank and engine wall.
LEIL17WHL0304AB 13
19. Fix the bracket (1) that supports the check valve (2)
to the muffler with two bolts, washers and nuts (3).
Connect the aspirator engine hose to the muffler with
LEIL17WHL0300AB 14
20. Connect the exhaust system pipe (1) to the engine

with the clamp (2). Torque the clamp to 5.4 – 5.9 N·m
(4 – 4.4 lb ft).
LEIL17WHL0301AB 15
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21. Connect the exhaust system pipe (4) to the muffler

with clamp (3). Torque the clamp to 18 – 22 N·m (13.3
– 16.2 lb ft).
22. Install the exhaust pipe support bracket (1) to the hy-
draulic tank with two bolts, washers and nuts (2). Se-
cure the exhaust system pipe (4) to the bracket (1)
with the clamp saddle (5), U-bolt (6), washers and
nuts.
LEIL17WHL0302AB 16
23. Connect the radiator vent hose (1) to the radiator

(through the engine wall). Secure the hose to the
Connect the ENG_H connector at this time.
LEIL17WHL0307AB 17
24. Install the hydraulic oil lines (1) and the related fittings.
LEIL15WHL0682AB 18
gine compartment cover (1), the exhaust stack, and
the precleaner (3) as an assembly. Carefully move
the assembly into position on the machine.
Install the mounting bolts (arrows) on the engine com-
partment top cover (1).
LEIL15WHL0679AB 19
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26. Tighten the clamp (1) on the air intake hose under the
air inlet engine hood.
Torque the clamp to 4.0 – 4.5 N·m (35 – 40 lb in).
NOTICE: for clarity the engine hood compartment top
cover is not shown in the figure.
LEIL17WHL0327AB 20
27. Fill the coolant tank to the required amount.

28. Fill the hydraulic tank to the required amount.
Next operation:
Cab - Install (90.150)
Engine hood - Install (90.105)
Ladder - Install (90.118)
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Oil cooler/Heat exchanger - Remove

parking brake.
3. Place the timed disconnect switch in the OFF position.
4. Open the frame of the engine cooling system.
LEIL15WHL0698AB 1
5. Loosen the filler cap on the hydraulic reservoir to re-

lease the air pressure in the reservoir. Connect a vac-
uum pump to the hydraulic reservoir, turn on the pump.
LEIL15WHL0825AA 2
6. Disconnect the top hose and install a plug in the hose

and a cap on the fitting.
LELI12WL30475AB 3
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7. Disconnect the hose from the bottom of the oil cooler.

Install a plug in the hose and a cap on the fitting.
LELI12WL30476AB 4
8. Loosen and remove the bolts (1) and the washers (2)
that fasten the oil cooler to the cooling frame. Remove
the oil cooler from the machine.
LELI12WL30477AB 5
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Oil cooler/Heat exchanger - Install

1. Place the oil cooler in position in the cooling frame.
Install and tighten the mounting washers (2) and bolts
(1).
LELI12WL30477AB 1
2. Connect the lower hose to the oil cooler to the cooling

frame.
LELI12WL30476AB 2
3. Connect the hose to the top of the oil cooler.
LELI12WL30475AB 3
4. Turn off the vacuum pump and disconnect from the hy-
draulic reservoir.
6. Start the engine and run the engine at low idle for two
minutes. Stop the engine and check for hydraulic oil
leakage at the ports on the oil cooler.
7. Check the level of the hydraulic oil in the reservoir and
add hydraulic oil as required.
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Thermal bypass valve - Remove

parking brake.
NOTICE: with the engine NOT running, pump the brake
repeatedly to be sure the brake accumulators have no hy-
draulic pressure, put the ignition switch in the ON position
then move the joystick back and forth several times to re-
lease any hydraulic pressure in the pilot control circuit, turn
the ignition switch OFF.
3. Locate the thermal bypass valve (5) on the inner left-
hand side of the cooling box.
LEIL16WHL1859AB 1
4. Tag and disconnect the hoses (1), (2), (3) and (4) from
the thermal bypass valve (5). Install a plug in the hose
and a cap on the fitting.
5. Remove the nuts (6), washer (7) and mounting bolts (8)
from the thermal bypass valve. Remove the thermal
bypass valve (5) from the machine.
LELI12WL30489BB 2
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Thermal bypass valve - Install

1. Place the thermal bypass valve (5) into position on the
machine.
2. Lubricate and install new O-rings in the fittings.
3. Install the bolts (8), washers (7) and nuts (6). Tighten
the nuts.
4. Connect the hoses (1), (2), (3) and (4) to the thermal
bypass valve, remove and discard tags.
draulic reservoir.
6. Check the level of the hydraulic oil in the reservoir.
minutes.
8. Stop the engine and check for hydraulic oil leakage at
the thermal bypass valve.
add as required. Tighten the filler cap on the reservoir.
LELI12WL30489BB 1
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Index

Oil cooler/Heat exchanger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oil cooler/Heat exchanger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil reservoir - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil reservoir - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Thermal bypass valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Thermal bypass valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Variable displacement pump - 106

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Contents
TECHNICAL DATA
Pump
SERVICE
Variable displacement pump

Service instruction - Testing and adjusting the high pressure pump differential pressure . . . . . . . . . . . . . 4
Service instruction - Testing and adjusting the low pressure pump differential pressure . . . . . . . . . . . . . . 6
Service instruction - High pressure pump flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Hydraulic systems - Variable displacement pump
Pump - General specification

1021G - Pump specifications
High pressure pump (closest to transmission)
Speed 2200 RPM
Displacement 100 cm³/rev (6.1 in³/rev)
Maximum flow 220 L/min (58.1 US gpm)
Maximum pressure 280 bar (4060 psi)
Delta P setting 25 – 27 bar (362 – 392 psi)
Rotation Clockwise as seen from the end of the shaft
Low pressure pump (furthest from transmission)
Speed 2200 RPM
1121G - Pump specifications

High pressure pump (closest to transmission)
Speed 2200 RPM
Low pressure pump (furthest from transmission)
Speed 2200 RPM
NOTE: both pump sections provide flow for both the steering and loader functions.
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Variable displacement pump - Service instruction - Testing and

adjusting the high pressure pump differential pressure
Pressure check
1. Install articulation lock.
LEIL15WHL1782AA 1
2. Make sure that the temperature of the hydraulic oil is at

least 54 – 57 °C (129 – 135 °F). The procedure to heat
the hydraulic oil is the following.
● Check the oil temperature through the display in the
cab (access to “Machine service – Sensor Status – Hy-
draulics” screens).
● Heat the hydraulic oil:
A. Start the engine and run at full throttle.
B. Hold the bucket control lever in the ROLLBACK posi-
tion while raising and lowering the lift arms from ground
level to full height.
C. Continue this procedure until the temperature of the
hydraulic oil is 54 – 57 °C (129 – 135 °F).
After heating the oil to the operating temperature, lower LEIL16WHL0891AA 2
the bucket to the ground, turn off the engine, and relieve
all pressure in the hydraulic system.
3. Connect two 69 bar (1000 psi) test gauges, one to the
test port (1) located on the priority valve, and one on the
pump load-sense pressure port (3) (closest to transmis-
sion).
NOTICE: do not steer or operate loader controls while the
gauges are connected, gauges could be damaged.
5. Make sure all of the controls are in the neutral position
and record the readings on the test ports (1) and (3).
6. Subtract the reading of the test port (3) from the reading
of the test port (1).
LEIL16WHL2734AB 3
7. The difference between the two readings should be 25
– 27 bar (362 – 392 psi).
8. If this reading is more or less than specified, it will be
necessary to adjust the pump load-sense pressure.
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Adjusting the high pressure pump differential pressure

1. The load-sense adjusting screw (4) is directly below the
load-sense pressure tap. Turn the screw clockwise to
increase the load-sense pressure. Turning the screw
counterclockwise will decrease the load-sense pres-
sure.
NOTE: one turn of the adjustment screw will change the
pressure approximately 16 bar (232 psi).
LEIL16WHL2734AB 4
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Variable displacement pump - Service instruction - Testing and

adjusting the low pressure pump differential pressure
Pressure check
LEIL15WHL1782AA 1

3. Connect two 69 bar (1000 psi) test gauges, one to the
test port (2) located on the priority valve, and one on
the pump load-sense pressure port (3) (furthest from
the transmission).
NOTICE: do not steer or operate loader controls while the
gauges are connected, gauges could be damaged.
5. Make sure all of the controls are in the neutral position
and record the readings on the test gauges (2) and (3).
6. Subtract the reading of the test port (3) from the reading
of the test port (2).
LEIL16WHL2734AB 3
7. The difference between the two readings should be 21
– 23 bar (304 – 334 psi).
necessary to adjust the pump load-sense pressure.
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Adjusting the low pressure pump differential pressure

1. The load-sense adjusting screw (4) is directly below the
load-sense pressure tap. Turn the screw clockwise to
increase the load-sense pressure. Turning the screw
counterclockwise will decrease the load-sense pres-
sure.
LEIL16WHL2734AB 4
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Variable displacement pump - Service instruction - High pressure

pump flow test
LEIL16WHL1852GB 1
1. Hydraulic return manifold 6. Articulation pressure hose 11. Flow meter inlet hose
2. Flow meter return hose 7. Load sense hose M14 ORB 12. Valve supply tube
3. Flow meter CAS10280 8. Needle valve 13. Loader main valve
4. Pumps 9. Union
5. Steering priority valve 10. T-fitting
NOTE: if unit is equipped with auxiliary steering a tee fitting will have to be used in this location.
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NOTE: the pump differential pressure must be set before attempting any other tests.
1. Connect the flow meter (3) CAS10280 by disconnect-
ing the articulation pressure hose (6) to the valve sup-
ply tube (12), installing a cap on the fitting at the valve
supply tube (12).
2. Disconnect the load sense hose (7) and install a cap
on the fitting at the loader main valve (13).
NOTE: this is the line that returns to the pump compensator
valve.
3. Connect a T-fitting (10) into the articulation pressure
hose (6) and to the flow meter inlet hose (11).
4. Use an union (9) and connect an in-line needle valve
(8) to the open port in the T-fitting (10), connect the load
sense hose (7) to the needle valve (8).
5. Make sure that the flow meter valve and the installed
needle valve are in the open position. Start and run the
engine at high idle, slowly close the flow meter valve
until a pressure reading of 103 bar (1494 psi) is ob-
tained.
6. Using the temperature gauge on the flow meter (3)
CAS10280, continue to run the engine at high idle un-
til the temperature of the hydraulic oil is at least 52 –
60 °C (126 – 140 °F).
7. Run the engine at low idle, fully open the flow meter
valve.
8. Open the needle valve (8) and operate the engine at
2000 RPM. At 0 bar (0 psi) the flow should be 250 –
255 L/min (66 – 67 US gpm).
9. Close the flow meter valve slowly and read the flow at
34.5 bar (500 psi) the flow should be 249 – 255 L/min
(66 – 67 US gpm).
10. Close the flow meter valve slowly and read the flow at
2000 RPM. The flow should read 244 – 247.5 L/min
(64 – 65 US gpm).
11. Continue to close the flow meter valve slowly, at ap-
proximately 200 bar (2900 psi) the flow should drop
significantly, this will be the low pressure pump de-
stroking.
12. Continue slowly closing the flow meter valve until
241.4 bar (3500 psi) is reached. The flow should
read between 120 – 122 L/min (32 – 32 US gpm).
13. If any of the pump flow readings are not within specifi-
cations, the pump may be out of calibration and Tech-
nical Support Services should be contacted.
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Variable displacement pump - Remove

NOTE: when disconnecting the hydraulic fittings, plug the hoses and cap fittings to prevent entry of foreign matter
into the hydraulic system.
bucket to the floor. Stop the engine and apply the park-
ing brake.
ignition switch OFF.
3. Loosen the filler cap on the reservoir to release any air
in the reservoir. Drain the tank.
4. Remove the ROPS cab. Refer to Cab - Remove
(90.150).
5. Remove the eight bolts (4) with the related washers.
Remove the four split flanges (5). Disconnect the tubes
(6) and (7) with the suction hoses (8) and (9) from the
main hydraulic pump (1). Remove and discard the
O-ring face seals from the flange heads of the tubes.
LEIL16WHL1855BB 1
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NOTE: instructions 6, 7 and 8 refer to figure 2.
LEIL16WHL1856FB 2
6. Tag and disconnect the drain line hose (3) from the
steering priority valve. Remove and discard the O-ring
face seal from the fitting.
7. Tag and disconnect the pump to tank hose (10) from the
case drain tube (11). Remove and discard the O-ring
8. Tag and disconnect the case drain tube (11) from the
elbows installed on the main hydraulic pump (1). Re-
move and discard the O-ring face seal from the elbows.
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9. Tag and disconnect the load sense hose (12)from the

steering priority valve. Remove and discard the O-ring
10. Remove the four bolts (13) with the related washers.
Remove the two split flanges (14). Tag and disconnect
the articulation pressure hose (15) from the steering
priority valve. Remove and discard the O-ring face
seal from the flange heads of the hose.
LEIL16WHL1857BB 3
11. Connect a lifting equipment to the main hydraulic

pump (1). Take up all slack in lifting equipment.
Remove the four mounting bolts (2) and washers
securing the pump to the transmission. Pull the main
hydraulic pump (1) from the transmission and remove
from the loader. Remove and discard the O-ring from
the pump.
LEIL16WHL1858AB 4
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Variable displacement pump - Install

NOTE: install new O-rings where required.
1. Install a new O-ring on the hydraulic pump flange.
Move the main hydraulic pump (1) into position and
install in the transmission. Install the four bolts (2)
with the related washers to secure the main hydraulic
pump (1) to the transmission. Tighten the bolts (2) to
149 – 170 N·m (110 – 125 lb ft). Disconnect the lifting
equipment from the main hydraulic pump (1).
LEIL16WHL1858AB 1
2. Connect the articulation pressure hose (15) to steering

priority valve.
3. Install the two split flanges (14). Install the four bolts
(13). Tighten the bolts (13) to 198 – 242 N·m (146 –
178 lb ft).
4. Connect load sense hose (12) to the steering priority
valve.
LEIL16WHL1857BB 2
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NOTE: instructions 5, 6 and 7 refer to figure 3.
LEIL16WHL1856FB 3
5. Connect the drain line hose (3) to the steering priority

valve.
6. Install and connect the case drain tube (11) to the el-
bows installed on the main hydraulic pump (1).
7. Connect the pump tank hose (10) to the case drain
tube.
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8. Install the tubes (6) with the related suction hose (8) to
the main hydraulic pump (1).
9. Install the tube (7) with the related suction hose (9) to
the main hydraulic pump (1).
10. Install the four split flanges (5) and the eight bolts (4)
with the related washers. to secure the tubes (6) and
(7) to the main hydraulic pump (1). Tighten the bolts
(4) to 73.4 – 90.4 N·m (650 – 800 lb in).
LEIL16WHL1855BB 4
11. Install the ROPS cab. Refer to Cab - Install (90.150).

12. Turn OFF the vacuum pump and disconnect from the
hydraulic tank.
minutes.
NOTE: if any unusual vibration is heard coming from the
pump, stop the machine immediately and check for ob-
structions in the pump suction line.
the hydraulic pump.
16. Check the level of the hydraulic oil in the tank and fill
with the proper hydraulic oil as required.
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Index

Pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Variable displacement pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Variable displacement pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Variable displacement pump - Service instruction - Testing and adjusting the low pressure pump
differential pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Variable displacement pump - Service instruction - High pressure pump flow test . . . . . . . . . . . . . . . 8
Variable displacement pump - Service instruction - Testing and adjusting the high pressure pump
differential pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Main control valve - 359

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Contents
TECHNICAL DATA
Main control valve

FUNCTIONAL DATA
Main control valve

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Main control valve

Service instruction - Testing and adjusting the circuit relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic systems - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Hydraulic systems - Main control valve
Main control valve - General specification

Manufacturer Rexroth
Special Torques
End plate mounting bolts 68 N·m (50 lb ft)
Pressure relief, flow limit, and pilot pressure reducing 20 – 25 N·m (15 – 18 lb ft)
valves
Allen head plugs 200 N·m (147.5 lb ft)
Allen head locking screw. 100 N·m (74 lb ft)
Allen head cover screws (short) 8.3 N·m (6.1 lb ft)
Allen head cover screws (long) 8.3 N·m (6.1 lb ft)
Anticavitation valves 100 N·m (74 lb ft)
Combination anticavitation and circuit relief 60 N·m (44.3 lb ft)
Main relief valve pressure settings (XR and Z-Bar) 248 – 255 bar (3596 – 3697.5 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (XR and Z-Bar) 290 bar (4205 psi)
Bucket A port (XR and Z-Bar) 290 bar (4205 psi)
Bucket B port (XR and Z-Bar) 290 bar (4205 psi)
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Main control valve - Exploded view

3 spool valve housing configuration
LELI12WL30949GB 1
1. Stud 12. Intermediate plate

2. Washer 13. O-rings
3. Hexagon nut 14. Plug
4. Plate 15. Anti-cavitation valve
5. Anti-cavitation valve 16. Check valve
6. O-rings 17. Locking plate
7. Throttle check valve 18. Cylinder screw
8. Anti-cavitation and circuit relief 19. Pressure relief valve
9. Housing 1M6-22 20. Flow limit valve
10. Flow compensator spool 21. Pressure reducing valve
11. Housing 2M-22
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3,4 and 5 spool mounting configuration
LELI12WL30951FB 2
38. Housing 40. Flow compensator spool

39. Anti-cavitation and circuit relief
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3,4 and 5 spool valve spool configuration
LEIL16WHL2737HB 3
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1. Stud 26. Cover

2. Washer 27. Bolt
3. Hexagon nut 28. Cover
4. Plate 29. Cap nut
6. O-rings 30. Jam nut
9. Housing 1M6-22 31. Spool
11. Housing 2M-22 32. Bolt
12. Intermediate plate 33. Cover
22. Threaded steel pipe fitting 34. Adjusting rod
23. Spring retainer 35. Locking spool
24. Spring 36. Locking screw
25. Spring 37. Spool
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Main control valve - Service instruction - Testing and adjusting the

circuit relief valves
Pressure check
1. Circuit relief valves are located as shown beside.
1. Circuit relief valves
2. Pump limit pressure adjustment
3. Bucket spool
4. Lift spool
5. Auxiliary spool
6. Main control valve
2. Raise the lift arms and install the safety strut on the lift
arm cylinder.
3. Loosen and remove the bolts and washers that fasten
the access cover plate for the main control valve. Re-
move the cover plate.
4. Remove the safety strut and lower the bucket to the
floor. Shut off the engine. Find an easy place to dis-
connect the line for the circuit to be tested.
5. Connect the hand pump to the disconnected line that
goes to the main control valve.
6. Make sure that the hand pump is full of hydraulic oil and
that the temperature of the oil is approximately 21 °C
(70 °F).
7. Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to be
LELI12WL30903BB 1
sure of the reading.
8. Compare the reading to the specifications.
9. If the pressure is not correct, adjust the circuit relief
valve.
Adjustment
1. Loosen the lock nut. Turn the adjustment screw clock-
wise to increase the pressure or counterclockwise to
decrease the pressure.
NOTE: one turn of the adjusting screw will change the pres-
sure approximately 138 bar (2001 psi).
2. Check the pressure again. Repeat the adjustment as
necessary.
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Main control valve - Remove

1. Park the machine on a level surface.
NOTICE: if the machine is equipped with quick-attached
components, disconnect them from machine prior to pro-
ceeding.
2. Raise the lift arms and install the safety link on the lift
arm cylinder.
3. Stop the engine and apply the parking brake.
draulic pressure, put the ignition switch in the “ON” position
ignition switch “OFF”.
4. Place the timed disconnect switch in the “OFF” position.
LEIL13WHL1244AA 1
5. Relieve the pressure in the ride control accumulator

with the manual bleeder valve located on the top of the
ride control valve. Remove the plug and turn the valve
two turns counter-clockwise.
6. Loosen the filler cap on the reservoir to release the air
pressure in the reservoir.
7. Drain the hydraulic reservoir.
LEIL13WHL1245AB 2
8. Loosen and remove the bolts and washers that fasten

the access cover plate for the main control valve. Re-
move the cover plate.
LEIL15WHL0851AB 3
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Hydraulic valve pilot line connections
3 spool main control valve
LEIL16WHL1890GB 4
1. Pilot dump hose (green) 4. Pilot rollback hose (orange)

2. Pilot raise/lower hose (red) 5. Pilot pressure hose
3. Pilot raise/lower hose (yellow) 6. Pilot pressure hose
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LEIL16WHL1895GB 5
1. Pilot dump hose (green) 5. Pilot pressure hose

2. Pilot lower hose (red) 6. Pilot accessory hose (red-white)
3. Pilot raise hose (yellow) 7. Pilot accessory hose (yellow-white)
4. Pilot rollback hose (orange) 8. Pilot pressure 3rd function hose
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LEIL16WHL1896GB 6
1. Pilot dump hose (green) 6. Pilot pressure 4th function hose

2. Pilot raise/lower hose (red) 7. Pilot 4 spool left hose (orange-white)
3. Pilot raise/lower hose (yellow) 8. Pilot accessory hose (yellow-white)
4. Pilot rollback hose (orange) 9. Pilot accessory hose (red-white)
5. Pilot pressure hose 10. Pilot accessory hose (green-white)
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Main control valve line connections
LELI12WL31215GB 7
1. Tilt left-hand base tube 5. Lift left-hand rod tube

2. Tilt right-hand base tube 6. Lift left-hand base tube
3. Lift cylinder hoses 7. Lift right-hand base tube
4. Lift right-hand rod tube 8. Main control valve
NOTE: the procedure from step 9 to step 15 is applicable to each type of main control valve installed on the machine:
3 spool, 4 spool or 5 spool main control valve.
9. Disconnect the hoses from the remote control valve(s)
at the main control valve. Install a plug in each hose
and a cap on each fitting.
NOTE: refer to figure 4, 5 or 6 for color coding, depending
on the main control valve installed on the machine.
10. Loosen and remove the tilt cylinder lines (1) and (2).
Install a plug in each line and a cap on each fitting.
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11. Loosen and remove the lines (4) and (5). Install a plug
in each line and a cap on each fitting.
12. Loosen and remove the lines (6) and (7). Install a plug
in each line and a cap on each fitting.
13. Loosen and remove the supply and return lines. Install
a plug in each line and a cap on each fitting.
14. Attach proper lifting equipment to lift the main control
valve.
15. Loosen and remove the three bolts, washers and
spacer that hold the loader control valve to the valve
mounting plate. Remove the main control valve.
LELI12WL31216BA 8
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Main control valve - Install

NOTE: the whole procedure is applicable to each type of main control valve installed on the machine: 3 spool, 4 spool
or 5 spool main control valve.
NOTICE: before installing the fittings or connecting the
tubes to the fittings, install new O-rings on the fittings.
1. Install and align the main control valve with the valve
mounting plate.
2. Install the bolts, washers and spacer that fasten the
main control valve to the valve mounting plate. Tighten
the bolts.
LELI12WL31216BA 1
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35.4 [35.359] / 15
LELI12WL31215GB 2
3. Tighten the left lift cylinder lines (5) and (6).

4. Install and tighten the supply and return lines.
5. Install and tighten right lift cylinder lines (4) and (7).
6. Install and tighten tilt cylinder lines (1) and (2).
7. Connect the hoses to the remote control valve(s) at
the main control valve Refer to Main control valve -
Remove (35.359) for color coding.
8. Fill the hydraulic reservoir with oil. Refer to ”Consum-
ables” in this manual for the correct oil.
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9. Tighten the accumulator manual bleeder valve located

on the top of the ride control valve to a torque of 3.5 N·m
(31 lb in). Install the plug and torque to 7 N·m (62 lb
in).
10. Place the master disconnect switch in the “ON” posi-
tion.
11. Raise the loader arms and remove the safety link.
12. Run engine at half throttle.
13. Slowly and completely extend and retract all cylinders
at least 10 times to remove any air from the circuits.
14. Stop the engine and check for leaks.
15. Install the access cover on the front of the machine.
16. Check the level of the hydraulic oil and add hydraulic
oil as required.
LEIL13WHL1244AA 3
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Main control valve - Disassemble

1. Remove the main control valve from the machine, see
Main control valve - Remove (35.359) .
NOTE: see Main control valve - Exploded view (35.359)
for reference for the items number in the following instruc-
tions.
2. Remove the bolts (27), the cover (28), the springs (24)
and (25), and the spring retainer (23).
3. Remove the bolts (32), the covers (33) and (26), the
spring (24), and the spring retainer (23).
4. Use a wooden dowel or brass drift and push the spools
(31), (35) and (37) from the housing (11).
NOTICE: do not force the spools from the housing, if the
spool binds work back and forth until the spool comes out
freely.
NOTE: repeat steps 3 and 4 for a 4 spool valve configura-
tion.
Repeat steps 3 and 4 two times for a 5 spool valve config-
uration.
5. Remove the anti-cavitation valves (5), (8) and (15).
NOTE: repeat the step for a 4 spool anti-cavitation valves
(39).
Repeat the step two times for a 5 spool anti-cavitation
valves (39)
6. Remove the flow compensator spool (10).
NOTE: repeat the step for a 4 spool for the flow compen-
sator spool (40).
Repeat the step two times for a 5 spool for the flow com-
pensator spool (40).
7. Remove the pressure relief valve (19).
8. Remove the flow limit valve (20).
9. Remove the check valve (16).
10. Remove the locking screw (14).
11. Remove the throttle check valve (7).
12. Remove the pilot pressure reducing valve (21).
13. Remove the cylinder screw (18) and the locking plate
(17).
14. Remove the hexagon nut (3) and the washers (2) from
the stud (1), remove the plate (4), the housing (9) and
the intermediate plate (12) from the housing (11).
NOTE: for a 4 spool configuration remove the housing (38)
from the housing (11).
For a 5 spool configuration remove the housings (38) from
the housing (11)
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15. Remove and discard the O-rings and the thrust rings
from the pilot pressure reducing valve (21).
1. O-rings
2. Thrust rings
LELI12WL30953AB 1
from flow limit valve (20).
1. O-rings
2. Thrust rings
LELI12WL30954AB 2
17. Remove and discard the O-rings and the thrust ring
from the plug (14).
1. O-rings
2. Thrust rings
LELI12WL30955AB 3
18. Remove and discard the O-rings, the thrust ring and
the spool seal from the anti-cavitation valve (5).
1. O-rings
2. Thrust rings
3. Spool seal
LELI12WL30956AB 4
48083742_EN 31/07/2018
35.4 [35.359] / 19
LELI12WL30957FB 5
from the pressure relief valve (19).
1. O-rings
2. Thrust rings
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35.4 [35.359] / 20
LELI12WL30958FB 6
from the anti-cavitation and circuit relief valves (8) and
(39).
1. O-rings
2. Thrust rings
3. Spool seal
4. Lock nut
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Hydraulic systems - Inspect

1. Discard all O-rings, thrust rings, and spool seals.
2. Clean all parts in cleaning solvent.
3. Check the spools and the spool bores for damage and
wear.
4. Check the parts of the pressure relief valve, anti-cav-
itation valves, and the anti-cavitation and circuit relief
valves. Use new parts as necessary.
5. Inspect the other parts of the control valve. If any of the
parts are damaged, install new parts.
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Main control valve - Assemble

NOTE: see Main control valve - Exploded view (35.359) for reference for the items number in the following instruc-
tions.
LELI12WL30959FB 1
1. O-rings 3. Spool seal

2. Thrust rings 4. Lock nut
1. Install new O-rings and thrust rings on the anti-cavita-
tion and circuit relief valves (8) and (39). Torque the
relief valve (A) into the anti-cavitation valve to 20 N·m
(14.8 lb ft).
NOTE: the spool seal mounting position is critical, the seal
must be mounted with the lip facing as shown above, pres-
sure is in the direction of the arrow.
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35.4 [35.359] / 23
LELI12WL30957FB 2
1. O-rings 2. Thrust rings

2. Install new O-rings and thrust rings on the pressure
relief valve (19).
3. Install new O-rings and thrust rings on the pilot pressure
reducing valve (21).
1. O-rings
2. Thrust rings
LELI12WL30953AB 3
4. Install new O-rings and thrust rings on the flow limit

valve (20).
1. O-rings
2. Thrust rings
LELI12WL30954AB 4
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35.4 [35.359] / 24
5. Install new O-rings and thrust ring on the plug (14).

1. O-rings
2. Thrust rings
LELI12WL30955AB 5
6. Install new O-rings, new thrust rings and a spool seal

on the anti-cavitation valve (5).
1. O-rings
2. Thrust rings
3. Spool seal
7. Install and torque the plug (14) to 100 N·m (73.8 lb ft).
8. Install and tighten the throttle check valve (7).
9. Install and torque the pilot pressure reducing valve (21)
to 60 N·m (44 lb ft).
LELI12WL30956AB 6
10. Install new O-rings on the housing (11). Install the

plate (4), the housing (9) and the intermediate plate
(12), the stud (1), the washers (2) and the hexagon
nut (3) onto the housing (11). Torque the nut to 68 N·m
(50 lb ft).
11. Install the locking plate (17) and the cylinder screw
(18). Torque the screw to 68 N·m (50 lb ft).
NOTE: repeat the step for a 4 spool configuration for the
housing (38).
Repeat the step two times for a 5 spool configuration for
the housings (38)
12. Install the anti-cavitation valves (5) and (8) and torque
to 100 N·m (73.8 lb ft).
NOTE: repeat the step for a 4 spool anti-cavitation valves
(39).
Repeat the step two times for a 5 spool anti-cavitation
valves (39)
13. Install the anti-cavitation valves (15) and torque to
60 N·m (44.3 lb ft).
14. Install and torque the flow limit valve (20) to 20 –
25 N·m (177 – 221 lb in).
15. Install the check valve (16). Torque the locking screw
to 100 N·m (73.8 lb ft).
16. Lubricate the spools with hydraulic oil and push the
spools (31), (35) and (37) into the housing (11).
NOTICE: do not force the spools into the housing.
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17. Install the spring retainers (23), the springs (24), the
covers (33) and (26),and the bolts (32). Torque the
bolts to 8.3 N·m (73.5 lb in).
NOTE: before the installation in the machine, test the circuit
reliefs .
18. Install the spring retainers (23), the spring (24) and
(25), the cover (28), and the bolts (27). Torque the
bolts to 8.3 N·m (73.5 lb in).
19. Install the main control valve in the machine, see Main
control valve - Install (35.359).
20. Check the loader limit pressure, see Front loader arm
hydraulic system - Service instruction - Testing
and adjusting the loader limit pressure (35.701).
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Index

Hydraulic systems - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Main control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Main control valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Main control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Main control valve - Service instruction - Testing and adjusting the circuit relief valves . . . . . . . . . . . 8
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Pilot system - 357

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Contents
Pilot system - 357
TECHNICAL DATA
Pilot accumulator
SERVICE
Pilot solenoid valve block

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Hydraulic systems - Pilot system
Pilot accumulator - General specification

Pilot accumulator fluid capacity: 0.32 L (19.5 in³)
Pre-charge pressure with dry nitrogen: 13 – 15 bar (188.5 – 217.5 psi) at 20 °C (68 °F)
Pilot accumulator maximum operating pressure: 210 bar ( 3046 psi)
NOTE: refer to the following table when check the pre-charge pressure.
Temperature Charge pressure

0 °C (32 °F) 13.0 bar (188.5 psi)
5 °C (41 °F) 13.3 bar (192.9 psi)
10 °C (50 °F) 13.5 bar (195.8 psi)
15 °C (59 °F) 13.8 bar (200.1 psi)
20 °C (68 °F) 14.0 bar (203.0 psi)
25 °C (77 °F) 14.2 bar (205.9 psi)
30 °C (86 °F) 14.5 bar (210.2 psi)
35 °C (95 °F) 14.7 bar (213.1 psi)
40 °C (104 °F) 15.0 bar (217.5 psi)
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Pilot solenoid valve block - Check

Pressure check
NOTE: this pressure is factory preset and is not adjustable.
least 54 – 57 °C (129.2 – 134.6 °F). The procedure to
heat the hydraulic oil is the following.
B. Hold the joystick in the ROLLBACK position while
raising and lowering the lift arms from ground level to
full height.
• To heat the hydraulic oil do the following:
LEIL16WHL0891AA 1
B. Hold the joystick in the ROLLBACK position while
raising and lowering the lift arms from ground level
to full height.
C. Continue this procedure until the temperature of
the hydraulic oil is 54 – 57 °C (129.2 – 134.6 °F) .
2. Raise lift arms to the top and turn off the engine. Turn
the ignition key to the “RUN” position.
3. Repeatedly put the joystick into “FLOAT” position and
back to neutral, as rapid as possible.
4. The system should allow a minimum of 10 actuations
into float and still cause the lift arms to come down.
NOTE: steps 1 through 4 are testing the pilot pressure accumulator. If 10 full actuations cannot be made, an internal
hydraulic leak exists, proceed to next step.
5. Start the machine, lower the bucket to the ground, and
turn off the engine. Turn the ignition key to the “RUN”
position and operate the pilot controls a minimum of 30
strokes to relieve any pressure in the system.
6. Open the right-hand side compartment to gain access
to the loader control handle.
7. Attach a gauge capable of reading 70 bar (1015.0 psi)
to the test port under loader control handle. This is test
point 9 (TP9) on the schematic.
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8. A pressure reading of 29 – 40 bar (421 – 580 psi)

should be obtained. If the pressure is not as specified,
replace the Pilot Pressure Reducing Valve. This valve
is part of the main control valve. Retest as required.
9. Lower the bucket to the ground and turn off the engine.
Turn the ignition switch to the “RUN” position.
10. Operate the pilot controls several times until the gauge
pressure suddenly drops to 0 bar (0.0 psi). The last
pressure reading before the drop to 0 bar (0.0 psi) is
the nitrogen charge pressure in the accumulator. If
the pressure is below 13 – 15 bar (188.5 – 217.5 psi) ,
replace the accumulator and retest. If the accumulator
test is good, go to the next step.
11. Replace the pilot control valve and retest the system.
12. Replace the main control valve, retest the system.
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Index
Pilot system - 357

Pilot accumulator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pilot solenoid valve block - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Remote control valves - 204

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Contents
SERVICE
Electro-hydraulic control valve

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Hydraulic systems - Remote control valves
Electro-hydraulic control valve - Remove

WARNING
Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.
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
1. Park the machine on firm, level ground. Lower the

parking brake.
draulic pressure. Turn the ignition switch to the ON posi-
tion and move the joystick in all directions several times to
release any hydraulic pressure in the pilot control circuit.
Turn the ignition key to the OFF position.
2. Put the articulation lock in the LOCKED position.
LEIL16WHL0048AB 1

lease any air pressure in the reservoir. Connect the
vacuum pump CAS10192 to the hydraulic reservoir.
Turn on the vacuum pump CAS10192.
5. Locate the electro-hydraulic control valve on the inner
left-hand side of the front frame.
LEIL16WHL2763AA 2
NOTE: the procedure showed from step 6 to step 13 refers to a machine equipped with a 4th function electro-hydraulic
control valve, but it is similar also to the 3th function electro-hydraulic control valve.
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6. Disconnect all the electrical wires from the electro-hy-

draulic control valve.
LEIL16WHL2742AA 3
7. Disconnect the electrical PST connector (ref. front

frame harness) from the electro-hydraulic control
valve.
LEIL16WHL2743AA 4
8. Disconnect and plug the following hoses from the elec-

tro-hydraulic control valve:
• pilot accessory hoses (1), (2), (4);
• pilot raise/lower hoses (3), (5);
• pilot dump hose (6).
LEIL16WHL2743AB 5
9. Remove and cap the following elbows and fittings from

the electro-hydraulic control valve:
• 90° elbows (1);
• 45° elbow (2);
• fittings (3);
• 90° elbow (4) and fitting (5).
LEIL16WHL2744AB 6
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10. Disconnect and plug the pilot 4th spool left hose (1)
and pilot rollback hose (2) from the electro-hydraulic
control valve.
Remove and cap the 90° elbow (3) and 45° elbow (4).
LEIL16WHL2745AB 7
11. Disconnect and plug the pilot pressure hose (2) and
pilot tank hose (1) from the electro-hydraulic control
valve.
Remove and cap the 90° elbow (3) and fitting (4) from
the electro-hydraulic control valve.
LEIL16WHL2746AB 8
12. Remove the three bolts, washers and nuts that secure
the electro-hydraulic valve mount bracket (1) to the
front frame.
LEIL16WHL2747AB 9
13. Remove the three bolts and washers to unfix the elec-
tro-hydraulic control valve from the bracket (1).
LEIL16WHL2748AB 10
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Electro-hydraulic control valve - Install

NOTE: the procedure showed from step 1 to step 17 refers to a machine equipped with a 4th function electro-hydraulic
control valve, but it is similar also to the 3th function electro-hydraulic control valve.
1. Fix the electro-hydraulic control valve to the bracket (1)
with three bolts and washers.
LEIL16WHL2748AB 1
2. Fix the electro-hydraulic control valve and bracket as-

sembly (1) to the front frame with three bolts, washers
and nuts.
LEIL16WHL2747AB 2
3. Remove the cap from the fitting (4) and 90° elbow (3).
Install the fitting (4) to the Pst port of electro-hydraulic
control valve and the 90° elbow (3) to the T port of the
electro-hydraulic control valve. Unplug and connect the
pilot pressure hose (2) to the fitting (4) and pilot tank
hose (1) the 90° elbow (3).
LEIL16WHL2746AB 3
4. Apply to the pilot pressure hose and pilot tank hose the
angle orientation shown in figure 4.
LEIL16WHL2751AB 4
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5. Remove the cap from the 90° elbow (3) and 45° elbow
(4). Install the 90° elbow (3) to the G port of the electro-
hydraulic control valve and the 45° elbow (4) to the C
port of the electro-hydraulic control valve. Unplug and
connect the pilot 4th spool left hose (1) to the 90° elbow
(3) and pilot rollback hose (2) to the 45° elbow (4).
LEIL16WHL2745AB 5
6. Apply to the pilot 4th spool left hose and pilot rollback
hose the angle orientation shown in figure 6.
LEIL16WHL2750AB 6
7. Remove the cap and connect the following elbows and

fittings to the electro-hydraulic control valve:
• 90° elbows (1) to the H2 and F2 ports;
• 45° elbow (2) to the E2 port;
• fittings (3) to the B2 and D2;
• fitting (5) and 90° elbow (4) to the A2 port.
LEIL16WHL2744AB 7
8. Unplug and connect the following hoses to the electro-

hydraulic control valve:
• pilot accessory hose (1) to the 90° elbow on H2 port;
• pilot accessory hose (2) to the 90° elbow on F2 port;
• pilot raise/lower hose (3) to the fitting on D2 port;
• pilot accessory hose (4) to the 45° elbow on E2 port.
• pilot raise/lower hose (5) to the fitting on B2 port;
• pilot dump hose (6) to the 90° elbow on A2 port.
LEIL16WHL2743AB 8
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9. Apply to the pilot accessory hoses, pilot raise/lower

hoses and pilot dump hose the angle orientation shown
in figure 9.
LEIL16WHL2749AB 9
10. Connect the electrical PST connector (ref. front frame

harness) to the electro-hydraulic control valve.
LEIL16WHL2743AA 10
11. Connect all the electrical wires to the electro-hydraulic

control valve.
LEIL16WHL2742AA 11
12. Turn off the vacuum pump CAS10192. Disconnect

the vacuum pump CAS10192 from the hydraulic
reservoir.
14. Start the engine. Run the engine at low idle for 2 min.
15. Turn the engine OFF and check for hydraulic oil leaks.
16. Inspect the level of the hydraulic oil in the reservoir. If
the oil level is not to specification, add oil as required.
Tighten the filler cap on the hydraulic reservoir.
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Index

Electro-hydraulic control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electro-hydraulic control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Hydraulic fan drive cooling system - 752

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Contents
SERVICE
Cooling fan valves

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Hydraulic systems - Hydraulic fan drive cooling system
Cooling fan valves - Remove

parking brake.
draulic pressure, then move the joystick back and forth sev-
eral times to release any hydraulic pressure in the pilot con-
trol circuit.
3. Disconnect the electrical connectors (1) for the fan re-
versing valve.
NOTE: non reversing valves do not have an electrical con-
nection.
RCPH11WHL156BAR 1
4. Tag and disconnect the fan valve tubes (1), (2) from the
fan reversing valve. Install plugs in the hoses and a cap
the fittings.
RCPH11WHL158BAR 2
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5. Tag and disconnect the fan valve return hose (1) from
the fan reversing valve. Install a plug in the hose and
a cap on the fitting. Tag and disconnect the fan valve
supply hose (2) from the fan reversing valve. Install a
plug in the hose and a cap on the fitting.
RCPH11WHL157BAR 3
6. Loosen and remove the hold-down bolts (1).
RCPH11WHL157BAR 4
7. Remove the fan reversing valve from the machine.

8. Remove and discard all O-rings from the fittings.
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Cooling fan valves - Install

1. Install the hold-down bolts (1).
RCPH11WHL157BAR 1
2. Connect the fan valve return hose (1) to the fan revers-
ing valve. Connect the fan valve supply hose (2) to the
fan reversing valve.
RCPH11WHL157BAR 2
3. Connect the fan valve tubes (1), (2) to the fan reversing
valve.
RCPH11WHL158BAR 3
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4. Connect the electrical connectors (1) to the fan revers-

ing valve.
RCPH11WHL156BAR 4
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Index

Cooling fan valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooling fan valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Front loader arm hydraulic system - 701

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Contents
TECHNICAL DATA
Lift arm cylinder

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Accumulator
General specification - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special tools - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA
Lift arm cylinder

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Ride control solenoid valve block
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE
Front loader arm hydraulic system

Service instruction - Testing and adjusting the loader limit pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service instruction - Testing and adjusting the loader pump cutoff pressure . . . . . . . . . . . . . . . . . . . . . . . 11
Lift arm cylinder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remove - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Ride control solenoid valve block
Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Accumulator
Remove - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Install - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Discharging - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Charging - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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Hydraulic systems - Front loader arm hydraulic system
Lift arm cylinder - General specification

1021G
Lift cylinder weight 281 kg (619.5 lb)
1121G
Lift cylinder weight 295 kg (650.4 lb)
Lift arm cylinder - Torque

Gland bolts bucket cylinder 535 – 660 N·m (394.6 – 486.8 lb ft)
Screw in gland for lift cylinders 420 – 500 N·m (309.8 – 368.8 lb ft)
Lift arm cylinder - Special tools

Torque multiplier CAS-1039
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Accumulator - General specification - Ride control

Ride control accumulator dry nitrogen pressure See Accumulator - Charging - Ride control (35.701)
Ride control accumulator fluid capacity 3.78 L (1.00 US gal)
Ride control accumulator maximum operating pressure 280 bar (4060 psi)
Accumulator - Special tools - Ride control

380001737 Nitrogen accumulator charging kit
LEIL15WHL1061AA 1
380001738 Gland wrench
LEIL13WHL1359AA 2
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Lift arm cylinder - Exploded view
LEIL16WHL1940HB 1
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1. Tube 13. Rod

2. Bushing 14. Bolt
3. Wiper 15. Piston
4. Gland 16. Loader ring
5. Wiper 17. Ring
6. Rod cup seal 18. Wear ring
7. Bolt 19. Washer
8. Cylinder rod ring 20. Backup ring
9. Backup ring 21. Backup ring
10. O-ring 22. Backup ring
11. Piston seal 23. Rod buffer seal
12. O-ring
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Ride control solenoid valve block - Sectional view
LEIL15WHL1065GB 1
1. Plug 7. Spool
2. Cap screw 8. Plug
3. Bushing 9. Solenoid
4. Spring carrier 10. Orifice
5. Spring 11. Poppet
6. Spring 12. Orifice
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Front loader arm hydraulic system - Service instruction - Testing

and adjusting the loader limit pressure
Pressure check
LEIL13WHL1236AA 1
2. Connect a 345 bar (5002 psi) test gauge to the test port
(1), located on the priority valve.
LEIL16WHL1935AB 2

4. Run the engine at full throttle.
5. Roll the loader bucket back against the stops.
6. Record the reading on the test gauge.
7. Reading should be 248 – 255 bar (3596 – 3698 psi).
necessary to adjust the loader limit pressure.
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Adjusting the loader limit pressure

1. The limit adjusting screw is located on the left-hand side
of the main control valve. Turn the screw clockwise to
increase the limit pressure. Turning the screw counter-
clockwise will decrease the limit pressure.
LELI12WL30499AB 4
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Front loader arm hydraulic system - Service instruction - Testing

and adjusting the loader pump cutoff pressure
Pressure check
LEIL13WHL1236AA 1
2. Connect two 345 bar (5002 psi) test gauge to the test
port (1) located on the steering priority valve.
LEIL16WHL1936AB 2

4. Adjust the loader limit pressure to maximum value all
the way in.
5. Start the engine and run at full throttle.
6. Roll the loader bucket back against the stops.
7. Record the reading on the test gauge.
8. Reading should be 280 bar (4060 psi).
necessary to adjust the pump cutoff pressure.
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10. Adjust the loader limit pressure back to the correct

setting 248 – 255 bar (3596 – 3698 psi).
Adjusting the loader pump cutoff pressure

1. The unloading adjuster (1) is the longer of the two ad-
justers on the loader pump. Turn the screw clockwise to
increase the cutoff pressure. Turning the screw coun-
terclockwise will decrease the cutoff pressure.
NOTE: the adjusting screw is located just above the steer-
ing priority valve on the pump furthest from the transmis-
sion.
LELI12WL30901AB 4
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Lift arm cylinder - Remove

ing brake.
2. Relieve the pressure in the Ride control accumulator
with the manual bleeder valve located at the rear of the
front chassis.
lease any pressure. Connect a vacuum pump to the
hydraulic reservoir. Turn ON the pump.
4. Remove the four bolts (1) and the related washers that
secure the rod tube (2) to the lift cylinder.
LEIL15WHL1067AB 1
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5. Remove the four bolts (3) and the related washers that
secure the base tube (4) to the lift cylinder.
6. Remove the bolts (6), the washers (7), the nuts (8) and
the plate (9) to remove the tube mounting blocks (10).
7. Remove the eight bolts (11) with the related washers
to remove the splint flange clamps (13). Remove and
discard the O-rings (12).
8. Remove the rod tube (2) and the base tube (4). Re-
move and the discard the O-rings (5) of the rod tube
(2) and base tube (4). Plug the hoses.
LEIL16WHL1961BB 2
9. Loosen and remove the bolt, washer and spacer that

hold the pivot pin for the yoke.
LEIL16WHL1962AB 3
10. Use a proper lifting device and secure a strap around

the lift cylinder.
LEIL15WHL1068AA 4
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11. Remove the pivot pin from the yoke end of the lift
cylinder.
LEIL16WHL1963AB 5
hold the pivot pin at the closed end of the lift cylinder.
LEIL15WHL1069AA 6
13. Remove the pivot pin from the closed end of the lift
cylinder.
14. Remove the lift cylinder from the machine.
LEIL15WHL1070AA 7
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Lift arm cylinder - Install

1. Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.
2. Use a proper lifting device and position the lift cylinder
on the machine.
LEIL15WHL1068AA 1
3. Align the closed end of the lift cylinder with the front
frame and install the pivot pin.
LEIL15WHL1070AA 2
4. Align the pivot pin with the front frame and install the
spacer, washer and bolt. Tighten the bolt.
LEIL15WHL1069AA 3
5. Install the four bolts (1) to secure the rod tube (2) to the
lift cylinder. Install a new O-ring prior to securing the
rod tube (2).
LEIL15WHL1067AB 4
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6. Install the four bolts (3) and the related washers to se-
cure the base tube (4) to the lift cylinder.
Install a new O-ring (5) prior to securing the base tube
(4).
7. Install the eight bolts (11) with the related washers to
install the splint flange clamps (13) to the rod tube (2)
and base tube (4). Tighten the bolts (11) to 137 N·m
(101 lb ft) +/-10%.
Install new O-rings (12) in the rod tube (2) and base
tube (4) prior to installing the split flange clamps (13).
8. Install the bolts (6), the washers (7), the nuts (8) and
the plate (9) to install the tube mounting blocks (10).
9. If the yoke of the lift cylinder is not aligned with the
loader frame, have another person start and run the
engine at low idle and use the loader control lever to
SLOWLY move the yoke into alignment with the loader
frame.
LEIL16WHL1961BB 5
10. Install the pivot pin for the yoke. Stop the engine.
LEIL16WHL1963AB 6
11. Align the pivot pin with the yoke and install the spacer,
washer and bolt. Tighten the bolt.
12. SLOWLY extend and retract the piston rod three times
to remove any air from the lift cylinders.
13. Lubricate the pivot pins with moly disulfide grease.
14. Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the hydraulic
reservoir.
LEIL16WHL1962AB 7
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Lift arm cylinder - Disassemble

NOTE: for the numbering, refer to Lift arm cylinder - Exploded view (35.701).
1. Clean the exterior of the cylinder. If the hoses were
removed with the cylinder, remove the hoses from the
cylinder.
2. Fasten the tube (1) in an acceptable repair stand or
other holding equipment. Do not damage the tube (1).
3. Use a wrench to loosen and remove the eight bolts (7)
of the gland (4) from the tube (1).
4. Pull the piston rod (13) straight out of the tube (1) to
prevent damage to the tube.
5. Fasten the piston rod eye or yoke in a vise and put a
support under the piston rod (13) near the piston (15).
Put a shop cloth between the support and the piston
rod to prevent damage to piston rod.
6. Remove the bolt (14).
7. Remove the piston (15) from the piston rod (13).
8. Remove and discard the backup ring (21), the piston
seal (11), the loader ring (16), the ring (17), the wear
ring (18), the backup ring (20), and the O-ring (10) from
the piston (15).
9. Remove and discard the wiper (5), the rod cup seal
(6), the backup ring (22), the rod buffer seal (23), the
backup ring (9), the O-ring (12) and the cylinder rod ring
(8) from the gland (4).
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Lift arm cylinder - Inspect

NOTE: for numbering, refer to Lift arm cylinder - Exploded view (35.701).
1. Clean all parts in cleaning solvent. Use only lint free
cloths for cleaning and drying.
2. Check to be sure that the piston rod (13) is straight. If
the piston rod is not straight, replace it with a new piston
rod.
3. Shine a light inside the tube (1) and check for deep
grooves and other damage. If there is any damage to
the tube, replace with a new tube.
4. Remove any small scratches on the piston rod (13) or
inside the tube (1) with emery cloth of medium grit. Use
emery cloth with a rotary motion.
5. Inspect the bushing (2) in the tube eye. Replace as
required.
6. Inspect the gland (4) for rust. Clean and remove rust
as necessary.
7. Inspect the gland end of the tube (1) for sharp edges
that may cut the piston seal (11) and remove as neces-
sary.
8. Inspect the piston (15) for damage and wear. If the
piston is damaged or worn, replace with a new piston.
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Lift arm cylinder - Assemble

NOTE: for numbering, refer to Lift arm cylinder - Exploded view (35.701).
NOTE: if a new gland is being used, put the part number of the cylinder on the new gland.
1. Install the cylinder rod ring (8) in the gland (4).
2. Install the rod buffer seal (23) in the gland (4) so that
the rod buffer seal (23) lips point toward the cylinder
rod ring (8).
3. Install a new backup ring (22) in the groove of the rod
buffer seal (23) lips, inside the gland (4).
4. Install the rod cup seal (6) in the gland (4) so that the
rod cup seal (6) lips point toward the rod buffer seal
(23).
5. Install a new wiper (5) in the gland (4). The lips of the
wiper must be toward the outside end of the gland (4).
6. Install a new backup ring (9) in the groove on the outer
diameter of the gland (4). If both sides of the backup
ring are not flat, the side that is not flat must be toward
the small end of the gland (4).
7. Install a new O-ring (12) in the groove on the outer
diameter of the gland (4).
8. Fasten the piston rod (13) eye or yoke in vise.
9. Remove any marks and sharp edges on the chamfer
at the end of the piston rod (13). Make sure that the
piston rod is clean.
10. Lubricate the bore of the gland (4) and piston rod (13)
with clean oil.
11. Push the gland (4) onto the piston rod (13). If neces-
sary, use a soft hammer to drive the gland onto piston
rod.
12. Put a support below and near the end of the piston rod
(13). Use a shop cloth between the support and the
piston rod to prevent damage to the piston rod.
13. Install a new backup ring (20) in the inner groove of
the piston (15).
14. Install a new O-ring (10) next to the backup ring (20),
inside the piston (15).
15. Install a new backup ring (20) next to the O-ring (10),
inside the piston (15).
16. Start the piston (15) onto the piston rod (13) and install
the bolt (14) on the piston (15).
17. Install the loader ring (16) on the groove of the outer
diameter on the top of the piston (15).
18. Install the backup rings (21) on the grooves of the
loader ring (16).
19. Install the piston seal (11) on the top of the loader ring
(16) (between the backup rings (21)).
20. Install a new wear ring (18) in the wide groove on the
outside of the piston (15).
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21. Install a new ring (17) in the other groove on the out-
side of the piston (15). Pass the ring (17) through the
upper hole of the bolt (14).
other holding equipment. Be careful to prevent dam-
age to the tube.
23. Lubricate the inside of the tube (1) and piston (15) with
clean oil.
24. Push the piston (15) straight into the tube (1).
25. When the piston (15) is in the smooth part of the tube
(1), start the gland (4) into the tube (1).
26. Lubricate the O-ring (12) on the gland (4) with clean
oil.
27. Install the eight bolts (7) with the washers (19) to se-
cure the gland (4) to the tube (1). Tighten the bolts (7)
to 535 – 660 N·m (394.6 – 486.8 lb ft).
28. If the hoses were removed with the cylinder, install
new O-rings, if equipped, on the hose fittings. Lubri-
cate the O-rings with clean oil. Install the hoses.
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Lift arm cylinder - Remove - Bushing

1. Put the piston tube (3) in a press.
2. Use an acceptable driver to press the wipers (1) and
the bushing (2) out of the piston tube (3) eye.
3. Clean the bore for the bushing (2) in the tube (3) eye.
LEIL16WHL1960AB 1
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Lift arm cylinder - Install - Bushing

1. Use an acceptable driver to press a new bushing (2)
into the tube (3) eye. The bushing shall be recessed
10 mm (0.394 in) in the tube (3) eye.
2. Use an acceptable driver to install the wipers (1) until
flush with the tube (3) eye. The lips of the wipers (1)
must be toward the outside of the bore.
LEIL16WHL1960AB 1
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Ride control solenoid valve block - Bleed

WARNING
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.
Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect
fluids in proper containers. Obey all local and environmental regulations when disposing of chemi-
cals.
W0371A
WARNING
Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.
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
1. Park machine on a level surface and lower the bucket

to the ground. Put transmission in neutral, apply the
parking brake then turn off the engine.
LEIL16WHL1544AA 1
2. Apply the articulation locking blocks to prevent acciden-

tal articulation of the machine.
LEIL13WHL1236AA 2
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3. Locate the Ride control valve within the front frame

structure.
LEIL16WHL1937AA 3
4. Place a small container underneath the Ride control

valve to capture hydraulic fluid.
NOTE: hydraulic fluid will flow out of the Ride control valve
during the bleeding process.
5. Fill the hydraulic reservoir with correct hydraulic fluid.
6. Start the engine and cycle the lift arm without activating
the Ride control system. Turn off the engine.
NOTE: unintended lift arm movement may occur during this
procedure.
NOTE: do NOT activate the Ride control system until step
14.
Required repeated procedures

7. Verify that the hydraulic reservoir is at the correct level.
Add hydraulic fluid if necessary.
8. If hydraulic fluid was added, restart engine and cycle
the lift arms again, otherwise go to the next step.
LEIL15WHL0700AB 4
9. Lower the lift arms to lowest position and stop the en-
gine.
10. Remove the bleeder screw plug located on the right-
hand side of the Ride control valve.
11. With a proper tool, turn the Ride control valve bleeder
screw two turns counter clockwise to remove air and
fluid from the Ride control valve and line. Remove the
tool after opening the bleeder screw.
NOTE: pressurized air will escape. DO NOT retighten
bleeder screw at this time.
NOTE: some hydraulic fluid will flow out of the Ride control
valve.
LEIL16WHL1938AB 5
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12. Start engine and cycle the lift arms three times. Then,
lower the lift arms to the lowest position and stop the
engine. Turn the Ride control valve bleeder screw two
turns clockwise to close it. Torque the bleeder screw
to 3.5 N·m (31.0 lb in) +10%.
13. Repeat steps 7 through 12 THREE more times.
14. Install bleeder screw plug and torque to 5 N·m (44.3 lb
in) +/-10% (1).
LEIL15WHL1158AB 6
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Ride control solenoid valve block - Remove

ing brake.
2. Relieve the pressure in the Ride control accumulators
with the manual bleeder screw (2) of the Ride control
valve (1). Remove the plug and turn the valve two turns
counterclockwise.
4. Place the timed disconnect switch in the “OFF” position.
LEIL16WHL1964AB 1
5. Disconnect the electrical connector from the Ride con-

trol valve.
LEIL16WHL1939AB 2
6. Tag and disconnect the right-hand accumulator hose

(3) and the left-hand accumulator hose (4) from the
Ride control valve (1). Install a plug in the hoses and
caps on fittings.
7. Tag and disconnect the Ride control hoses (5) and (6)
from the Ride control valve (1). Install a plug in the
hoses and caps on fittings.
8. Tag and disconnect the Ride control tank hose (7) from
the Ride control valve (1). Install a plug in the hose and
caps on fittings.
LEIL16WHL1972AB 3
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9. Loosen and remove the three bolts (8) and washers (9)
that secure the Ride control valve (1).
10. Remove the Ride control valve (1) from the machine.
11. Remove and discard all O-rings.
LEIL16WHL1965AB 4
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Ride control solenoid valve block - Install

1. Install the Ride control valve (1) in position on the front
frame.
2. Install the washers (9) and bolts (8) to secure the Ride
control valve (1) to the relevant bracket. Tighten the
bolts (8).
LEIL16WHL1965AB 1
3. Tighten the bleeder screw (2) of the Ride control valve

(1) to a torque of 3.5 N·m (31 lb in). Install the plug and
LEIL16WHL1975AB 2
4. Lubricate and install new O-rings.

5. Connect the Ride control tank hose (7) to the Ride con-
trol valve (1).
6. Connect the Ride control hoses (5) and (6) to the Ride
control valve (1).
7. Connect the right-hand accumulator hose (3) and the
left-hand accumulator hose (4) to the Ride control valve
(1).
LEIL16WHL1972AB 3
8. Connect the electrical connector to the Ride control

valve.
LEIL16WHL1939AB 4
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draulic reservoir.
10. Place the timed disconnect switch in the “ON” position.
11. Start and run the engine at low idle for 2 min.
the Ride control valve.
reservoir.
14. Refer to Ride control solenoid valve block - Test
(35.701) and perform the “Ride control test” proce-
dure.
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Ride control solenoid valve block - Disassemble

NOTE: for numbering, refer to Ride control solenoid valve block - Sectional view (35.701).
1. Remove the Ride control valve, refer to Ride control
solenoid valve block - Remove (35.701).
2. Remove the plugs (1) and (8).
3. Remove the solenoid (9).
4. Remove the spool (7) from the valve block.
5. Remove the cap screw (2), the bushing (3), the spring
carrier (4), the springs (5) and (6) from the spool (7).
6. Remove the orifice (10), the poppet (11) and the orifice
(12).
7. Remove the accumulator drain screw.
8. Remove the pressure relief valve.
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Ride control solenoid valve block - Inspect

1. Discard all O-rings.
3. Check the spools and the spool bores for damage and
wear.
4. Check the parts of the pressure relief valve.
If any of the parts are damaged, install new parts.
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Ride control solenoid valve block - Assemble

NOTE: for numbering, refer to Ride control solenoid valve block - Sectional view (35.701).
1. Install new O-rings.
2. Install and torque the pressure relief valve to 50 N·m
(37 lb ft).
3. Install and torque the accumulator drain screw to
20 N·m (177 lb in).
4. Install and torque the orifice (12) to 15 N·m (11 lb ft),
install the poppet (11), install and torque the orifice (10)
to 15 N·m (11 lb ft).
5. Install and torque the solenoid valve (9) to 12 N·m
(106 lb in).
6. Install the springs (5) and (6), the spring carrier (4), the
bushing (3), the cap screw (2) onto the spool (7) and
torque the cap screw (2) to 23 N·m (204 lb in).
7. Install the spool (7) into the valve block.
8. Install and torque the plug (1) to 420 N·m (309.8 lb ft).
9. Install the plug (8) and torque to 330 N·m (243.4 lb ft).
10. Install the Ride control valve in the machine, see Ride
control solenoid valve block - Install (35.701) .
11. Test the Ride control system, see Ride control sole-
noid valve block - Test (35.701).
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Ride control solenoid valve block - Test

Not running machine
1. Move the machine to a clear level surface with clear-
ance for full lift arm and bucket movement.
2. Install the articulation lock, start the machine, activate
the parking brake.
LEIL15WHL1782AA 1
3. With the transmission in neutral, press the Ride con-

trol button on the multifunction keypad (right-hand side)
to activate the Ride control function. The button LED
should illuminate.
4. Press again the Ride control button to deactivate the
Ride control function. Observe the button LED, the
button LED should go out
NOTE: this indicates that the button is operating correctly
and has power.
LEIL16WHL1125AA 2
5. Raise the lift arms to the top of their travel and dump
the bucket.
6. Dump the bucket until it hits the dump stops. Hold the
bucket in the dump position for 5 – 10 s .
NOTE: this will charge the Ride control accumulator.
7. Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
their stops. Place the pilot control lever in the neutral
position.
8. Press the Ride control button to activate the Ride con-
trol function. The lift arms should rise 15 – 30 cm (5.9
– 11.8 in) with an empty bucket.
NOTE: test results will be for a machine with an empty
factory bucket and no attachments.
9. If there is little or no lift arm raise, the test may have
been done too slowly. The elapsed time between step
6 and step 8 should not exceed 6 s .
NOTE: if the test was done too slowly repeat in the allotted
time.
10. If test was completed in the allotted time and the lift
arms still do not rise, test the nitrogen charge in the
accumulator.
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Running machine
1. Move the machine to a clear level area with sufficient
space to accelerate the machine to 5 km/hr ( 3 mph)
for 30 seconds and stop.
3. Activate the Ride control. Press the Ride control button
to activate the Ride control function. The button LED
will not illuminate at this time.
LEIL16WHL1125AA 3
4. Raise the lift arms to near the top of their travel.

5. Rapidly dump the bucket until it hits the dump stops.
This will create a down force on the lift arms and they
should drop visibly. Repeat this process 2 or 3 times if
necessary.
NOTE: the oil displaced from the lift cylinders is used to
charge the Ride control accumulator.
their stops.
7. Accelerate the machine to at least 5 km/hr ( 3 mph).
At 5 km/hr ( 3 mph) the lift arms should raise a visible
amount, 102 – 635 mm ( 4 – 12 inches ) depending on
bucket and coupler weight. This is an indication that the
ride control is functioning. As the machine continues
to travel there should be visible cylinder movement in
response to the road conditions.
NOTE: with an empty bucket, cylinder travel will not exceed
25 mm ( 1 inch ).
8. With the machine traveling over 5 km/hr ( 3 mph)
check the LED on the Ride control button, it should be
illuminated.
9. Slow the machine down and observe the button LED.
The button LED should go out when the machine slows
below 5 km/hr ( 3 mph).
10. Stop the machine.
11. De-activate the Ride control with the button. Repeat
steps 5, 6 and 7.
This time there should be no visible raising of the lift
arms and the light should remain off. The quality of the
ride should be noticeably worse with the ride control
de-activated.
13. Stop the machine.
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Ride control solenoid valve block - Test

Static Ride control test
1. Move the machine to a clear level surface with clear-
ance for full lift arm and bucket movement. Put the
transmission in neutral, apply the parking brake. Turn
off the engine.
2. Start the engine. Put the transmission in neutral, and
activate the parking brake.
3. Place the pilot control lever in the neutral position.
trol. The green LED above the symbol will illuminate.
NOTE: the Ride control button is located in the multifunc-
tion keypad on the right-hand side, inside the cab.
LEIL16WHL0936AA 1
5. Use the keypad on the right-hand of the display to se-

lect the key to access to the “Machine service” screens.
LEIL16WHL0908AA 2
6. Use the keypad on the right-hand of the display to

select the key to switch to the “Calibration Settings”
screens.
LEIL16WHL0874AA 3
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7. Use the keypad on the right-hand of the display to se-

lect the “Ride Control Test”.
Conditions to be satisfied to start the Ride Control Test:
• Place Transmission in Neutral
• Turn On Parking Brake
8. Select “Start” to proceed with the Ride control test.
LEIL16WHL0903AA 4
9. “Ride Control Test is in Progress” and the Ride control

valve status are displayed.
Once the test is completed, select “Done” to exit
LEIL16WHL0904AA 5
10. Press the Ride control button in the multifunction key-

pad to deactivate the Ride control. The green LED will
turn off.
11. If the Ride control test fails, check the Ride control
system. If necessary service the Ride control system.
12. If test was completed in the allotted time and the lift
arms still do not rise, test the nitrogen charge in the
accumulator.
Dynamic Ride control test

2. Check for leaks. Remove the articulation lock from the
machine and lower the bucket to a carry position.
3. Move the machine to a clear level area with sufficient
space to accelerate the machine to 5 km/h (3 mph).
trol. The green LED above the symbol will illuminate.
LEIL16WHL0936AA 6
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5. Raise the lift arms to near the top of their travel.

6. Rapidly dump the bucket until it hits the dump stops.
This will create a down force on the lift arms and they
should drop visibly. Repeat this process 2 or 3 times if
necessary.
NOTE: the oil displaced from the lift cylinders is used to
charge the Ride control accumulator.
their stops.
8. Accelerate the machine to at least 5 km/h (3 mph).
At 5 km/h (3 mph) the lift arms should raise a visi-
ble amount, 10 – 305 mm (0.4 – 12 in) depending on
bucket and coupler weight. This indicates that the Ride
control is functioning. As the machine continues to
travel there should be visible cylinder movement in re-
sponse to the road conditions.
NOTE: with an empty bucket, the cylinder travel will not
exceed 25 mm (1.0 in)
9. Bring the machine to a safe stop.
10. Deactivate the Ride control by pressing the button, the
green LED will turn off. Repeat steps 5, 6 and 7.
This time there should be no visible raising of the lift
arms and the light should remain off. The quality of the
ride should be noticeably worse with the ride control
de-activated.
12. Bring the machine to a complete stop.
13. Check for hydraulic leaks.
14. Check the hydraulic oil level. Add more oil if needed.
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Accumulator - Remove - Ride control

ing brake.
2. Relieve the pressure in the Ride control accumulators
with the manual bleeder screw (2) of the Ride control
valve (1). Remove the plug and turn the valve two turns
counterclockwise.
LEIL16WHL1964AB 1
4. Tag and disconnect the accumulator hoses (3) from the

elbows at the top of the Ride control accumulators. In-
stall a plug in the hoses and a cap on the fittings.
LEIL16WHL1973AB 2
5. Loosen and remove the nuts (4) and washers (5) from
the U-bolts (6). Remove the U-bolts (6).
6. Remove the Ride control accumulators from the ma-
chine.
LEIL16WHL1974AB 3
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Accumulator - Install - Ride control

1. Place the Ride control accumulators in position on the
front frame.
2. Install the U-bolts (6), the washers (5) and the nuts (4).
Tighten the nuts (4).
LEIL16WHL1974AB 1
3. Remove the caps and plugs and install the accumulator

hoses (3) on the elbows at the top of the Ride control
accumulators.
4. Turn OFF and disconnect the vacuum pump from the
hydraulic reservoir.
LEIL16WHL1973AB 2
5. Tighten the accumulator manual bleeder screw (2)

located on the Ride control valve (1) to a torque of
3.5 N·m (31 lb in). Install the bleeder screw plug and
LEIL16WHL1964AB 3
6. Refer to Accumulator - Charging - Ride control

(35.701) for the proper charging of the accumulator to
check for leaks.
reservoir.
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Accumulator - Discharging - Ride control

The nitrogen charge on an accumulator
LELI12WL30967EB 1
1. Use the Nitrogen Charging Kit to discharge the accu-

mulator, refer to the illustration above. The tool must
be disconnected from the nitrogen tank.
2. Close valves B, C and D.
3. Adjust the regulator A to the minimum pressure setting
by turning the knob counterclockwise.
4. Turn the T-handle on valve F fully out.
5. Remove the guard and valve assembly cap from the
accumulator.
6. Connect valve F to the valve 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 and check the charge pressure on gauge
E.
9. To discharge the accumulator, partially open valve B.
The accumulator charge will bleed down through the
regulator.
10. Once the accumulator is fully discharged, disconnect
valve F from the valve stem.
11. The accumulator can now be disassembled.
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Accumulator - Charging - Ride control

Charging the accumulator with nitrogen
LEIL15WHL1062FB 1
1. Valve C 4. Valve B
2. To nitrogen tank 5. Valve D
3. Valve A 6. To accumulator
NOTICE: use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an explosion.
NOTICE: do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar (450 psi). If
the charging valve breaks away from the accumulator, the escaping nitrogen will propel the accumulator at a danger-
ous rate of speed.
NOTICE: do not expose the accumulator to temperatures above 49 °C (120 °F). A charged accumulator contains
nitrogen compressed to 31 bar (450 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.
NOTICE: the four valves must be in the positions noted in the procedure before connecting the Nitrogen Accumulator
Charging Kit to the machine or nitrogen, refer to Fig. 1.
NOTICE: to help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during high
pressure ( 10 bar (145 psi) and above) applications.
1. Close the shutoff valve A by turning it all the way to the
left (counterclockwise), refer to Fig. 1.
2. Open valve B by turning it out all the way to the left
(counterclockwise).
3. Close valve C by turning it all the way to the right (clock-
wise).
4. Close the gauge valve D by turning it all the way to the
right (clockwise).
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5. Connect the charging hose to the nitrogen supply tank.

6. SLOWLY turn valve A clockwise while watching the
high pressure gauge. Stop turning valve A when the
needle on the gauge reaches 31 bar (450 psi).
NOTE: if the needle goes over the needed pressure,
quickly open and close valve D and check the pressure
setting again.
The charging kit is now ready to be installed on the ac-
cumulator.
7. Remove the valve cap from the pressure valve on the
accumulator.
8. Back off the needle valve on the accumulator end of
the charging hose by turning i t counterclockwise to the
maximum amount. This prevents nitrogen from escap-
ing from the accumulator when the charging hose is
attached to the accumulator gas charging valve.
9. Install the charging hose fitting onto the accumulator
pressure valve.
10. Tighten the needle valve by turning it clockwise.
Slowly open the gauge valve D and observe the
reading on the gauge. This reading is the nitrogen
pressure level inside the accumulator.
11. Open the shutoff valve A on the nitrogen supply tank.
While observing the pressure on the gauge, slightly
open the needle valve on the accumulator charge
hose. By regulating the needle valve, fill the accu-
mulator to pressure according to temperature chart
below. Close the needle valve. Close the shutoff
valve A on the nitrogen supply tank.
Table 1
Temperature/Charge pressure ride control accumulator

Temperature Charge pressure
10 °C (50 °F) 1636 kPa (237 psi)
13 °C (55 °F) 1655 kPa (240 psi)
16 °C (61 °F) 1674 kPa (243 psi)
18 °C (64 °F) 1687 kPa (245 psi)
21 °C (70 °F) 1706 kPa (247 psi)
24 °C (75 °F) 1726 kPa (250 psi)
27 °C (81 °F) 1745 kPa (253 psi)
29 °C (84 °F) 1758 kPa (255 psi)
32 °C (90 °F) 1777 kPa (258 psi)
35 °C (95 °F) 1796 kPa (260 psi)
38 °C (100 °F) 1815 kPa (263 psi)
12. Close valve B by turning to the right (clockwise). After

a few minutes, check the accumulator for leakage.
13. Back off the needle valve on the accumulator end of
the charging hose by turning it counterclockwise the
maximum amount. This will prevent nitrogen from es-
caping from the accumulator as the hose is removed.
Remove the charging hose from the accumulator
pressure valve.
14. Install the valve cap onto the pressure valve on the
accumulator.
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15. Remove the charging hose from the nitrogen supply

tank.
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Index

Accumulator - Charging - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Accumulator - Discharging - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Accumulator - General specification - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Accumulator - Install - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Accumulator - Remove - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Accumulator - Special tools - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front loader arm hydraulic system - Service instruction - Testing and adjusting the loader limit pres-
sure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front loader arm hydraulic system - Service instruction - Testing and adjusting the loader pump
cutoff pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lift arm cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lift arm cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lift arm cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lift arm cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lift arm cylinder - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lift arm cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Lift arm cylinder - Install - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lift arm cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lift arm cylinder - Remove - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lift arm cylinder - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lift arm cylinder - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ride control solenoid valve block - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Ride control solenoid valve block - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Ride control solenoid valve block - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Ride control solenoid valve block - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Ride control solenoid valve block - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Ride control solenoid valve block - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Ride control solenoid valve block - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ride control solenoid valve block - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Ride control solenoid valve block - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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Front loader bucket hydraulic system - 723

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Contents
TECHNICAL DATA
Loader bucket control cylinder

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Hydraulic systems - Front loader bucket hydraulic system
Loader bucket control cylinder - General specification

1021G
Bucket cylinder Approximate weight: 290 kg (639.3 lb)
1121G
Bucket cylinder Approximate weight: 305 kg (672.4 lb)
Loader bucket control cylinder - Torque

Gland bolts bucket cylinder 535 – 660 N·m (394.6 – 486.8 lb ft)
Loader bucket control cylinder - Special tools

Torque multiplier CAS-1039
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Loader bucket control cylinder - Exploded view
LEIL16WHL2009HB 1
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1. Tube 13. Rod cup seal

2. Cap screw 14. Rod buffer seal
3. Gland 15. Backup ring
4. Piston rod 16. Loader ring
5. Piston wear ring 17. Wear ring
6. Piston seal 18. Washer
7. Piston 19. Rod wiper
8. Backup ring 20. Bushing
9. O-ring 21. O-ring
10. Retaining ring 22. Backup ring
11. Pin 23. Backup ring
12. Wiper rod seal
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Loader bucket control cylinder - Remove

ing brake.
uum pump to the hydraulic reservoir. Turn ON the
pump.
3. Remove the bolts (2) with the relevant washers. Dis-
connect the tube (1) from the bucket cylinder head.
4. Remove the four bolts (4) with the relevant washers.
Remove the two split flanges (5) and disconnect the
hose (3) from the left-hand side of the bucket cylinder.
Install a plug in the hose (3).
NOTE: remove and discard the O-rings of the hoses and
tubes of the bucket cylinder.
LEIL16WHL1997AB 1
5. Remove the two bolts (6), the washers (7) and the nuts
(8). Remove the plate (9) and the tube mounting block
(10).
6. Remove the four bolts (11) with the relevant washers.
Disconnect and remove the tube (1) from the bucket
cylinder hose of the right-hand side.
NOTE: remove and discard the O-rings of the hoses and
tubes of the bucket cylinder.
7. Remove the two bolts (12) with the relevant washers.
Remove the two-plate assembly (13) from the right-
hand side of the bucket cylinder.
LEIL16WHL1998AB 2
8. Use acceptable equipment to hold the bucket cylinder.

fasten the pivot pins to both ends of the bucket cylinder.
NOTE: it is not necessary to remove the grease line from
the pivot pin unless the pivot pin is to be replaced.
LEIL16WHL1999AB 3
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35.9 [35.723] / 6
10. Remove the pivot pin from the rod end of the bucket
cylinder.
LEIL16WHL2001AB 4
11. Remove the pivot pin from the head end of the bucket
cylinder.
NOTE: it is not necessary to remove the grease line from
the pivot pin unless the pivot pin is to be replaced.
LEIL13WHL1272AA 5
12. Raise the bucket cylinder and remove the cylinder

from the machine.
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Loader bucket control cylinder - Install

1. Apply antiseize compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.
2. Use acceptable lifting equipment to lower the bucket
cylinder into position.
3. Install the pivot pin to the head end of the bucket cylin-
der.
4. Install the spacer, washer and bolt that fasten the pivot
pin to the front frame. Tighten the bolt.
NOTE: if a new pivot pin is being installed, connect the
grease line to the pivot pin.
LEIL13WHL1272AA 1
5. Install the two-plate assembly (13) to the right-hand

side of the bucket cylinder. Install the two bolts (12)
with the relevant washers to secure the assembly (13)
to the bucket cylinder.
6. Connect the tube (1) to the bucket cylinder hose of
the right-hand side. Install the four bolts (11) with the
relevant washers to secure the tube (1).
NOTE: install a new O-ring at the end of the hose and tube.
7. Install the tube mounting block (10) and the plate (9) to
fasten the tube (1) together with the two-plate assembly
(13).
Install the two bolts (6), the washers (7) and the nuts LEIL16WHL1998AB 2
(8) to secure the tube (1) to the tube mounting block
(10) and the plate (9).
8. Install the four bolts (2) with the relevant washers to
secure the tube (1) to the bucket cylinder head.
9. Connect the hose (3) to the left-hand side of the bucket
cylinder. Install the two split flanges (5) and the four
bolts (4) with the relevant washers to secure the hose
(3) to the bucket cylinder.
NOTE: install new O-rings at the ends of the hose (3) and
tube (1).
LEIL16WHL1997AB 3
10. If the rod end of the bucket cylinder is not aligned with
the bellcrank, have another person start the engine
and run the engine at low idle and use the bucket
control lever to SLOWLY move the piston rod eye into
alignment with the bellcrank.
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11. Install the pivot pin to fasten the rod end of the bucket
cylinder to the bellcrank. Stop the engine.
LEIL16WHL2001AB 4
12. Install the spacer, washer and bolt that fasten the pivot
pin to the bellcrank. Tighten the bolt.
NOTE: if a new pivot pin is being installed, connect the
grease line to the pivot pin.
LEIL16WHL1999AB 5
13. Start and run the engine at low idle.

14. SLOWLY extend and retract the piston rod three times
to remove any air from the bucket cylinder.
15. Lubricate the pivot pins with moly disulfde grease.
reservoir.
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Loader bucket control cylinder - Disassemble

1. Clean the outside of the cylinder. If the hoses were
removed with the cylinder, remove the hoses from the
cylinder.
NOTE: for numbering, refer to Loader bucket control
cylinder - Exploded view (35.723).
other holding equipment. Do not damage the tube (1).
3. Loosen and remove the cap screws (2) and hardened
washers (18) from the gland (3) and the tube (1).
4. Pull the piston rod (4) straight out of the tube (1) to
prevent damage to the tube (1).
5. Fasten the piston rod eye or yoke in a vise and put a
support under the piston rod (4) near the piston (7). Put
a shop cloth between the support and the piston rod (4)
to prevent damage to the piston rod (4).
6. Remove the retaining ring (10) that fastens the pin (11)
in the piston (7) and piston rod (4).
7. Remove the pin (11) from the piston (7) and the piston
rod (4).
8. Turn the piston (7) off the piston rod (4) and remove the
piston (7).
9. Remove the gland (3) from the piston rod (4).
10. Remove the backup rings (15), the piston seal (6) and
the loader ring (16) from the outside diameter of the
piston (7).
11. Remove the wear ring (5) from the outside diameter
of the piston (7).
12. Remove the backup rings (8) and the O-ring (9) from
the inside diameter of the piston (7).
13. Remove the O-ring (21) and the backup ring (22) from
the outside diameter of the gland (3).
14. Remove the wiper rod seal (12), the rod cup seal (13),
the backup ring (23), the rod buffer seal (14) and the
wear ring (17) from the inside diameter of the gland
(3).
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Loader bucket control cylinder - Inspect

1. Discard the parts that were removed from the piston
and the gland.
2. Clean all parts in cleaning solvent. Use only lint free
cloths for cleaning and drying.
3. Check to be sure that the piston rod is straight. If the
piston rod is not straight, replace it with a new piston
rod.
4. Illuminate the inside of the tube for deep grooves and
other damage. If there is any damage to the tube, re-
place it with a new tube.
5. Remove any small scratches on the piston rod or in-
side the tube with emery cloth of medium grit. Use the
emery cloth with a rotary motion.
6. Inspect the bushings in the piston rod eye or yoke and
the tube. Replace as required.
7. Inspect the gland for rust and clean and remove rust as
necessary.
8. Inspect the gland end of the tube for sharp edges that
will cut the gland O-ring and remove as necessary.
9. Inspect the piston for damage and wear. If the piston is
damaged or worn, replace it with a new piston.
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Loader bucket control cylinder - Assemble

NOTE: for numbering, refer to Loader bucket control cylinder - Exploded view (35.723).
NOTE: if a new gland is being used, put the part number of the cylinder on the new gland.
1. Install the wear ring (17) in the gland (3).
2. Install the rod buffer seal (14) in the gland (3) so that
the rod buffer seal (14) lips point toward the wear ring
(17).
3. Install a new backup ring (23) in the groove of the rod
buffer seal (14) lips, inside the gland (3).
4. Install the rod cup seal (13) in the gland (3) so that the
rod cup seal (13) lips point toward the rod buffer seal
(14).
5. Install a new wiper rod seal (12) in the gland (3). The
lips of the wiper rod seal must be toward the outside
end of the gland (3).
6. Install a new backup ring (22) in the groove on the out-
side of the gland (3). If both sides of the backup ring
(22) are not flat, the side that is not flat must be toward
the small end of the gland (3).
7. Install the O-ring (21) next to the backup ring (22) in the
groove on the outside of the gland (3).
8. Remove any marks and sharp edges on the chamfer at
the end of the piston rod (4). Make sure that the piston
rod (4) is clean.
9. Lubricate the bore of the gland (3) and the piston rod
(4) with clean oil.
10. Push the gland (3) onto the piston rod (4). If neces-
sary, use a soft hammer to drive the gland (3) onto the
piston rod (4).
11. Put a support below and near the end of the piston
rod (4). Use a shop cloth between the support and
the piston rod (4) to prevent damage to the piston rod
(4).
12. Install a new backup ring (8) in the groove in the inside
diameter of the piston (7).
13. Install a new O-ring (9) in the groove in the inside
diameter of the piston (7) next to the backup ring (8).
14. Install the other new backup ring (8) in the groove in
the inside diameter of the piston (7) next to the O-ring
(9). If both sides of the backup ring (8) are not flat, the
side that is not flat must be toward the O-ring (9).
15. Lubricate the inside diameter of the piston (7) with
clean oil.
16. Start the piston (7) onto the piston rod (4). Turn the
piston (7) onto the piston rod (4) until the piston (7) is
seated against the shoulder of the piston rod (4).
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17. If none of the holes in the piston (7) align with the holes
in the piston rod (4), turn the piston (7) counterclock-
wise until one of the holes in the piston (7) aligns with
one of holes in the piston rod (4). Do not turn the pis-
ton (7) more than 90°.
18. Install the pin (11) in the piston (7) and the piston rod
(4).
19. Install the retaining ring (10) in the pin (11).
20. Install the loader ring (16) on the groove of the outer
diameter on the top of the piston (7).
LEIL13WHL1353AB 1
21. Install the backup rings (15) on the grooves of the

loader ring (16).
22. Install the piston seal (6) on the top of the loader ring
(16) (between the backup rings (15)).
23. Install a new piston wear ring (5) in the wide groove
on the outside diameter of the piston (7).
other holding equipment. Be careful to prevent dam-
age to the tube (1).
25. Lubricate the inside of the tube (1) and the outside of
the piston (7) with clean oil.
26. Push the piston (7) straight into the tube (1).
27. Lubricate the O-ring (21) on the gland (3) with clean
oil.
28. Push the gland into the tube (1) and align the holes in
the tube (1).
29. Install the cap screws (2) and the washers (18).
30. Tighten the cap screws (2) in the sequence shown.
Torque to 535 – 660 N·m (395 – 487 lb ft).
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Loader bucket control cylinder - Remove - Bushing

1. Put the piston rod eye (3) in a press.
2. Use an acceptable driver to press the wipers (1) and
the bushing (2) out of the piston rod eye (3).
3. Put the tube (4) in a press.
4. Use an acceptable driver to press the bushing (2) out
of tube (4) eye.
5. Clean the bore for the bushings (2) in the piston rod eye
(3) and the tube (4) eye.
LEIL16WHL2014BB 1
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Loader bucket control cylinder - Install - Bushing

1. Use an acceptable driver to press a new bushing
(2) into the piston rod eye (3) until recessed 10 mm
(0.394 in).
2. Use an acceptable driver to install the wipers (1) until
flush with the piston rod eye (3). The lips of the wipers
(1) must be towards outside of the bore.
3. Use an acceptable driver to press a new bushing (2)
into the tube (4) eye until recessed 10 mm (0.394 in).
4. Use an acceptable driver to install wipers (1) until flush
with tube (4) eye. The lips of the wipers (1) must be
towards outside of the bore.
LEIL16WHL2014BB 1
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Index

Loader bucket control cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Loader bucket control cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Loader bucket control cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Loader bucket control cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Loader bucket control cylinder - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Loader bucket control cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Loader bucket control cylinder - Install - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Loader bucket control cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Loader bucket control cylinder - Remove - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Loader bucket control cylinder - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Loader bucket control cylinder - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN ITALY
48083742_EN 31/07/2018
EN
SERVICE MANUAL
Frames and ballasting

48083742_EN 31/07/2018
39
Contents
Frames and ballasting - 39
[39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
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39
Frame - 100

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39.1 [39.100] / 1
Contents
Frame - 100
TECHNICAL DATA
Articulation frame pivot

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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39.1 [39.100] / 2
Frames and ballasting - Frame
Articulation frame pivot - Special tools

5870 287 007 Hand pump
CAS10193 Vacuum pump ( 12 volt)
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39.1 [39.100] / 3
Articulation frame pivot - Exploded view
LEIL15WHL0766GB 1
Articulation frame pivot assembly
R. Rear chassis
W. Upper plate of the front chassis upper joint
X. Lower plate of the front chassis upper joint
Y. Lower plate of the front chassis lower joint
Z. Upper plate of the front chassis lower joint
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39.1 [39.100] / 4
1. Upper pivot pin (Quantity 1) 17. Shim (upper articulation joint) (Quantity as required)
2. Lower pivot pin (Quantity 1) 18. Shim (upper articulation joint) (Quantity as required)
3. Lower pivot bearing (Quantity 1) 19. Shim (upper articulation) (Quantity as required)
4. Lower bearing spacer (Quantity 1) 20. Shim (lower articulation) (Quantity as required)
5. Lower bearing retainer (Quantity 1) 21. Shim (lower articulation) (Quantity as required)
6. Lower bearing spacer (Quantity 1) 22. Shim (lower articulation) (Quantity as required)
7. Lower pin plate (Quantity 1) 23. Washer 22x37x4 mm (Quantity 6)
8. Upper pivot bearing (Quantity 1) 24. Washer 26x44x5 mm (Quantity 3)
9. Upper bearing retainer (Quantity 1) 25. Washer 17.5x34x5 mm (Quantity 8)
10. Lower pivot seal (Quantity 1) 26. Linkage pin spacer (Quantity 1)
11. Lower pivot seal (Quantity 1) 27. Washer (Quantity 1)
12. Lower pivot seal (Quantity 1) 28. Bolt M20x50 (Quantity 7)
13. Lower pivot seal (Quantity 1) 29. Screw M24x100 (Quantity 3)
14. Shim (lower articulation joint) (Quantity as required) 30. Bolt M16x130 (Quantity 4)
15. Shim (upper articulation joint) (Quantity as required) 31. Bolt M16x100 (Quantity 4)
16. Shim (lower articulation joint) (Quantity as required)
NOTE: * Apply LOCTITE® 243™
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39.1 [39.100] / 5
Articulation frame pivot - Remove

Preparation
1. Remove all dirt and grease from the area of the center
pivot. Park the machine on a level surface.
2. Lower the bucket until the bucket is flat on the floor.
4. Remove the covers from both sides of the machine.
5. Disconnect the front wiring harness from the cab floor.
6. Remove any tie straps that fasten the front wiring har-
ness to the chassis near the center pivot.
7. Loosen and remove the nut and washer that fasten the
chassis ground wire and cab ground wire to the studs.
8. Loosen and remove the bolt, lock washer, and nut that
fasten the clamp on the front wiring harness to the
bracket on the rear frame. Move the front wiring har-
ness out of the way.
9. Loosen and remove the fill cap for the hydraulic reser-
voir.
10. Connect the vacuum pump CAS10193 to the hy-
draulic reservoir.
11. Disconnect the brake hose from the backside of front
brake line bracket.
12. Install a plug in the tube and a cap on the fitting.
13. Disconnect the hoses for the steering cylinder.
14. Install caps on the fittings and plugs in the hoses.
15. Loosen and remove the bolts, lock washers, and self-
locking nuts that fasten the mounting bracket for the
hoses to the bracket on the front frame.
16. Loosen and remove the bolts, flat washers, and self-
locking nuts that fasten the bracket for the hoses to
the rear frame.
17. Disconnect the return hose.
18. Install the cap on the hose and a plug in the fitting.
19. Disconnect the supply hose.
20. Install a cap on the hose and a plug in the fitting.
22. Loosen and remove the self-locking nut and bolt that
hold the pivot pin for the steering cylinder rod eye.
23. Remove the pivot pin from the rear frame and the
steering cylinder rod eye.
24. Remove the washer from the rear frame. Move the
steering cylinder out of the way.
25. Repeat steps for the other steering cylinder.
26. Loosen and remove the Ferry head screws and retain-
ers that fasten the drive shaft to the front yoke. Move
the drive shaft out of the way.
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39.1 [39.100] / 6
27. Place two stands below and in contact with the front
frame.
28. Install blocks between the rear axle and the rear frame
on both sides of the machine to prevent the rear frame
from tipping.
29. Put a jack in contact with both sides of the rear frame
near the center pivot area. Use another jack at the
rear of the machine to prevent the rear frame from
tipping.
Upper pivot pin removal

NOTE: for the numbering, refer to Articulation frame pivot - Exploded view (39.100).
30. Loosen and remove the bolt (28), the washer (27), and
the spacer (26) that fasten the upper pivot pin (1) to
the upper plate of front chassis upper joint (W).
31. Use a pry-bar to remove the upper pivot pin (1).
Lower pivot pin removal

32. Loosen and remove the bolts (28) and (29), and the
washers (23) and (24) that fasten the lower pin plate
(7) to the lower pivot pin (2).
33. Use the ram and the hand pump to remove the lower
pivot pin (2) from the lower plate of the front chassis
lower joint (Y).
34. Install the puller on the spacer (6). Remove the spacer
(6).
35. Release the parking brake.
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39.1 [39.100] / 7
Articulation frame pivot - Disassemble

1. Remove the articulation frame pivot (upper and lower).
Refer to Articulation frame pivot - Remove (39.100).
2. Use a pry-bars to turn the left-hand rear wheel back-
wards and the right-hand rear wheel forward to move
the front of the rear frame to the left-hand for access to
the bearings.
3. Install blocks under the wheels to prevent the rear
frame from moving.
Lower bearing removal

5. Hold the bearing retainer (5) in place and remove the
bolts (30) and the washers (25) that fasten the bearing
retainer (5) and the shims to the bottom of the rear
pivot.
6. Remove the bearing retainer (5) and the shims.
7. Remove the lower bearing spacer (4) from the top of
the lower pivot.
8. Use a suitable puller, the hydraulic ram, and the hand
pump 5870 287 007 to remove the lower pivot bearing
(3) from the bottom pivot.
NOTE: the spacers are matched to the bearing sets. Do
not mix the spacers. Do not use the old spacers if new
bearing sets are being installed.
9. Use an acceptable driver to press the seals (10) and
(11) out of bearing retainer (5).
Upper bearing removal

10. Loosen and remove the bolts (31) and the washers
(25) that fasten the bearing retainer (9) and the shims
to the top of the top pivot.
11. Remove the bearing retainer (9) and the shims.
12. Use an acceptable driver, the hydraulic ram, and the
hand pump to remove the upper pivot bearing (8) from
the top pivot.
NOTE: the spacers are matched to the bearing sets. Do
not mix the spacers. Do not use the old spacers if new
bearing sets are being installed.
13. Use an acceptable driver to press the seals (12) and
(13) out of bearing retainer (9).
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39.1 [39.100] / 8
Articulation frame pivot - Assemble

Upper bearing assemble
1. Lubricate the bore in the upper pivot with grease.
2. Press one cup (A) into the bore (wide edge of cup first).
3. Install the spacer (B) and the two bearing cones (C)
packed with grease. Be careful not to mix the bearing
cones.
4. Press the remaining bearing cup (A) into the bore (thin
edge of cup first), until seated in the spacer (B).
NOTE: the spacer is matched with each two bearing sets.
Do not switch the spacers.
LEIL15WHL0767AB 1
5. Install the bearing retainer plate (9), pulling the retainer

plate tight against the bearings.
6. Measure the gap (D) between the bearing retainer plate
(9) and the upper pivot plate.
Make a record of the measurement.
Subtract 0.076 – 0.102 mm (0.003 – 0.004 in) from the
measurement.
Select shims (17), (18), or (19) equal to that value.
7. Install the shims, the bearing retainer plate (9), the
washers (25) and the bolts (31).
Apply one drop of 15W40 engine oil to each bolts.
Tighten the bolts (31) to 224 – 278 N·m (165.2 –
205.0 lb ft).
8. Install the seal (13) in the bearing retainer (9).
The top of the seal (13) must be even with the top of
the bearing retainer (9).
LEIL13WHL1080AA 2
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39.1 [39.100] / 9

The bottom of the seal (13) must be even with the bot-
tom of the bearing retainer (9).
NOTE: with both seal cavities (S) toward the bearing cavity,
the seals are forced out when the lubricant is applied.
Do not press seals past flush location, seals could be dam-
aged by the bearings.
10. Grease the outer diameter of the upper pivot pin (1)
and install it.
11. Lubricate the bearings until lubricant is forced out the
lower seal (12).
LEIL13WHL1081AA 3
12. Check the installation rotating the upper pivot pin by
hand (pin must rotate smooth but hard). Remove the
upper pivot pin (1) just before front frame and rear
frame are assembled together.
Lower bearing assemble

1. Lubricate the bore in the lower pivot with grease.
2. Press one cup (A) into the bore (wide edge of cup first).
3. Install the spacer (B) and the two bearing cones (C)
packed with grease.
Be careful not to mix the bearing cones.
4. Press the remaining bearing cup (A) into the bore (thin
edge of cup first), until seated in the spacer (B).
NOTE: the spacer is matched with each two bearing sets.
Do not switch the spacers.
5. Install the bearing retainer plate (5), pulling the retainer
plate tight against the bearings. LEIL15WHL0768AB 4
6. Measure the gap (D) between the bearing retainer plate

(5) and the upper pivot plate.
Subtract 0.076 – 0.102 mm (0.003 – 0.004 in) from the
measurement.
7. Install the shims, the bearing retainer plate (5), the
washers (25) and the bolts (30).
Apply one drop of 15W40 engine oil to each bolts.
205.0 lb ft).
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39.1 [39.100] / 10
8. Install the seal (11) in the bearing retainer (5). The

bottom of the seal (11) must be even with the bottom of
LEIL13WHL1081AA 5

The top of the seal (10) must be even with the top of
NOTE: with both seal cavities (S) toward the bearing cavity,
the seals are forced out when the lubricant is applied.
Do not press the seals after the installation. The seals
could be damaged by bearings.
10. Grease the outer diameter of the lower pivot pin (2)
and install it.
11. Lubricate the bearings until lubricant is forced out the
lower seal (11).
LEIL13WHL1080AA 6
12. Check the installation rotating the lower pivot pin by
hand (pin must rotate smooth but hard).
Remove the lower pivot pin (2) and the spacer (6)
just before front frame and rear frame are assembled
together.
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39.1 [39.100] / 11
Articulation frame pivot - Install

Connecting the front frame to the rear frame
1. Release the parking brake.
2. Use a suitable hoisting equipment and move the rear
frame into alignment with the front frame.
3. Move the steering cylinders as required to move the
rear frame into alignment with the front frame.
Upper pivot pin installation

5. Apply grease to the upper pivot pin (1).
6. Install the upper pivot pin (1), the spacer (26), the
washer (27), and the bolt (28). Be careful not to dam-
age the seal (13).
Apply on drop of 15W40 engine oil to the bolt.
Tighten the bolt (28) to 404 – 448 N·m (298.0 – 330.4 lb
ft).
Lower pivot pin installation

7. Apply grease to the lower pivot pin (2) and install it from
top, down through the frame articulation plates (Y) and
(Z).
8. Install the spacer (6) sliding through the lower plate of
the front chassis lower joint (Y) until the spacer (6) is in
contact with the bearing (3).
9. Install the retainer plate (7) to the lower pivot pin (2),
using three inner screws (29).
Tighten the screws (29) to 69 N·m (51 lb ft).
10. Measure the gap (G) between the lower plate (Y) and
the bottom of the lower pivot pin (2).
Subtract 0.0762 – 0.1016 mm (0.003 – 0.004 in) from
the measurement.
LEIL15WHL0769AB 1
11. Loosen the inner screws (29).
12. Install the shims, the washers (23), and the outer bolts
(28). Apply one drop of 15W40 engine oil to each bolt.
330.4 lb ft).
13. Remove the inner screws (29).
Apply one drop of LOCTITE® 243™ to each screw.
Tighten the screws (29) to 603 – 752 N·m (444 –
554 lb ft).
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39.1 [39.100] / 12
Final steps
14. Remove the jacks from the rear frame.
15. Remove the blocks from the rear axle.
16. Remove the stands from the front frame.
17. Put the drive shaft in position on the front yoke. (Refer
to Cardan Shaft - Install)
18. Install the steering cylinders. (Refer to Steering cylin-
der - Install (41.216))
19. Start the vacuum pump.
20. Connect the return hose.
21. Connect the supply hose.
22. Put the bracket for the hoses in position on the rear
frame. Install the bolts, flat washers, and self-locking
nuts that fasten the bracket to the rear frame.
23. Put the bracket for the hoses in position on the front
frame.
24. Install the bolts, flat washers, and self-locking nuts
that fasten the bracket to the front frame.
25. Connect the hoses for the steering cylinders.
26. Connect the brake hose for the front brakes at the front
bracket.
28. Connect the front wiring harness to the rear wiring
harness.
29. Put the clamp on the wiring harness in position on
the bracket. Install the bolt, lock washer, and nut that
fasten the clamp on the wiring harness to the bracket.
30. Put the ground wire in position on the stud. Install the
washer and nut that fasten the ground wire to the stud.
31. Install a tie strap to fasten the wiring harness to the
tube.
32. Disconnect the vacuum pump from the hydraulic
reservoir.
33. Check the fluid level in the hydraulic reservoir. Add oil
as required.
34. Install the fill cap in the hydraulic reservoir.
35. Bleed air from the front axle bleed screws.
36. Lubricate the pivot pins for the steering cylinder rod
eyes.
37. Install the covers on both sides of the machine.
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39.1 [39.100] / 13
Index
Frame - 100
Articulation frame pivot - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Articulation frame pivot - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Articulation frame pivot - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Articulation frame pivot - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Articulation frame pivot - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Articulation frame pivot - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN ITALY
48083742_EN 31/07/2018
EN
SERVICE MANUAL
Steering

48083742_EN 31/07/2018
41
Contents
Steering - 41
[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1
[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2
[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3
[41.910] Auxiliary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4
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41
Steering - 41
Steering control - 101

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41.1 [41.101] / 1
Contents
Steering - 41
SERVICE
Steering column
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
48083742_EN 31/07/2018
41.1 [41.101] / 2
Steering - Steering control
Steering column - Remove

1. Remove the floor mat (1).
LEIL18WHL0318AB 1
2. Remove the emblem plug (1).
LEIL18WHL0270AB 2
3. Unscrew the nut (1) with the relevant washer (2), and
remove the steering wheel (3).
LEIL18WHL0311AB 3
48083742_EN 31/07/2018
41.1 [41.101] / 3
4. Remove the four screws (1) that fix the top steering
column cover (2) to the left-hand and right-hand upper
steering column covers (3) and (4).
LEIL18WHL0312AB 4
LEIL18WHL0313AB 5
5. Remove the four screws (1) that hold the right-hand

upper steering column cover (2) to the left-hand upper
steering column cover. Remove the right-hand upper
steering column cover (2) from the machine.
LEIL18WHL0314AB 6
LEIL18WHL0315AB 7
48083742_EN 31/07/2018
41.1 [41.101] / 4
6. Remove the two screws (1) that hold the left-hand

upper steering column cover (2) to steering column
bracket.
LEIL18WHL0316AB 8
7. Disconnect the connector X-S_HZD (Receptacle) (2)

from the flasher switch.
Disconnect the connector X-TT (Receptacle) (3) from
the lamp indicator console.
Disconnect the connector X-SRWP (Receptacle) (4)
from the rear wiper switch.
Remove the two screws (1). Remove the top steering
column cover (5) from the machine.
LEIL18WHL0317AB 9
8. Remove the three screws (1) to remove the right-hand

lower steering column cover (2).
LEIL18WHL0326AB 10
9. Remove the two screws (1) to remove the (2) the left-
hand lower steering column cover (2).
LEIL18WHL0327AB 11
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41.1 [41.101] / 5
10. Remove the eight screws (1) that fix the top front con-
sole (2). Remove the top front console (2) from the
machine.
LEIL18WHL0319AB 12
11. Disconnect the connector X-PED_2 (Plug) (1) from

the connector X-CAB_P2 (Receptacle) of the main
cab harness.
Disconnect the connector X-PED (Receptacle) (2)
from the connector X-CAB_P (Plug) of the main cab
harness.
Cut the cable tie (arrow).
LEIL18WHL0320AB 13
12. Disconnect the connector X-TS2 (Receptacle) (3)

and the connector X-GND_PED (Plug) (2).
Loosen the screw (1) to remove the transmission con-
trol lever (4).
LEIL18WHL0322AB 14
13. Disconnect the connector X-STLK (Receptacle) from

the right-hand multifunction lever (2).
Unscrew the three screws (1) to remove the multifunc-
tion lever (3).
LEIL18WHL0323AB 15
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14. Loosen and remove the bolts washers, and nuts that
fasten the right-hand rear cab skirt (1), the right-hand
cab skirt (2) and the center cab skirt (3) to have access
to the steering control valve bracket.
LEIL16WHL1189FB 16
15. Remove the four nuts (1) with the eight washers (un-
der bolt head and nut) and the four bolts to sepa-
rate the steering valve bracket (2) from the cab frame
steering column assembly (3).
Disengage the steering control valve (4) from the
steering shaft.
Remove the steering column (with the pedestal har-
ness) from the machine.
NOTE: the cab floor is NOT shown, for clarity.
LEIL18WHL0328AB 17
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16. Remove the ground strap (1) unscrewing the two fix-
ing screws and related washers.
Separate the connector X-TERM (Receptacle) from
the steering column (5).
Remove the three clamp (3).
Separate the pedestal harness (4) from the steering
column (5).
LEIL18WHL0324BB 18
LEIL18WHL0325BA 19
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Steering column - Install

1. Install the ground strap (1) on the steering column (5)
with two fixing screws.
Install the three clamp (3) to joint the pedestal harness
(4) to the steering column (5).
Fix the connector X-TERM (Receptacle) to the steer-
ing column (5).
LEIL18WHL0324BB 1
2. Engage the steering control valve (4) into the steering

shaft.
Tighten the four nuts (1) with the eight washers (under
bolt head and nut) and the four bolts to fasten the steer-
ing valve bracket (2) to the cab frame steering column
assembly (3).
NOTE: the cab floor is NOT shown, for clarity.
LEIL18WHL0328AB 2
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3. Install the bolts, washers, and nuts to mount the right-

hand rear cab skirt (1), the right-hand cab skirt (2) and
the center cab skirt (3) on the cab.
LEIL16WHL1189FB 3
4. Install the multifunction lever (3) with the three screws

(1).
Connect the connector X-STLK (Receptacle) (2) to the
right-hand multifunction lever (3).
LEIL18WHL0323AB 4
5. Install the transmission control lever (4) with the screw

(1).
Connect the connector X-TS2 (Receptacle) (3) and the
connector X-GND_PED (Plug) (2).
LEIL18WHL0322AB 5
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6. Connect the connector X-PED (Receptacle) (2) of the

pedestal harness to the connector X-CAB_P (Plug) of
the main cab harness.
Connect the connector X-PED_2 (Plug) (1) of the
pedestal harness to the connector X-CAB_P2 (Re-
ceptacle) of the main cab harness.
Install a new cable tie (arrow).
LEIL18WHL0320AB 6
7. Place the top front console (2) in the correct position.

Tighten the eight screws (1) to fix the top front console
(2).
LEIL18WHL0319AB 7
8. Install the top steering column cover (5) with the two
screws (1).
Connect the connector X-S_HZD (Receptacle) (2) to
the flasher switch.
Connect the connector X-TT (Receptacle) (3) to the
lamp indicator console.
Connect the connector X-SRWP (Receptacle) (4) to
the rear wiper switch.
LEIL18WHL0317AB 8
9. Install the left-hand lower steering column cover (2) to

the steering column bracket. Tighten the two screws
(1).
LEIL18WHL0327AB 9
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10. Install the right-hand lower steering column cover (2).

Tighten the three screws (1).
LEIL18WHL0326AB 10
11. Install the left-hand upper steering column cover (2) to

steering column bracket. Tighten the two screws (1).
LEIL18WHL0316AB 11
12. Install the right-hand upper steering column cover (2).

Tighten the four screws (1).
LEIL18WHL0314AB 12
LEIL18WHL0315AB 13
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13. Tighten the four screws (1) to fix the top steering col-
umn cover (2) to the left-hand and right-hand upper
steering column cover (3) and (4).
LEIL18WHL0312AB 14
LEIL18WHL0313AB 15
14. Install the steering wheel (3). Tighten the nut (1), with
the relevant washer (2), to 43.0 – 57.0 N·m (31.7 –
42.0 lb ft).
15. Install the emblem plug (1).
LEIL18WHL0270AB 16
16. Place the floor mat (1) in the cab.
LEIL18WHL0318AB 17
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Index
Steering - 41

Steering column - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Steering column - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Steering - 41
Hydraulic control components - 200

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Contents
Steering - 41
TECHNICAL DATA
Hydraulic control components

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Hydraulic steering system

Component identification - Standard steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component identification - Standard steering with JSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Component identification - Steering system with Auxiliary Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Component identification - Steering system with Auxiliary Steering and JSS . . . . . . . . . . . . . . . . . . . . . . 22
SERVICE
Hydraulic steering system

Remove - Steering EHPS and cut-off valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install - Steering EHPS and cut-off valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Adjust - Joystick Steering System (JSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Steering valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Main priority valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Steering circuit relief valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Auxiliary steering priority valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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Steering - Hydraulic control components
Hydraulic control components - Special tools

CAS10280 Flow meter
LEIL13WHL0655AA 1
380001740 Flow meter fitting kit
LEIL13WHL0656AA 2
CAS1804 Pressure test fitting kit
LEIL13WHL0657AA 3
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Hydraulic steering system - Component identification - Standard

steering
HYDRAULIC COMPONENTS OF THE STANDARD STEERING SYSTEM - Sheet 1 of 3
1. Check valve 13. 90° elbow

2. Hydraulic connector 14. O-ring
3. Steering supply hose 15. 90° elbow
4. Cap 16. 90° elbow
5. O-ring 17. Load sense hose
6. Plug 18. Steering pump isolator
7. Orbitrol valve 19. Steel bushing
8. Priority valve 20. Rubber bushing
9. Main pump 21. Belleville washer, M10x22
10. Return hose manifold 22. Bolt, M10x30
11. Cap 23. Tie strap
12. Cap
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LEIL16WHL1625JB 1
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12. Cap
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LEIL16WHL1626JB 2
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12. Cap
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LEIL16WHL1627JB 3
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Hydraulic steering system - Component identification - Standard steering

with JSS
HYDRAULIC COMPONENTS OF THE STANDARD STEERING SYSTEM WITH JOYSTICK STEERING (JSS) - Sheet 1 of 3
1. Steering EHPS valve 25. Bolt, M8x20

2. Bracket, JSS mount 26. O-ring
3. Hydraulic connector 27. Hose (to cylinder)
4. 90° elbow 28. Hose (to cylinder)
5. Hydraulic connector 29. Bracket, JSS sensor mount
6. Hydraulic connector 30. Washer, 9x16x1.6 mm
7. Hydraulic shuttle tee valve 31. Bolt, M8x10
8. 45° elbow 32. Steering angle sensor
9. Tee 33. Nut
10. Spacer 34. Steering pump isolator
11. 90° elbow 35. Rubber bushing
12. Loader valve return fitting 36. Steel bushing
13. Cut-off valve 37. Belleville washer, M10x22
14. 90° elbow 38. Bolt, M10x30
15. Clamp 39. Bracket, valve mount
16. Hose (orbitrol to joystick valve) 40. Bracket, valve mount adjust
17. 90° elbow 41. Washer, 9x17x2 mm
18. Hose (JSS valve to priority valve) 42. Bolt, M8x25
19. Hose (joystick to priority valve) 43. Washer, 6.6x12x1.6 mm
20. 45° elbow 44. Washer, 6.6x12.5x2 mm
21. Hose (to return manifold) 45. Nut
22. Washer, 13.5x28x2.5 mm 46. Bolt, M6x90
23. Nut 47. Orbitrol valve
24. Washer, 9x20x1.6 mm 48. Priority valve
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LEIL16WHL1614JB 1
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9. Tee 33. Nut
14. 90° elbow 38. Bolt, M10x30
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LEIL16WHL1615JB 2
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9. Tee 33. Nut
14. 90° elbow 38. Bolt, M10x30
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LEIL16WHL1616JB 3
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Hydraulic steering system - Component identification - Steering system with Auxiliary Steering
HYDRAULIC COMPONENTS OF THE STEERING SYSTEM WITH AUXILIARY STEERING - Sheet 1 of 3 14. Hydraulic connector 42. 90° elbow
15. Pressure sensor 43. 90° elbow
1. Bracket, manifold and pump 29. Washer, 17.5x30x4 mm 16. Check valve 44. Hose (relief to return)
2. Auxiliary steering manifold 30. Bolt, M16x50 17. 90° elbow 45. Hose (load sense to auxiliary steering)
3. Auxiliary steering pump 31. O-ring 18. Hose (priority valve to auxiliary steering valve) 46. Cap
4. 90° elbow 32. Secondary steering harness 19. Washer, 6.6x18x1.6 mm 47. Cap
5. 90° elbow 33. Cable, battery - negative 20. Washer, 6.6x22x2 mm 48. O-ring
6. Hydraulic connector 34. Cable 21. Bolt, M6x110 49. Steering pump isolator
7. Hose (orbitrol to manifold) 35. Washer, 11x20x2 mm 22. Washer, 10.5x18x1.6 mm 50. Rubber bushing
8. Hydraulic connector 36. Nut 23. Washer, 11x24x3 mm 51. Steel bushing
9. Hose (manifold to orbitrol) 37. Cable tie 24. Bolt, M10x30 52. Belleville washer, M10x22
10. Hydraulic tank filter 38. Clamp 25. Electrical boot 53. Bolt, M10x35
11. Hydraulic connector 39. Priority valve 26. Nut
12. 90° elbow 40. Orbitrol 27. Nut
13. Hose (tank to pump) 41. Tie strap 28. Hose (to return manifold)
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LEIL16WHL1637JB 1
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HYDRAULIC COMPONENTS OF THE STEERING SYSTEM WITH AUXILIARY STEERING - Sheet 2 of 3 15. Pressure sensor 43. 90° elbow
16. Check valve 44. Hose (relief to return)
1. Bracket, manifold and pump 29. Washer, 17.5x30x4 mm
17. 90° elbow 45. Hose (load sense to auxiliary steering)
2. Auxiliary steering manifold 30. Bolt, M16x50
18. Hose (priority valve to auxiliary steering valve) 46. Cap
3. Auxiliary steering pump 31. O-ring
19. Washer, 6.6x18x1.6 mm 47. Cap
4. 90° elbow 32. Secondary steering harness
20. Washer, 6.6x22x2 mm 48. O-ring
5. 90° elbow 33. Cable, battery - negative
21. Bolt, M6x110 49. Steering pump isolator
6. Hydraulic connector 34. Cable
22. Washer, 10.5x18x1.6 mm 50. Rubber bushing
7. Hose (orbitrol to manifold) 35. Washer, 11x20x2 mm
23. Washer, 11x24x3 mm 51. Steel bushing
8. Hydraulic connector 36. Nut
24. Bolt, M10x30 52. Belleville washer, M10x22
9. Hose (manifold to orbitrol) 37. Cable tie 25. Electrical boot 53. Bolt, M10x35
10. Hydraulic tank filter 38. Clamp 26. Nut
12. 90° elbow 40. Orbitrol 28. Hose (to return manifold)
13. Hose (tank to pump) 41. Tie strap
14. Hydraulic connector 42. 90° elbow
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LEIL16WHL1638JB 2
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HYDRAULIC COMPONENTS OF THE STEERING SYSTEM WITH AUXILIARY STEERING - Sheet 3 of 3 15. Pressure sensor 43. 90° elbow
16. Check valve 44. Hose (relief to return)
1. Bracket, manifold and pump 29. Washer, 17.5x30x4 mm
17. 90° elbow 45. Hose (load sense to auxiliary steering)
2. Auxiliary steering manifold 30. Bolt, M16x50
18. Hose (priority valve to auxiliary steering valve) 46. Cap
3. Auxiliary steering pump 31. O-ring
19. Washer, 6.6x18x1.6 mm 47. Cap
4. 90° elbow 32. Secondary steering harness
20. Washer, 6.6x22x2 mm 48. O-ring
5. 90° elbow 33. Cable, battery - negative
21. Bolt, M6x110 49. Steering pump isolator
6. Hydraulic connector 34. Cable
22. Washer, 10.5x18x1.6 mm 50. Rubber bushing
7. Hose (orbitrol to manifold) 35. Washer, 11x20x2 mm
23. Washer, 11x24x3 mm 51. Steel bushing
8. Hydraulic connector 36. Nut
24. Bolt, M10x30 52. Belleville washer, M10x22
9. Hose (manifold to orbitrol) 37. Cable tie 25. Electrical boot 53. Bolt, M10x35
10. Hydraulic tank filter 38. Clamp 26. Nut
12. 90° elbow 40. Orbitrol 28. Hose (to return manifold)
13. Hose (tank to pump) 41. Tie strap
14. Hydraulic connector 42. 90° elbow
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LEIL16WHL1639JB 3
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Hydraulic steering system - Component identification - Steering system

with Auxiliary Steering and JSS
HYDRAULIC COMPONENTS OF THE STEERING SYSTEM WITH AUXILIARY STEERING AND JOYSTICK STEERING
(JSS) - Sheet 1 of 2

3. Hydraulic connector 25. Hose (joystick steering left-hand)
4. 90° elbow 26. Hose (joystick steering right-hand)
5. Hydraulic connector 27. Bracket, JSS sensor mounting
8. Tee 30. Steering angle sensor
9. Spacer 31. Nut
10. 90° elbow 32. Steering pump isolator
11. Loader valve return fitting 33. Rubber bushing
12. Cut-off valve 34. Steel bushing
13. Hydraulic connector 35. Belleville washer, M10x22
14. Cable tie 36. Bolt, M10x30
15. Hose (orbitrol to joystick valve) 37. Bracket, valve mount
16. Hose (JSS valve to priority valve) 38. Bracket, valve mount adjust
17. Hose (joystick to priority valve) 39. Washer, 9x17x2 mm
18. 45° elbow 40. Bolt, M8x25
19. Hose (to return manifold) 41. Washer, 6.6x12x1.6 mm
20. Washer, 13.5x28x2.5 mm 42. Washer, 6.6x12.5x2 mm
21. Nut 43. Nut
22. Washer, 9x20x1.6 mm 44. Bolt, M6x90
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LEIL16WHL1640JB 1
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HYDRAULIC COMPONENTS OF THE STEERING SYSTEM WITH AUXILIARY STEERING AND JOYSTICK STEERING
(JSS) - Sheet 2 of 2

3. Hydraulic connector 25. Hose (joystick steering LH)
4. 90° elbow 26. Hose (joystick steering RH)
5. Hydraulic connector 27. Bracket, JSS sensor mounting
8. Tee 30. Steering angle sensor
9. Spacer 31. Nut
10. 90° elbow 32. Steering pump isolator
11. Loader valve return fitting 33. Rubber bushing
12. Cut-off valve 34. Steel bushing
13. Hydraulic connector 35. Belleville washer, M10x22
14. Cable tie 36. Bolt, M10x30
15. Hose (orbitrol to joystick valve) 37. Bracket, valve mount
16. Hose (JSS valve to priority valve) 38. Bracket, valve mount adjust
17. Hose (joystick to priority valve) 39. Washer, 9x17x2 mm
18. 45° elbow 40. Bolt, M8x25
19. Hose (to return manifold) 41. Washer, 6.6x12x1.6 mm
20. Washer, 13.5x28x2.5 mm 42. Washer, 6.6x12.5x2 mm
21. Nut 43. Nut
22. Washer, 9x20x1.6 mm 44. Bolt, M6x90
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LEIL16WHL1650JB 2
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Hydraulic steering system - Remove - Steering EHPS and cut-off

valves
1. Clean all dirt and grease from the steering valves and
adjacent areas.
2. Disconnect the electrical connector (9) from the steer-
ing EHPS valve (1).
LEIL16WHL1673AA 1
3. Disconnect the electrical connectors (10), (11), (12)

and (13) from the cut-off valves (2) and (3).
LEIL16WHL1674AA 2
4. Tag and disconnect the steering LS hose (4), the suc-

tion valve hose (5) and the hose (to tank) (6) from the
steering EHPS valve (1). Plug the hoses and cap the
fittings.
5. Tag and disconnect the hose (to cylinder) (7) from the
cut-off valve (2) and the hose (to cylinder) (8) from the
cut-off valve (3). Plug the hoses and cap the fittings.
LEIL16WHL1675AA 3
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6. Remove the nuts, washers and spacers at the three

locations to unfix the bracket supporting the steering
valve assembly from the rear chassis.
LEIL16WHL1676AA 4
7. Remove the three bolts M8x20 and washers to unfix

the bracket from the steering EHPS valve.
LEIL16WHL1677AA 5
8. Remove the bolts M8x25, washers (under bolt head

and nut) and nuts at the two locations.
LEIL16WHL1678AA 6

and nut) and nuts at the two locations to unfix the
bracket (1) from the cut-off valve (2). Remove the
bracket (1).
LEIL16WHL1678AA 7
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10. Remove the bolts M8x20 and washers (under bolt

head) at the two locations.
LEIL16WHL1679AA 8

and nut) and nuts at the two locations to unfix the
bracket (3) from the cut-off valve (4). Remove the
bracket (3).
LEIL16WHL1679AA 9
12. Disconnect the two cut-off valves from the steering

EHPS valve.
13. Unscrew all hydraulic connectors and elbows from the
steering EHPS valve and cut-off valves.
LEIL16WHL1681AA 10
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Hydraulic steering system - Install - Steering EHPS and cut-off

valves
NOTE: before assembling the steering valves, clean the parts with solvent and dry them.
1. Inspect each part for defects.
2. Replace all damaged or deformed parts with new ones.
3. Install the hydraulic connectors to the steering EHPS
valve (1):
A. install the fitting (4) to the LS port; tighten to 35 N·m
(26 lb ft);
B. install the fitting (6) to the T port; tighten to 70 N·m
(52 lb ft);
C. connect the 90° elbow (5) to the P port; tighten to
100 N·m (74 lb ft).
LEIL16WHL1682BA 1
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4. Install the two cut-off valves (2) and (3) to the steering
EHPS valve (1):
A. install the fitting (7) to the CL port of the steering
EHPS valve (1); tighten to 70 N·m (52 lb ft);
B. install the fitting (9) to the P2 port of the cut-off
valve (2); tighten to 100 N·m (74 lb ft);
C. connect the cut-off valve (2) to the fitting (7)
through the fitting (9); tighten to 60 N·m (44 lb ft);
D. install the 90° elbow (8) to the CR port of the
steering EHPS valve (1); tighten to 70 N·m (52 lb
ft);
E. install the fitting (10) to the P2 port of the cut-off
valve (3); tighten to 100 N·m (74 lb ft);
F. connect the cut-off valve (3) to the 90° elbow (8)
through the fitting (10); tighten to 60 N·m (44 lb
ft);
G. install the 90° elbows (11) and (12) to the P1 port
of the two cut-off valves; tighten the fittings to
100 N·m (74 lb ft).
LEIL16WHL1682BA 2
5. Install the bracket (4) to the steering EHPS valve (1) by

using two bolts M8x20 (11) and washers (12).
6. Fix the bracket (4) to the cut-off valve (2) by using two
bolts M6x90 (6), washers (under bolt head) (7), (8),
washers (under nut) (10), nuts (9).
7. Install the bracket (5) by using two bolts M8x25 (13),
washers (under bolt head) (14), washers (under nut)
(16), nuts (15).
8. Fix the bracket (5) to the cut-off valve (3) by using two
bolts M6x90 (17), washers (under bolt head) (18), (19),
washers (under nut) (21), nuts (20).
LEIL16WHL1688BB 3
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9. Fix the bracket (2) to the steering EHPS valve (1) with
three bolts M8x20 (3) and washers (under bolt head)
(4).
LEIL16WHL1689AB 4
10. Fix the steering valve assembly to the three studs (1)
on rear chassis by using three spacers (2), washers
(3) and nuts (4).
LEIL16WHL1690AB 5
11. Connect the hoses to the steering EHPS valve (1):

A. connect the suction valve hose (5) to the 90°
elbow pre-mounted into the P port; tighten to
90 N·m (66 lb ft);
B. connect the hose (tank to) (6) to the fitting pre-
mounted into the T port; tighten to 60 N·m (44 lb
ft);
C. connect the steering LS hose (4) to the fitting pre-
mounted into LS port; tighten to 14 N·m (10 lb ft).
12. Connect the hoses (to cylinder) (7), (8) to the 90° el-
bows pre-mounted into the P1 port of cut-off valves
(2), (3). Tighten to 90 N·m (66 lb ft). LEIL16WHL1675AA 6
13. Connect the electrical connectors (10), (11), (12) and

(13) to the cut-off valves (2) and (3).
LEIL16WHL1674AA 7
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14. Connect the electrical connector (9) to the steering

EHPS valve (1).
LEIL16WHL1673AA 8
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Hydraulic steering system - Adjust - Joystick Steering System (JSS)

Pressure adjustments
LELI12WL31105FB 1
1. Pressure point G1 2. Pressure point G2 3. Priority valve
NOTICE: when performing the following pressure check

and adjustment, the articulation lock must be installed. Use
caution when working in or near the articulation area.
A. Main hydraulic pressure setting of the pumps

These settings are given by the difference between the
pressure of the hydraulic pump 1 and LS signal, which
must be within 25 – 27 bar (362 – 391 psi) and the dif-
ference between the pressure of the hydraulic pump 2
and LS signal, which must be within 21 – 23 bar (304 –
334 psi).
With the engine OFF and bucket on the ground, connect
a quick coupling pressure gauge to the pressure point
G1 (1) and pressure point G2 (2) of the priority valve
(3), Fig. 1, to the LS pressure point (4) of the hydraulic
pump 1 (5) and hydraulic pump 2 (6), Fig. 2.
With the engine at idle speed, with all the controls in
neutral, JSS NOT active, the difference between the
pressures measured at the G1 and LS ports must be
equal to 25 – 27 bar (363 – 392 psi) (hydraulic pump
1) and the difference between the pressures measured
at the G2 and LS ports must be equal to 21 – 23 bar
(304 – 334 psi) (hydraulic pump 2).
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neutral, JSS ON and joystick in neutral, the difference
between the pressures measured at the G1 and LS
ports must be equal to 25 – 27 bar (363 – 392 psi) (hy-
draulic pump 1) and the difference between the pres-
sures measured at the G2 and LS ports must be equal
to 21 – 23 bar (304 – 334 psi) (hydraulic pump 2).
neutral, JSS ON and joystick NOT in neutral, the differ-
ence between the pressures measured at the G1 and
LS ports must be equal to 25 – 27 bar (363 – 392 psi)
(hydraulic pump 1 ) and the difference between the
pressures measured at the G2 and LS ports must be
equal to 21 – 23 bar (304 – 334 psi) (hydraulic pump
2).
neutral, JSS ON and joystick NOT in neutral, the differ-
ence between the pressures measured at the G1 and
LS ports must be equal to 25 – 27 bar (363 – 392 psi)
(hydraulic pump 1) and the difference between the pres-
sures measured at the G2 and LS ports must be equal
to 21 – 23 bar (304 – 334 psi) (hydraulic pump 2).
If the settings are not correct, verify that all the hydraulic
connections are exact, particularly the connections on
the hydraulic steering EHPS valve that manages the LS
signals.
LEIL15WHL1344FB 2
4. Pressure point LS hydraulic pump 1 and pump 2 7. Pressure regulator hydraulic pump 1
5. Hydraulic pump 1 8. Pressure regulator hydraulic pump 2
6. Hydraulic pump 2
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B. Steering pressure limit setting

With the engine at high idle, the pressure of the
port G1 must be between 239 – 243 bar (3465.50 –
3523.50 psi).
• Make sure that the pressure value stated in para-
graph A is as specified 25 – 27 bar (362.50 –
391.50 psi).
• With the engine OFF and bucket on the ground, con-
nect a quick coupling pressure gauge on the pres-
sure point G1 of the front and bottom of the priority
valve Fig. 1
• With the articulation locked, engine at high idle and
JSS ON begin steering with the joystick in both direc-
tions to its limit stop. Keep this condition and read
the pressure value on the pressure gauge, which
must be equal to that specified above 239 – 243 bar
(3466 – 3523.50 psi).
• If the pressure gauge records a pressure above or
below the specified one, check that all the hydraulic
connections have been made correctly.
C. Steering speed level setting

NOTICE: when performing the following procedure check
that the articulation of the unit is NOT locked.
The JSS can be set through the display in the cab on
three different levels of steering speed.
The three speed levels are:
1. Slow - from 4.5 s to 5.5 s *
2. Medium - from 3.2 s to 4.5 s *
3. Fast - from 2.8 s to 3.2 s *
NOTE: * time to take the machine from all right to all left.
LEIL15WHL0533AA 3
The purpose of this setting is to make steering the ma-

chine equipped with the JSS similar to the standard
steering system.
neutral and JSS ON, steer the machine completely to
the left.
Set a speed level (e.g. 1, 2 or 3).
Move the joystick completely to the right and at the
same time, with a chronometer, start measuring the
time. Stop the chronometer when the machine is com-
pletely steered on the right-hand side. Take the time to
compare it with the time specified in the table of speed
levels.
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Move the joystick completely to the left and at the same

time, with a chronometer, start measuring the time.
Stop the chronometer when the machine is completely
steered on the left-hand side. Take the time to compare
it with the time specified in the table of speed levels. If
the value is not in the range shown in the table, follow
the system calibration procedure.
Repeat what is specified in the previous four points with
the engine at high idle.
If the adjustments are not exact, verify the specifica-
tions given in paragraphs A and B.
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Steering valve - Remove

1. Remove the cab skirts from the cab.
2. Remove all dirt and grease from the steering control
valve.
LEIL13WHL1162AA 1
3. Remove the fill cap of the hydraulic reservoir, attach a

vacuum pump to the reservoir, start the pump.
4. Tag and disconnect the hoses from the steering control
valve:
• load sense hose (1);
• steering cylinder hose (2);
• return hose (4);
• supply hose (5).
NOTE: for machines equipped with JSS, disconnect the
electrical connector from the steering control valve.
LEIL16WHL1701AB 2
5. Install protective caps to the hoses. Cap or plug the

fittings and the hoses, turn off the vacuum pump.
6. Loosen the four nuts to unfix the steering valve bracket
from the cab frame. Disengage the steering control
valve from the steering shaft.
LEIL16WHL1700AB 3
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7. Remove the four bolts (4), washers (5), steel bush-

ings and rubber bushings (not visible in figure) to un-
fix the steering control valve (3) from the steering valve
bracket (2). Pay attention to the release of the steering
isolator (1).
LEIL16WHL1171AA 4
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Steering valve - Install

1. Place the steering isolator (1) between the steering
control valve (3) and the steering valve bracket (2). Ori-
ent the steering isolator (1) with boss features towards
cab. Install and tighten the four mounting bolts (4) with
the washers (5), steel bushings and rubber bushings
(not visible in figure) to fix the steering control valve (3)
to steering valve bracket (2).
LEIL16WHL1171AA 1
2. Engage the steering control valve into the steering

shaft.
3. Tighten the four nuts to fix the steering valve bracket to
the cab frame.
4. Start the vacuum pump. Remove the caps and plugs
from the fittings and hoses.
LEIL16WHL1700AB 2
5. Connect the hoses to the steering control valve accord-

ing to the tags applied during removal:
• return hose (4);
• supply hose (5).
NOTE: for machines equipped with JSS, connect the elec-
trical connector to the steering control valve.
LEIL16WHL1701AB 3
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Main priority valve - Remove

1. Park the machine on level ground and lower the bucket
to the ground. Put the transmission in NEUTRAL, apply
the parking brake, and shut down the engine.
2. Put the timed disconnect switch in OFF position.
3. Remove all dirt and grease from the main priority valve
(1) and adjacent area.
4. Remove the hydraulic reservoir fill cap.
7. Disconnect the hoses (3) and (4) from the main priority
valve (1) to the steering pump (2).
8. Disconnect the load sense hose (5).
9. Remove the four bolts M16x55 (6), the four washers
(7), and the two semi-flanges (8) to disconnect the
pressure hose (9). Discard the O-ring (10).
LEIL16WHL1661FA 1
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10. Disconnect the drain line hose (11).

(13), and the two semi-flanges (14).
(16).
13. Remove the connection tube (17) between the main
priority valve (1) and the steering pump (2). Discard
the O-rings (18).
14. Remove the four screws M14x170 (19), the eight
15. Remove the main priority valve (1). Discard the O-ring
(22).
LEIL16WHL1662FA 2
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Main priority valve - Install

1. Install a new O-ring (22) and position the main priority
valve (1) to the steering pump (2).
2. Install the eight washers (20) and (21), and the four
screws M14x170 (19). Do not tighten the screws (19).
3. Install two new O-rings (18) to the connection tube (17).
Position the connection tube (17) between the main
priority valve (1) and the steering pump (2).
4. Install the four washers (16) and the four bolts M14x75
(15). Install the two semi-flanges (14), the four washers
(13), and the four bolts M14x45 (12).
LEIL16WHL1662FA 1
5. Tighten the bolts (12) and (15) to 84.7 – 101.7 N·m

(62.5 – 75.0 lb ft). The proper torque sequence is
shown in figure.
LEIL15WHL1117AB 2
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6. Connect the drain line hose (11). Orient the hose (11)
as indicated in figure.
LEIL16WHL1663AA 3
7. Install a new O-ring (10) on the pressure hose (9). Lock

the pressure hose (9) with the two semi-flanges (8), the
four washers (7), and the four bolts M16x55 (6).
Tighten the bolts (6) to 198 – 242 N·m (146 – 178 lb ft).
8. Connect the load sense hose (5).
NOTE: secure the load sense hose (5) along the top of the
pressure hose (9) with tie straps (A) evenly spaced and
oriented as indicated in figure.
LEIL15WHL1118AB 4
9. Connect the hoses (3) and (4) from the main priority
valve (1) to the steering pump (2). Orient the hose (4)
as indicated in figure.
LEIL16WHL1664AA 5
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LEIL16WHL1661FA 6

11. Disconnect the vacuum pump from the hydraulic
reservoir.
12. Install the fill cap on the hydraulic reservoir.
13. Put the timed disconnect switch in ON position. Start
the engine and run at low idle for 30 seconds. Stop
the engine and check for leaks.
14. Check to make sure that the main priority valve oper-
ates correctly.
15. Check the fluid level in the hydraulic reservoir. Add oil
as required.
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Main priority valve - Test

NOTE: the loader/steering pump differential pressure must be properly adjusted before doing this test.
Pressure setting test

NOTICE: when performing the following pressure check
and adjustment, the articulation lock must be installed. Use
caution when working in or near the articulation area.
RCPH10WHL063BAL 1
2. Remove the dust cap from the test port located on the
steering priority valve.
3. Connect a 345 bar (5002 psi) pressure gauge to the
test port (1).
NOTE: make sure when you connect the pressure gauge
that you do so in a manner that you can read the pressure
gauge while sitting in the operators seat.
LEIL16WHL1697AB 2
4. Make sure that the temperature of the hydraulic oil is

54 – 57 °C (129 – 135 °F).
5. Use the display in the cab to check the temperature of
the hydraulic oil (access to “Machine service – Sensor
Status – Hydraulics” screens).
7. Start and run the engine at full throttle.
8. Lower the lift arms and hold the control lever in the
FLOAT position.
9. Hold the bucket control lever in the rollback position.
LEIL16WHL0891AA 3
10. Continue holding until the specified temperature of the
oil is reached.
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12. Start the engine and operate the machine at full throt-
tle.
13. With the articulation lock still in place, turn and hold
the steering wheel for a hard right turn.
14. Continue holding the steering wheel, and read the
pressure gauge.
15. The pressure gauge must indicate 239 – 243 bar
(3466 – 3524 psi). If the pressure is not correct,
adjust the steering relief valve.
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Main priority valve - Adjust

Pressure setting adjustment
1. Turn the limit valve of the steering priority valve clock-
wise to increase the pressure setting. Turn the limit
valve counterclockwise to decrease the pressure set-
ting.
2. Repeat the pressure test procedure.
3. If necessary, adjust the limit valve again until within the
specified range.
4. Stop the engine before removing the pressure gauge.
LEIL16WHL1698AB 1
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Steering circuit relief valve - Remove
LEIL15WHL1125FB 1

to the ground. Put the transmission in NEUTRAL, apply
the parking brake, and shut down the engine
7. Disconnect the following hoses from the steering circuit
relief valve (1):
• relief valve hoses (2) (from the tee (P) located on P
port);
• return hose (from hydraulic connector (T) located on
T port).
8. Remove the two bolts M6x80 (3) and the two nuts (4)
to remove the cover (5).
9. Remove the two nuts (6), the two washers (7), the two
spacers (8), and the steering circuit relief valve (1).
10. Remove the tee (P) and the hydraulic connector (P)
from the steering circuit relief valve (1).
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Steering circuit relief valve - Install
LEIL15WHL1125FB 1
1. Pre-assemble the steering circuit relief valve (1). Install

the tee (P) in the P port and the hydraulic connector (T)
in the T port.
2. Install the steering circuit relief valve (1) on the frame
and lock with the two spacers (8), the two washers (7),
the two nuts (6), and the two bolts M6x80 (3).
3. Install the cover (5) and lock with the two nuts (4).
4. Connect the following hoses to the steering circuit relief
valve (1):
• relief valve hoses (2) (to the tee (P) located on P
port);
• return hose (to the hydraulic connector (T) located
on T port).
6. Install and tighten the reservoir fill cap.
7. Remove the articulation lock. Start and run the ma-
chine at low idle, turn the steering wheel from full left-
hand lock to full right-hand lock, holding the steering
over relief.
8. Stop the machine and check for leaks.
9. Check the fluid level in hydraulic reservoir. Add oil as
required.
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Steering circuit relief valve - Test

1. Disconnect the return hose from the hydraulic connec-
tor located on the T port of the steering circuit relief
valve.
2. Install a “T” fitting and connect a pressure gauge capa-
ble of reading 35 bar (508 psi).
3. Start and run the machine at high idle.
4. Turn the steering wheel and observe the pressure.
5. The pressure should be 8 – 10 bar (116 – 145 psi).
6. If pressure is not as specified, replace the relief valve.
NOTE: the relief valve is not adjustable.
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Auxiliary steering priority valve - Remove

to ground. Put the transmission in NEUTRAL, apply the
parking brake, and shut down the engine.
3. Remove all dirt and grease from the auxiliary steering
priority valve and adjacent area.
7. Tag and disconnect the secondary steering harnesses
from the auxiliary steering priority valve.
LEIL16WHL1704AA 1
8. Tag and disconnect the following hoses from the auxil-

iary steering priority valve:
• hose (relief to return) (1);
• hose (orbitrol to manifold) (2);
• hose (to return manifold) (4);
• hose (manifold to orbitrol) (5);
• hose (to priority valve) (6).
LEIL16WHL1705AA 2
LEIL16WHL1706AA 3
9. Remove the fittings from the ports of the auxiliary steer-

ing valve. Install protective caps to the hoses and fit-
tings.
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10. Loosen the four nuts and unfix the auxiliary steering
valve from the bracket. Pay attention to the release of
the washers and bolts.
LEIL16WHL1707AA 4
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Auxiliary steering priority valve - Install

1. Position the auxiliary steering priority valve on the
bracket. Lock with the four bolts M6x110 (1), washers
(under bolt head) (2), washers (under nut) (3) and nuts
(4).
LEIL16WHL1708AB 1
2. Connect the hydraulic connectors and hoses to the

auxiliary steering priority valve:
• fitting to P port – tighten to 100 N·m (74 lb ft);
90° elbow to fitting – tighten to 60 N·m (44 lb ft);
hose (relief to return) (1) to 90° elbow – tighten to
60 N·m (44 lb ft);
• 90° elbow to SLS port – tighten to 45 N·m (33 lb ft);
hose (orbitrol to manifold) (2) to 90° elbow – tighten
to 14 N·m (10 lb ft);
• 90° elbow to LS port – tighten to 45 N·m (33 lb ft);
load sense hose (3) to 90° elbow – tighten to 14 N·m
(10 lb ft);
LEIL16WHL1705AA 2
• fitting to T port – tighten to 100 N·m (74 lb ft);
hose (to return manifold) (4) to fitting – tighten to
60 N·m (44 lb ft);
• fitting to ST port – tighten to 310 N·m (229 lb ft);
hose (manifold to orbitrol) (5) to fitting – tighten to
90 N·m (66 lb ft);
• fitting to ST port – tighten to 310 N·m (229 lb ft);
hose (to priority valve) (6) to fitting – tighten to
90 N·m (66 lb ft).
LEIL16WHL1706AA 3
3. Connect the secondary steering harnesses to the aux-

iliary steering priority valve.
LEIL16WHL1704AA 4
4. Stop the vacuum pump. Disconnect the vacuum pump

from the hydraulic reservoir.
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5. Install the fill cap on the hydraulic reservoir.

6. Put the battery timed disconnect switch in ON position.
Start the engine and run at low idle for 30 seconds.
Stop the engine and check for leaks.
7. Check to make sure that the auxiliary steering priority
valve operates correctly.
required.
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Index
Steering - 41

Auxiliary steering priority valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Auxiliary steering priority valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Hydraulic control components - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic steering system - Adjust - Joystick Steering System (JSS) . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hydraulic steering system - Component identification - Standard steering . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic steering system - Component identification - Standard steering with JSS . . . . . . . . . . . . . 10
Hydraulic steering system - Component identification - Steering system with Auxiliary Steering . . . 16
Hydraulic steering system - Component identification - Steering system with Auxiliary Steering and
JSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hydraulic steering system - Install - Steering EHPS and cut-off valves . . . . . . . . . . . . . . . . . . . . . . . . 30
Hydraulic steering system - Remove - Steering EHPS and cut-off valves . . . . . . . . . . . . . . . . . . . . . . 27
Main priority valve - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Main priority valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Main priority valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Main priority valve - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Steering circuit relief valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Steering circuit relief valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Steering circuit relief valve - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Steering valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Steering valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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Steering - 41
Cylinders - 216

48083742_EN 31/07/2018
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Contents
Steering - 41
Cylinders - 216
FUNCTIONAL DATA
Steering cylinder
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Steering cylinder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Steering - Cylinders
Steering cylinder - Exploded view
LELI12WL30382GB 1
1. Gland 11. Wear ring

2. Rod wiper 12. Ring loader
3. Rod seal 13. Seal
4. Buffer seal 14. Piston rod
5. Bearing 15. Grease fitting
6. Backup ring 16. Retaining ring
7. O-ring 17. Bushing
8. Bolt and washer 18. Tube
9. Piston 19. Screw
10. Ring cast iron 20. Seal
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Steering cylinder - Remove

to the ground.
2. Put the transmission in NEUTRAL, apply the parking
brake, and shut down the engine
5. Loosen the fill cap of the hydraulic reservoir to release
pressure in the reservoir, then tighten the fill cap.
6. On the front and rear chassis side, disconnect the right-
hand (left-hand) grease hoses (2) from the right-hand
(left-hand) steering cylinders (1).
NOTE: the figures show the right-hand steering cylinder.
The procedure for the left-hand steering cylinder is similar.
LEIL15WHL1126AB 1
LEIL15WHL1127AB 2
7. Disconnect the right-hand side (left-hand side) flexible

hoses (3) from the steering cylinder (1).
LEIL16WHL2722AB 3
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8. Disconnect the right-hand (left-hand) relief valve hoses

(4) from the right-hand (left-hand) steering cylinder (1).
Install a protective plug in the disconnected hoses.
LEIL15WHL1129AB 4
9. Sling the steering cylinder to be removed and connect

to a suitable lifting device.
NOTE: the weight of the steering cylinder is approximately
427 kg (941 lb).
10. From the right-hand (left-hand) front side of chassis,
remove the bolt M12x40 (5), the washer (6), and the
spacer (7).
Use a suitable driver to remove the pin (8).
Withdraw the right-hand (left-hand) steering cylinder
(1) and remove the washers (9).
LEIL15WHL1130AB 5
11. From the right-hand (left-hand) rear side of chassis,

remove the bolt M12x40 (10), the washer (11), and
the spacer (12).
Use a suitable driver to remove the pin (13). Remove
the right-hand (left-hand) steering cylinder (1).
LEIL15WHL1131AB 6
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Steering cylinder - Install

1. Sling the steering cylinder to be installed and connect
to a suitable lifting device.
NOTE: the weight of the steering cylinder is approximately
427 kg (941 lb).
2. Put the steering cylinder (1) in position on the machine.
3. Use a suitable driver to install the pin (13).
4. Install the spacer (12), the washer (11), and the bolt
M12x40 (10) to lock the pin (13).
NOTE: the figures show the right-hand steering cylinder.
The procedure for the left-hand steering cylinder is similar.
LEIL15WHL1131AB 1
5. Make sure that the washers (9) are positioned as

shown in figure, and insert the steering cylinder (1) in
position on the front chassis.
6. Use a suitable driver to install the pin (8).
7. Install the spacer (7), the washer (6), and the bolt
M12x40 (5) to lock the pin (8).
LEIL15WHL1130AB 2
8. Connect the right-hand (left-hand) relief valve hoses (4)

to the steering cylinder (1).
LEIL15WHL1129AB 3
9. Connect the right-hand side (left-hand side) flexible

hoses (3) to the steering cylinder (1).
LEIL16WHL2722AB 4
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10. On the front and rear chassis side, connect the right-
hand (left-hand) grease hoses (2) from the steering
cylinders (1).
11. Tighten the hydraulic reservoir fill cap.
13. Turn the steering wheel all the way to the right-hand
and then to the left-hand several times.
required.
LEIL15WHL1126AB 5
LEIL15WHL1127AB 6
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Steering cylinder - Leakage test

NOTE: make sure all persons are clear of the area of the center pivot. Make sure the center pivot is free of any
obstructions.
1. Park the machine on a level surface.
2. Turn the machine all the way to the right.
4. Find the tube that is connected to the rod end of the
left-hand steering cylinder. Disconnect the tube from
the left-hand cylinder.
5. Install a plug in the tube.
6. Start and run the engine at idle throttle.
7. Turn the steering wheel to the right. Hold the steering
wheel for a full right turn. Have another person check
for leakage from the opening of the rod end of the left-
hand steering cylinder.
8. If there is constant leakage from the rod end, the piston
packing in the left-hand steering cylinder is damaged.
Repairs must be made.
9. Connect the tube to the rod end of the left-hand steering
cylinder.
10. Turn the machine all the way to the left.
12. Find the tube that is connected to the rod end of the
right-hand steering cylinder. Disconnect the tube from
the right-hand steering cylinder.
13. Install a plug in the tube.
14. Start and run the engine at idle throttle.
15. Turn the steering wheel to the left. Hold the steering
wheel for a full left turn. Have another person check
for leakage at the opening of the rod end of the right-
hand steering cylinder.
16. If there is constant leakage from the rod end, the pis-
ton packing in the right-hand steering cylinder is dam-
aged. Repairs must be made.
17. Connect the tube to the rod end of the right-hand
steering cylinder.
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Steering cylinder - Disassemble

NOTE: refer to Steering cylinder - Exploded view for the numbering of procedure.
1. Fasten tube (18) in a vise. Be careful not to damage
the tube.
2. Remove the gland (1) from the tube (18).
3. Pull the piston rod (14) and the piston (9) straight out
of the tube (18).
4. Fasten the piston rod (14) yoke in a vise and put a
support below the piston rod near the piston (9) . Put
a shop cloth between the support and the piston rod to
prevent damage to the piston rod.
5. Loosen and remove the bolt and the washer (8) that
hold the piston (9).
6. Remove the piston (9) from the piston rod (14).
7. Remove and discard the seal (13), the loader ring (12),
the wear ring (11), and the cast iron ring (10) from the
piston (9).
8. Remove the gland (1) from the piston rod (14).
9. Remove and discard the O-ring (7), the backup ring (6),
the rod wiper (2), the rod seal (3), the buffer seal (4),
and the bearing (5) from the gland (1).
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Steering cylinder - Inspect

2. Check to be sure that piston rod (14) is straight. If
piston rod is bent, install a new piston rod.
3. Inspect inside of tube (18) for deep grooves and other
damage. If there is any damage to tube, a new tube
must be used.
4. Remove small scratches on piston rod (14) or inside
tube (18) with emery cloth of medium grit. Use emery
cloth with a rotary motion.
5. Inspect bushing (17). If bushing requires replacement,
remove grease fitting (15) and retaining rings (16) then
press bushing from tube end.
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Steering cylinder - Assemble

1. Install the bearing (5) in the gland (1).
2. Install the buffer seal (4) in the gland (1) so that the lips
of the seal are toward small end of the gland.
3. Install the rod seal (3) in the gland (1). Rod seal must
be installed so that the lips of the seal are toward the
small end of the gland. Seal can be difficult to install.
Use tools that will not damage seal.
4. Install the rod wiper (2) in the gland (1) with wiper lips
toward large end of the gland.
5. Install the O-ring (7) on the gland (1).
6. Install the backup ring (6) on the gland (1). The backup
ring must be toward large end of the gland. If the
backup ring is not flat on both sides, the side that is
not flat must be toward the O-ring (7).
7. Fasten the piston rod (14) yoke in vise.
8. Lubricate the piston rod (15) and bore in the gland (1)
with clean hydraulic oil.
NOTE: If a new gland (1) is being installed, write part num-
ber of cylinder on gland.
9. Push the gland (1) onto the piston rod (14) large end
first. If necessary, use a soft hammer to drive the gland
onto the piston rod.
10. Put a support below and near the end of the piston rod
(14). Put a cloth between support and the piston rod
to prevent damaging the piston rod.
11. Install new cast iron ring (10) on the piston (9).
12. Install a new wear ring (11) on the piston (9).
13. Install a new loader ring (12) on the piston (9).
14. Install a new seal (13) over the loader ring (12).
15. Clean the threads on the end of the piston rod (14)
and threads of the bolt (8) using Loctite cleaning sol-
vent. Allow to dry. Apply LOCTITE® 243™ to the piston
rod threads 6.4 mm (0.3 in) from open end of the pis-
ton rod so that there is 12.7 mm (0.5 in) of LOCTITE®
243™ on the piston rod threads. DO NOT apply Loc-
tite to first 6.4 mm (0.3 in) of the piston rod threads.
16. Install the bolt and hardened washer (8) in the piston
(9).
17. Install the piston (9) on the piston rod (14) and start
bolt (8) into the piston rod.
18. Tighten the bolt (8) to a torque of 1600 – 1830 N·m
(1180 – 1350 lb ft).
19. Fasten the tube (18) in vise. Be careful not to damage
tube.
20. Install the O-rings (7) and the backup ring (6) on the
gland (1) and to the sealing surface in tube (18).
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21. Lubricate the piston (9) and inside of tube (18) with
clean hydraulic oil.
22. Push the piston (9) straight into tube (18). Be careful
not to damage the cast iron ring (10), the wear ring
(11), and the seal (13) on the piston (9).
23. When the piston (9) is in smooth part of the tube (18),
the start gland (1) into the tube (18).
24. If the original parts are being assembled:
A. Tighten the gland to a torque of 339 – 475 N·m
(250 – 350 lb ft).
B. Install and tighten the self-tapping screw (19) to a
torque of 2.3 N·m (20.4 lb in).
C. If, after tightening the gland, the self-tapping screw
(19) holes are not aligned, a new hole for self-tap-
ping screw must be drilled.
25. If a new gland (1) or a new tube (18) are being assem-
bled.
A. Tighten the gland (1) to a torque of 339 – 475 N·m
(250 – 350 lb ft).
B. Use a No. 27 drill bit and drill a hole half in the
gland (1) and half in the tube (18). Drill to a depth
of 11 mm (0 in). Do not drill within 13 mm (1 in) of
a hole for gland wrench.
C. Install and tighten the self-tapping screw (19) to a
torque of 2.3 N·m (20.4 lb in).
26. If hoses were removed with cylinder, install new
O-rings, if equipped, on hose fittings. Lubricate
O-rings with clean oil. Install hoses.
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Index
Steering - 41
Cylinders - 216
Steering cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Steering cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Steering cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering cylinder - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Steering cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Steering cylinder - Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Steering cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Steering - 41
Auxiliary steering - 910

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Contents
Steering - 41
TECHNICAL DATA
Pump
Motor
FUNCTIONAL DATA
Auxiliary steering
Component identification - Pump and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exploded view - Motor and pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Auxiliary steering
Remove - Pump and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install - Pump and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassemble - Motor and pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspect - Motor and pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assemble - Motor and pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pump
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Steering - Auxiliary steering
Pump - General specification

Auxiliary steering pump
Maximum oil flow: 20.8 L/min (5.5 US gpm) at 104 bar (1508 psi) at 320 A.
Minimum oil flow: 14.8 L/min (3.9 US gpm) at 248 bar (3596 psi) at 615 A.
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Motor - General specification

Auxiliary steering motor
Maximum amperes: 30 A
Minimum armature speed: 6950 RPM
Motor: 24 V
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Auxiliary steering - Component identification - Pump and motor
LEIL16WHL1710GA 1
1. Ground cable 5. Pressure tube

2. Positive cable 6. Auxiliary steering priority valve
3. Bolts (4) 7. Auxiliary steering pump and motor
4. Suction hose 8. Wiring harness
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Auxiliary steering - Exploded view - Motor and pump
LELI12WL30395GB 1
1. Motor 13. Gasket

2. Bolt 14. Lock washer
3. Retaining ring 15. Screw
4. Seal 16. Wire
5. Backup ring 17. Plate
6. Seal 18. Body
7. O-ring 19. Driven gear
8. Switch 20. Drive gear
9. Cable 21. End plate
10. Screw 22. Pins
11. Lock washer 23. Wear plate
12. Washer
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Auxiliary steering - Remove - Pump and motor

NOTE: refer to Auxiliary steering - Component identification for the numbering of procedure.
1. Park the machine on level ground and lower bucket to
ground. Put transmission in NEUTRAL, apply parking
brake, and shut down the engine.
3. Tag and disconnect the two wiring harnesses (8) from
auxiliary steering pump and motor (7) solenoid.
4. Tag and disconnect the positive cable (2) from the B+
stud of the auxiliary steering pump and motor.
5. Tag and disconnect the ground cable (1) from the
ground stud of the auxiliary steering pump and motor
(7).
9. Disconnect the suction hose (4) from the auxiliary
steering pump and motor (7). Install a plug in suction
hose and cap on fitting.
11. Loosen the fittings on pressure tube (5).
12. Support the auxiliary steering pump and motor (7).
Remove bolts (3) and washers securing the auxiliary
steering pump and motor (7).
13. Remove the pressure tube (5) and the auxiliary steer-
ing pump and motor (7).
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Auxiliary steering - Install - Pump and motor

NOTE: refer to Auxiliary steering - Component identification for the numbering of procedure.
1. Position the auxiliary steering pump and motor (7) on
its mounting plate while connecting and hand tightening
the pressure tube (5) to auxiliary steering priority valve
(6).
2. While the supporting auxiliary steering pump and motor
(7) have an assistant install washers and bolts (3) to se-
cure the auxiliary steering pump and motor (7), tighten
the nuts.
3. Tighten the pressure tube (5) fittings securely.
5. Remove the plug from suction hose (4) and cap from
elbow. Connect the suction hose to elbow installed in
auxiliary steering pump and motor (7).
6. Stop and disconnect the vacuum pump. Install the fill
cap in hydraulic reservoir.
7. Connect the ground cable (1) to the ground stud of
auxiliary steering pump and motor (7) following tag in-
stalled during removal.
8. Connect the positive cable (2) to B+ stud of auxiliary
steering pump and motor (7) following tag installed dur-
ing removal.
9. Connect the wiring harness wires (8) to the auxiliary
steering pump and motor (7) following tags installed
during removal.
10. Put the timed disconnect switch in ON position.
11. Start and run the engine at low idle and raise bucket
500 mm (20 in) above ground. Check that the auxil-
iary steering light on information center is OFF.
NOTICE: in following step, do not run auxiliary steering
pump and motor continuously for more than 20 s at a time
without a two minute cool down.
12. With the engine at low idle and machine steering
straight ahead, turn the key switch to OFF position
to stop engine and then immediately back to ON
position (not START position). Auxiliary the steering
pump and motor should start operating immediately.
Check that the auxiliary steering light on information
center is ON and the auxiliary steering pump and
motor is operating.
13. Turn the steering wheel all the way to left and right to
make sure that the auxiliary steering pump and motor
operates correctly.
14. Restart engine. Check that the auxiliary steering light
on information center stays ON and the auxiliary steer-
ing pump and motor is operating. After about three
seconds the motor should stop operating and auxil-
iary steering light should go out.
15. Let the engine run and allow batteries to recharge for
a minimum of 10 min.
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Auxiliary steering - Test

Pump test
Equipment required
380001731 Flowmeter
380001740 Flowmeter fitting kit
Test procedure
NOTE: when performing this pressure check, always be
sure the articulation lock is in place, especially when work-
ing in the articulation joint areas.
2. Loosen and remove the outlet hose to the Auxiliary
Steering Pump from the Auxiliary Steering Priority
Valve.
3. Install a plug into the Auxiliary Steering Priority Valve.
4. Connect the inlet of the flowmeter to the outlet line of
the Auxiliary Steering Pump.
5. Install the outlet hose of the flowmeter in the hydraulic
1
reservoir and hold in place with wire. RCPH10WHL063BAL
6. Connect the ammeter clamp (1) to the cable as in illus-

tration.
7. Make sure that the parking brake is applied and the
bucket is on the floor.
8. Make sure that the oil is at operating temperature.
9. Make sure that the load valve for the flowmeter is open
(zero pressure).
10. Start and run the engine.
11. Stop the engine and turn the key back to the On posi-
tion.
LEIL13WHL0658AB 2
12. Turn the steering wheel, this will activate the auxiliary
steering pump.
13. Turn the load valve on the flowmeter towards
CLOSED until the pressure is 104 bar (1508 psi).
14. Read the flowmeter and ammeter gauges and record
the readings.
15. The flowmeter reading must not be less than 24.6 L/
min (6.5 US gpm). The ammeter reading must be
315 A.
16. Turn the key switch to the OFF position. If the flow
was less than the specification, or if the amperage was
more than 315 A, remove the auxiliary steering motor
and pump. Test the auxiliary steering motor. If the
motor is good, make repairs to the pump.
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Motor test
Equipment required
A 24 volt battery that is fully charged.
NOTE: a 24 volt battery system (two 12 volt batteries in a
series) is used for this test. A 12 volt battery system will
cause damage to the auxiliary steering motor.
A remote starter switch.
A tachometer to check the armature speed.
A Sun Electric VAT-33 Starting and Charging System
Tester.
Test procedure
1. Remove the connector that is between the terminals on
the magnetic switch and the auxiliary steering motor. .
2. Remove the auxiliary steering motor from the auxiliary
steering pump.
3. Remove the drive coupling from the auxiliary steering
motor (3).
4. Connect the auxiliary steering motor (3), remote starter
switch (1) and tester (2) to the 24 volt battery system
(5) as illustrated.
LEIL13WHL0659AB 3
5. Push the button on the remote starter switch (1) and

look at the voltmeter in the tester.
6. Turn the load control (8) until the voltmeter (7) indicates
24 volts. Look at the ammeter (6) in the tester. Make a
record of the ammeter indication.
LEIL13WHL0660AB 4
7. Hold the tachometer against the armature shaft. Look

at the tachometer. Make a record of the indication.
8. Release the button on the remote starter switch (1).
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Understanding the results of the test

1. If the ammeter indication in step 6 was 30 A or less and
the tachometer indication in step 7 was 6950 RPM or
more, the auxiliary steering motor is good.
2. If the armature speed was less than 6950 RPM and the
ammeter indication was higher than 30 A, replace the
motor.
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Auxiliary steering - Disassemble - Motor and pump

NOTE: refer to Auxiliary steering - Exploded view for the numbering of procedure.
NOTE: the pump is the only component that is disassembled. The switch (8) and motor (1) are replaced as units and
are not serviced.
1. Make an alignment mark on the pump assembly and
the motor (1).
NOTE: The pump is the only component that is disassem-
bled. The switch (8) and the motor (1) are replaced as units
and are not serviced.
2. Loosen and remove the two screws (15) and the lock
washers (14) that hold the pump assembly to the motor
(1).
3. Remove and discard the mounting gasket (13), the re-
taining ring (3) and the seal (4) from the pump assem-
bly.
4. Loosen and remove the four bolts (2) that hold the
pump assembly together.
5. Remove the end plate (21) from the body (18).
6. Remove and discard the seal (6) and the backup ring
(5) from the end plate (21).
7. Remove the wear plate (23), the drive gear (20) and
the driven gear (19) from the body (18).
8. Remove the body (18) from the plate (17).
9. Remove and discard the O-rings (7) from the body (18).
10. Remove the pins (22) and the wear plate (23) from the
body (18).
11. Remove and discard the seal (6) and the backup ring
(5) from the plate (17).
NOTE: the only serviceable items on the pump assembly
are the seals (6), the backup rings (5), the O-rings (7), the
seal (4), the retaining ring (3) and the gasket (13). If any of
the other items are damaged, replace the pump assembly.
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Auxiliary steering - Inspect - Motor and pump

1. Inspect the wear plates (23) for grooves, scoring and
pitting. If damage is found replace the pump assembly.
2. Inspect the drive gear (20) and driven gear (19). If the
shafts are worn or damaged, replace the pump assem-
bly.
3. Clean all parts in cleaning solvent and air dry.
4. Inspect the plate (17), end plate (21) and body (18).
Replace the pump assembly as necessary.
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Auxiliary steering - Assemble - Motor and pump

1. Lubricate all parts with clean hydraulic oil before as-
sembly.
2. Lubricate and install a new seal (4) and the retaining
ring (3) on the plate (17).
3. Lubricate and install a new backup ring (5) and a new
seal (6) on the plate (17).
4. Lubricate and install new O-rings (7) on the body (18) .
5. Lubricate and install the pins (22), the drive gear (20),
the driven gear (19) and the wear plates (23) on the
body (18).
6. Lubricate and install a new backup ring (5) and a new
seal (6) on the end plate (21).
7. Align the marks, made during disassembly, on the end
plate (21), the body (18) and the plate (17) and install
the four bolts (2). Tighten the four bolts (2).
8. Install a new gasket (13) on the pump assembly.
9. Align the marks, made during disassembly, on the
pump assembly and on the motor (1).
10. Install the lock washer (14) and the screw (15). Torque
the screw (15) to 35 – 39 N·m (310 – 345 lb in).
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Pump - Test
Auxiliary steering pump flow test
NOTE: the following procedures is for the steering pump section flow test, readings will be much lower than that of a
combined flow test.
NOTE: if unit is equipped with auxiliary steering a tee fitting will have to be used in this location
LEIL13WHL1364GB 1
1. Pump inlet hoses 8. Steering pressure hose

2. Filter inlet manifold 9. Steering pump section
3. Flowmeter outlet hose 10. Loader pump
4. Filters 11. Loader pressure hose
5. 380001731 Flowmeter 12. Check valve
6. Flowmeter inlet hose 13. Articulation pressure hose
7. Elbow 14. Priority valve
48083742_EN 31/07/2018
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1. Connect the flow meter to the filter manifold as shown.

2. Disconnect steering pressure hose (8) from elbow (7).
3. Cap elbow (7) and connect the flowmeter inlet hose (6)
to the steering pressure hose (8).
4. Make sure the load control of the flow meter is open.
Start the engine. Run the engine at full throttle. Make
sure the oil is at operating temperature.
5. Measure the flow at 0 bar ( 0 psi ). Record the flow
reading. Slowly close the load valve on the flow meter
and read the flow at 170 bar ( 2500 psi ). Record the
flow reading.
6. Divide the flow reading at 170 bar ( 2500 psi) by the
reading at 0 bar ( 0 psi). Multiply the result by 100.
This is the percent efficiency of the pump. If the effi-
ciency of the pump is less than 85%, repair or replace
the pump.
7. Stop the engine. Remove cap from elbow (7).
8. Disconnect the flowmeter inlet hose (6) from the steer-
ing pressure hose (8).
9. Connect steering pressure hose (8) to elbow (7).
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Index
Steering - 41

Auxiliary steering - Assemble - Motor and pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Auxiliary steering - Component identification - Pump and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Auxiliary steering - Disassemble - Motor and pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Auxiliary steering - Exploded view - Motor and pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Auxiliary steering - Inspect - Motor and pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Auxiliary steering - Install - Pump and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Auxiliary steering - Remove - Pump and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Auxiliary steering - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Motor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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PRINTED IN ITALY
48083742_EN 31/07/2018
EN
SERVICE MANUAL
Wheels

48083742_EN 31/07/2018
44
Contents
Wheels - 44
[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1
[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2
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44
Wheels - 44
Front wheels - 511

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Contents
Wheels - 44
Front wheels - 511
TECHNICAL DATA
Front wheels
Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Front wheels
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Wheels - Front wheels
Front wheels - Tire pressure

WARNING
Explosion hazard!
Never weld on a wheel. Welding can cause stresses that will cause a wheel to crack or break unexpect-
edly. Tires can separate explosively during welding. Always have a qualified tire mechanic service
wheels and tires.
W0124A
Service specifications - Normal Work Tire Inflations

1021G Tire type Front pressure
26.5 x 25 L3 Bias 20 Ply 3.5 bar (50 psi)
26.5 R25 L3 Radial 4.5 bar (65 psi)

1121G Tire type Front pressure
26.5 R25 L3 Radial 5 bar (73 psi)
26.5 R25 L5 Radial 5 bar (73 psi)
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Front wheels - Service instruction

NOTE: this instruction is applicable both to the front and the rear tires.
1. The wheel bolts must be tightened after every 20 hours
of operation until the wheel bolts stay tight:
A. If the machine is new.
B. If a wheel has been removed and installed.
NOTICE: The split rim wheels used on this machine can be dangerous. When inflating a tire on the machine, use a
self-locking nozzle and stand at the front or rear of the tire.
When inflating a tire off the machine, put the wheel in a tire inflation cage. The retaining ring and rim can come off
with enough force to result in death to a person in front of the rim.
NOTICE: Have a qualified tire mechanic service the split rim wheels used on this machine. The correct tire equipment,
especially a tire inflation cage, is required. Using the wrong procedure for a split rim wheel can result in death.
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Front wheels - Install

1. Make sure the mounting surfaces of the rim and axle
flange are clean and free of dirt and grease.
2. Install the wheel, hardened washers and wheel bolts.
3. Use a hand wrench (not an impact) to tighten the wheel
bolts to pull the wheel against the planetary housing.
DO NOT use an impact wrench to tighten the wheel
bolts.
Stud mounted wheels

Machines are equipped with stud mounted wheels.
Wheel studs offer greater strength due to an increase
in clamping force and resistance to loosening.
RCPH11WHL073AAH 1
4. Tighten the wheel bolts to 278 N·m (205.0 lb ft), then

tighten to a final torque of 640 – 720 N·m (472.0 –
531.0 lb ft), using the same sequence.
LEEN11T0189AA 2
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Index
Wheels - 44
Front wheels - 511

Front wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front wheels - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front wheels - Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Wheels - 44
Rear wheels - 520

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Contents
Wheels - 44
Rear wheels - 520
TECHNICAL DATA
Rear wheels
Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Rear wheels
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Wheels - Rear wheels
Rear wheels - Tire pressure

WARNING
Explosion hazard!
Never weld on a wheel. Welding can cause stresses that will cause a wheel to crack or break unexpect-
edly. Tires can separate explosively during welding. Always have a qualified tire mechanic service
wheels and tires.
W0124A

1021G Tire type Rear pressure

1121G Tire type Rear pressure
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Wheels - Rear wheels
Rear wheels - Install

1. Make sure the mounting surfaces of the rim and axle
flange are clean and free of dirt and grease.
2. Install the wheel, hardened washers and wheel bolts.
3. Use a hand wrench (not an impact) to tighten the wheel
bolts to pull the wheel against the planetary housing.
DO NOT use an impact wrench to tighten the wheel
bolts.
Stud mounted wheels

Machines are equipped with stud mounted wheels.
Wheel studs offer greater strength due to an increase
in clamping force and resistance to loosening.
RCPH11WHL073AAH 1
4. Tighten the wheel bolts to 278 N·m (205.0 lb ft), then

tighten to a final torque of 640 – 720 N·m (472.0 –
531.0 lb ft), using the same sequence.
LEEN11T0189AA 2
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Index
Wheels - 44
Rear wheels - 520

Rear wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear wheels - Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN ITALY
48083742_EN 31/07/2018
EN
SERVICE MANUAL
Cab climate control

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50
Contents
Cab climate control - 50
[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
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Heating - 100

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Contents
Heating - 100
SERVICE
Heater core
Remove - and water valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install - and water valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Cab climate control - Heating
Heater core - Remove - and water valve

bucket to the ground.
2. Put the articulation lock in the locked position.
3. Turn the timed disconnect switch in the OFF position.
4. Put a suitable container below the radiator drain. Re-
move cap and drain coolant into container. Install cap
5. Open the cab window to facilitate the removal of bolts
(arrows).
Remove the six bolts (arrows) and related washers to
unfix the HVAC cover.
LEIL16WHL1190AB 1
6. Loosen the clamps (1).

Remove the air intake hose (2).
LEIL16WHL1209AB 2
7. Disconnect the PRH2 connector (1) of the engine and

rear chassis harness. Remove the clamps (2) securing
the wire to the cab frame.
LEIL16WHL1193AB 3
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8. Loosen the clamp (2). Disconnect and plug the heater

hoses (1).
LEIL16WHL1241AB 4
9. Remove the grommet.
LEIL18WHL0452AB 5
10. Remove the three retaining knobs that hold the cab
air recirculation filter cover in place.
LEIL18WHL0453AB 6
11. Extract the cab air recirculation filter.
LEIL18WHL0454AB 7
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12. Position the cover case in place. Install the cover case
with 16 screws.
NOTE: for clarity, only one of the 16 screws is indicated in
figure 8.
LEIL18WHL0459AB 8
13. Disconnect the electrical connector.
LEIL18WHL0466AB 9
14. Remove the bolts (1) holding the heat exchanger (2)
on the cab heater case.
LEIL16WHL1247AB 10
15. Extract the heat exchanger as an assembly.
LEIL16WHL1248AA 11
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50.1 [50.100] / 5
16. On bench, disassemble heat exchanger.

Remove the two clamps (3) to separate the heater
core (1) from the water valve (2). Remove the two
screws (4) to separate the bracket (5) to the water
valve (2).
LEIL18WHL0468FB 12
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Heater core - Install - and water valve
LEIL18WHL0468FB 1
1. On bench, install the heater core (1) to the water valve

(2) with two clamps (3).
Install the bracket (5) to the water valve (2) with the two
screws (4).
2. Insert the cab heater assembly in case.
Fix the cab heater assembly (2) with the bolts (1).
LEIL16WHL1247AB 2
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3. Connect the electrical connector.
LEIL18WHL0466AB 3

with 16 screws.
figure 4.
LEIL18WHL0459AB 4
5. Insert the cab air recirculation filter.
LEIL18WHL0454AB 5
6. Install the cab air recirculation filter cover with the three
retaining knobs.
LEIL18WHL0453AB 6
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7. Install the grommet.
LEIL18WHL0452AB 7
8. Remove plugs from the heater hoses (1). Tighten the

clamps (2).
LEIL16WHL1241AB 8
9. Connect the PRH2 connector (1) of the engine and rear

chassis harness. Install the clamps (2) securing the
wire to the cab frame.
LEIL16WHL1193AB 9
10. Install the air intake hose (2) with the clamps (1).
Tighten the clamps (1) to 3.4 N·m (30.1 lb in).
LEIL16WHL1209AB 10
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11. Open the cab window to facilitate the installation of

bolts (arrows). Tighten the six mounting bolts and
washers to install the HVAC cover.
LEIL16WHL1190AB 11
12. Put the timed disconnect switch to ON position

13. Put the articulation lock in OPERATING position.
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Index
Heating - 100
Heater core - Install - and water valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Heater core - Remove - and water valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Air conditioning - 200

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Contents
TECHNICAL DATA
Air conditioning
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Air conditioning
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE
Air conditioning
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service instruction - Safety procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Service instruction - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Air-conditioning compressor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Air-conditioning condenser
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Receiver-dryer
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Air-conditioning evaporator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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Cab climate control - Air conditioning
Air conditioning - General specification

Pressure/Temperature chart
Ambient Temperature Normal Low Pressure Normal High Pressure Air Louver Maximum
Indication Indication Temperature
27 °C (80 °F) 0.62 – 0.83 bar (9 – 12 psi) 10.0 – 11.5 bar (145 – 14 °C (57 °F)
165 psi)
32 °C (90 °F) 0.76 – 1.00 bar (11 – 13.1 – 14.5 bar (190 – 18 °C (64 °F)
15 psi) 210 psi)
35 °C (95 °F) 1.10 – 1.24 bar (16 – 14.5 – 15.8 bar (210 – 20 °C (68 °F)
18 psi) 230 psi)
38 °C (100 °F) 1.17 – 1.31 bar (17 – 16.2 – 17.6 bar (235 – 22 °C (72 °F)
19 psi) 255 psi)
41 °C (106 °F) 1.38 – 1.45 bar (20 – 17.9 – 19.3 bar (260 – 23 °C (73 °F)
21 psi) 280 psi)
43 °C (109 °F) 1.90 – 2.14 bar (27 – 20.0 – 21.4 bar (290 – 25 °C (77 °F)
31 psi) 310 psi)
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) Air Conditioning switch ON. Both cab doors open.
(5) All panels and access doors installed and closed.
(6) Cab filters clean and installed. Heater valve at engine closed.
(7) Measurements taken 15 minutes after start-up.
Refrigerant charge 1.67 – 1.73 kg (3.75 – 3.81 lb)
Air conditioning - Special tools

380001325 Belt tension tool
LEIL13WHL1088AA 1
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OEM1598 Refrigerant recovery, recycling and charging

station
LEIL13WHL1085AA 2
380001327 Electronic leak detector
LEIL13WHL1086AA 3
Air conditioning - Torque

Tube connections torque chart
Description Parts to be Tube size Thread size Hexagonal size Material Torque
connected
Receiver/Dryer Dryer, HFC- 3/8 5/8-18 3/4 Steel to steel 31 – 36 N·m
outlet 134a (23 – 27 lb ft)
Low Pressure Switch for low - M10x1.25 - 6G 9/16 Steel to steel 8 – 10 N·m
Switch air conditioning (6 – 7 lb ft)
pressure
Cab air Tube for cab 3/8 5/8-18 3/4 Steel to steel 31 – 36 N·m
conditioning air conditioning (23 – 27 lb ft)
inlet liquid
Cab air Tube for cab 5/8 7/8-14 1 1/8 Steel to steel 45 – 52 N·m
conditioning air conditioning (33 – 38 lb ft)
outlet suction
Compressor Compressor - 1-14 1 1/8 Steel to 45 – 52 N·m
inlet aluminium (33 – 38 lb ft)
Compressor Compressor - 1-14 1 1/8 Steel to 45 – 52 N·m
outlet aluminium (33 – 38 lb ft)
High Pressure Switch for high - M10x1.25 - 6G 9/16 Steel to steel 8 – 10 N·m
Switch air conditioning (6 – 7 lb ft)
pressure
Condenser Condenser 3/8 5/8-18 3/4 Brass to steel 24 – 30 N·m
inlet hose (18 – 22 lb ft)
Condenser Condenser 3/8 5/8-18 3/4 Brass to steel 18 – 23 N·m
outlet (13 – 17 lb ft)
Receiver/Dryer Dryer, HFC- 3/8 5/8-18 3/4 Brass to steel 31 – 36 N·m
inlet 134a (23 – 27 lb ft)
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NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used.
NOTE: Special care is required when tightening the fittings on the compressor, condenser and evaporator since these
connections are easily distorted. Overtightening connections may crush the O-rings and cause leaks.
NOTE: O-rings must be oiled and properly positioned prior to making the connection. Un-oiled O-rings may become
cut or misaligned.
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Air conditioning - Dynamic description

The refrigerant circuit of the air conditioning system contains five major components: compressor (3), condenser (4),
receiver-drier (5), expansion valve (1) and evaporator (2). These components are connected by tubes and hoses and
operate as a closed system. The air conditioner system is charged with HFC R134A refrigerant.
The compressor receives the refrigerant as a low pressure gas. The compressor then compresses the refrigerant
and sends it in the form of a high pressure gas to the condenser. The air flow through the condenser then removes
the heat from the refrigerant. As the heat is removed the refrigerant changes to a high pressure liquid.
The high pressure refrigerant liquid then flows from the condenser to the receiver-drier. The receiver-drier is a con-
tainer filled with moisture removing material, which removes any moisture that may have entered the air conditioner
system in order to prevent corrosion of the internal components of the air conditioner system.
The refrigerant, still in a high pressure liquid form, then flows from the receiver-drier to the expansion valve. The ex-
pansion valve then causes a restriction in flow of refrigerant to the evaporator core. The evaporator meters refrigerant
flow based on evaporator heat load.
As the refrigerant flows through the evaporator core, the refrigerant is heated by the air around and flowing through
the evaporator fins. The combination of increased heat and decreased pressure causes the air flow through the
evaporator fins to become very cool and the liquid refrigerant to become a low pressure gas. The cooled air then
passes from the evaporator to the cab for the operator’s comfort.
The electrical circuit of the air conditioning system consists of a fan speed control, temperature control, one relay, a
blower motor, blower resistor, Air Conditioning compressor clutch, Air Conditioning low pressure switch, Air Condi-
tioning high pressure switch, and Air Conditioning warning light.
LEIL15WHL0770FB 1
1. Expansion valve 4. Condenser B. Low pressure liquid

2. Evaporator 5. Dryer C. High pressure gas
3. Compressor A. Low pressure gas D. High pressure liquid
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Air conditioning - Exploded view
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1. Cases assembly 16. Driver

2. Driver plate 17. Resistor
3. Evaporator 18. Harness
4. Heater 19. HVAC label
5. Drain water tank 20. Cover air filter O-ring
6. Blower 24 V 21. Cases O-ring
7. Air filter cover 22. Knobs
8. Air filter 23. Insert M6
9. Blower flange 24. Bushing
10. Gasket 25. Clamp
11. Drain water gasket 26. Plastic blocks
12. Cases gasket 27. Screws
13. Evaporator sensor 28. Insulation ring
14. Evaporator sensor bracket 29. Grommet
15. Blower flange gasket 30. Rubber washer
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Air conditioning - Visual inspection

Perform a visual inspection of the machine. Check the
following and correct as necessary:
1. Obtain service history if possible.
2. Is compressor drive belt in place and tensioned?
3. Are grille screens, fan blades, condenser, air filter and
evaporator unobstructed?
4. Are there any sharp bends or kinks in the hoses?
5. Are there heavy accumulations of oil, or oily dust
around the fittings, indicating refrigerant leakage?
6. Are air ducts undamaged, sealed properly and in posi-
tion?
7. Are the condensation drain hoses and the check valves
present and unobstructed?
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Air conditioning - Service instruction

Problem: no cooling
See pressure - temperature chart on Air conditioning
- General specification (50.200).
Temperature of low pressure gauge: very low
Temperature of high pressure gauge: very low
Indication of no refrigerant or low refrigerant charge:

1. Leak test the system. It may be necessary to
add refrigerant.
2. Evacuate and reclaim remaining refrigerant
from system.
A. Discharge air from evaporator is warm. 3. Repair system leaks as needed. Follow the
given repair procedure.
B. Compressor does not run, or cycles off Yes
rapidly after start-up. (Air conditioning 4. Check level of oil in compressor - possible for
warning light in cab should illuminate). compressor to have an oil loss.
5. Remove air and moisture from the system.
6. Charge system with new refrigerant.
7. Continue performance test for other possible
problems.

Temperature of low pressure gauge: high
Temperature of high pressure gauge: high
Indication of large quantity of air in the system:

1. Evacuate and reclaim refrigerant from
system.
Discharge air from evaporator is warm Yes
Condenser malfunctioning - Indications:

1. Check for loose or worn compressor or
engine fan belt and proper condenser fan
operation.
2. Check to see that condenser is clean and
unobstructed and that the fins are straight.
3. Check system for too much refrigerant.
Evacuate, reclaim and recharge refrigerant
until gauge pressure is normal.
A. Liquid line (between evaporator and
condenser) is very hot. 4. Remove and check condenser for restrictions
caused by oil or reduced heat transfer.
B. Discharge air from evaporator is warm.
A. Remove refrigerant from the system.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the system.
5. Continue the performance test for other
possible problems.
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Expansion valve malfunctioning - Indications:

A. Discharge air from heater/evaporator is
warm.
B. Excess condensation on suction hose at Replace the expansion valve.
compressor.
C. Excess condensation on evaporator outlet.
Refrigerant contamination:
1. See table below and check stable saturation
pressures at given temperature to determine
if contamination exists.
A. Measure pressure from gauge on
reclamation unit.
B. Measure temperature from refrigerant in
Refrigerant Contamination reclamation tank. If refrigerant has been
in reclamation unit for some time, use
ambient temperature. The numbers in
the table represent the boiling point for
R134A.
C. Pressure readings below range given in
chart indicate contaminated refrigerant.
NOTICE: do not use contaminated refrigerant or mix with uncontaminated refrigerant. Dispose of in accordance with
all applicable laws and local procedure.
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HFC-134a stable saturation pressure / temperature chart

Temperature °F (° C) Pressure PSIG (Bar)
50 (10) 45 (3.1)
55 (13) 51 (3.5)
60 (16) 57 (3.9)
65 (18) 64 (4.4)
70 (21) 71 (4.9)
75 (24) 78 (5.4)
80 (27) 88 (6.1)
85 (29) 95 (6.6)
90 (32) 104 (7.2)
95 (35) 114 (7.9)
100 (38) 124 (8.6)
102 (39) 129 (8.9)
104 (40) 133 (9.2)
106 (41) 138 (9.5)
108 (42) 142 (9.8)
110 (43) 147 (10.1)
112 (44) 152 (10.5)
114 (46) 157 (10.8)
116 (47) 162 (11.2)
118 (48) 167 (11.5)
120 (49) 172 (11.9)
Problem: not enough cooling

- General specification (50.200)
Temperature of low pressure gauge: normal to slightly
high
Temperature of high pressure gauge: normal
Air in the system - Indications:

1. Test system for leaks.
2. Discharge system of refrigerant.
A. Suction line is warm to the touch.
3. Repair system leak as necessary.
B. Discharge air from heater/evaporator is only
4. Check compressor oil level.
a little cool.

Temperature of low pressure gauge: low
Temperature of high pressure gauge: low
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Not enough refrigerant - Indications:

1. Leak test system - system has a loss of refrigerant.
A. If leak is found, go to Step 2.
B. If no leak is found, go to Step 6.
A. Discharge air from evaporator 2. Discharge refrigerant from system.
is either cool or warm - not
cold. 3. Repair system leaks as needed.
4. Check oil level in compressor - It is possible for compressor to lose oil.
NOTE: normally, the system will lose 1/2 – 1 ounce ( 14.7 – 29.5 grams ) of refrigerant between seasons.
High side restriction - Indications:

1. Discharge refrigerant from system-restriction
A. Discharge air from heater/evaporator is only in receiver-drier or liquid line must be
a little cool. removed.
B. Condensation or frost on receiver-drier. 2. Remove and replace part with restriction.
C. Liquid line to receive drier is cool, with frost 3. Remove air and moisture from the system.
or condensation present.
NOTE: the frost will form downstream from or at the point of the restriction.
Expansion valve not operating - Indications:

1. Expansion valve outlet with condensation or
frost present is an indication of a restriction
A. Discharge air from evaporator is either cool in the expansion valve. Replace expansion
or warm - not cold. valve.
B. Condensation or frost is present on 2. Inlet end of expansion valve is warm (not hot),
expansion valve outlet. indicating expansion valve is not completely
C. Inlet end of expansion valve is warm. open. If the valve is stuck closed, there will
be little or no flow of refrigerant through the
valve. Replace expansion valve.
See the pressure - temperature chart on Air condition-

ing - General specification (50.200).
Temperature of high pressure gauge: low
Compressor turning but not pumping properly - Indications:

1. Discharge refrigerant from system.
2. Remove the compressor from the machine.
A. System is fully charged. 3. Remove and replace compressor because
there is indication of internal leak in
B. Discharge air from evaporator is cool. compressor.
4. Replace compressor.
5. Charge the system with refrigerant.
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Expansion valve stuck open

Expansion Valve Stuck Open 1. Replace expansion valve.

Condenser not operating - Indications:

1. Check for loose or worn compressor belt and
proper condenser fan operation.
2. Check to see that condenser is clean and
that the fins are straight.
3. Check system for too much refrigerant.
A. Remove refrigerant from system until
gauge pressure is below normal.
B. Add refrigerant until gauge pressures are
A. Liquid line is very hot. normal.
B. Discharge air from evaporator is warm. C. If problem persists, see step 4.
4. Remove and inspect condenser for
restrictions caused by oil or reduced heat
transfer.
A. Discharge refrigerant from system.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Charge system with new refrigerant.
Air in the system - Indications:

1. Discharge refrigerant from system.
2. Replace receiver-drier.
Discharge air from evaporator is warm.
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Problem: Intermittent cooling

Temperature of low pressure gauge: normal T
emperature of high pressure gauge: normal
Moisture in the system - Indications:

1. Discharge system of refrigerant. If too much
moisture enters the orifice of the expansion
valve, the freezing of this moisture can stop
refrigerant flow.
Cooling is acceptable during cool part of day but 2. Replace receiver-drier. The moisture
not acceptable during hot part of day. removing material could be full to capacity
with moisture.
NOTE: the time needed to remove a large amount of moisture will be two to three hours minimum.
Problem: Noise in system

Temperature of low pressure gauge: normal to high
Too much refrigerant in system - Indications:

1. Remove refrigerant from system until gauge
A. Discharge air from heater/evaporator is cool. readings are below normal.
B. Compressor makes noise. 2. Add new refrigerant until gauge readings are
normal.
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Air conditioning - Service instruction - Safety procedures

DANGER
Avoid injury!
Observe ALL precautions listed below when servicing the air-conditioning system and handling re-
frigerant.
Failure to comply will result in death or serious injury.
D0043A
Refrigerant HFC-134a is the most stable, and easiest to work with of the refrigerants now used in air conditioner
systems. Refrigerant HFC-134a does not contain any chlorofluorocarbons (CFC's) which are harmful to the earth's
ozone layer.
Safety procedures must be followed when working with Refrigerant HFC-134a to prevent possible personal injury.
NOTICE: only authorized technicians certified by an approved training and certification organization may service or
repair motor vehicle or mobile air conditioning systems. It is mandatory that all refrigerant must be RECOVERED and
RECYCLED when removed from a system during servicing.
1. Always wear safety goggles when doing any service
work near an air conditioner system. Liquid refrigerant
getting into the eyes can cause serious injury. Do the
following if you get refrigerant near or in your eyes:
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately.
2. A drop of liquid refrigerant on your skin may cause frost-
bite. Open the fittings carefully and slowly when it is
necessary to service the air conditioner system. Your
skin must be treated for frostbite or a physician must
be seen if you get refrigerant on your skin.
3. Keep refrigerant containers in the correct upright po-
sition. Always keep refrigerant containers away from
heat and sunlight. The pressure in a container will in-
crease with heat.
4. Always reclaim refrigerant from the system, if you are
going to weld or steam clean near the air conditioner
system.
5. Always check the temperature and pressure of the air
conditioner system before reclaiming refrigerant and
when you test the system.
6. Dangerous gas can form when refrigerant comes in
contact with an open flame. Never permit fumes to be
inhaled.
7. Never leak test with compressed air or flame testers.
Tests have indicated that compressed mixtures of HFC-
134a and air can form a combustible gas.
8. Always reclaim refrigerant from the system before re-
moving any air conditioning component.
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Air conditioning - Pressure test

NOTICE: refer to .”Air conditioning – General specification”.
Manifold Gauge Set

NOTE: The gauge set is not accurate enough to optimize
an existing charge of HFC-134a. The best use of the gauge
set is to determine whether undercharge or overcharge ex-
ists, and then evacuate, reclaim and recharge system with
the recommended quantity (charge) of HFC-134a.
The manifold gauge set is the most important tool used
to service the air conditioning system. The manifold
gauge set is used to measure the high and low pres-
sures of the system, as a tool to troubleshoot for cor-
rect refrigerant charge quantity, system diagnosis, and
operating efficiency. The manifold gauge set can read
both the high (discharge) and low (suction) sides at the
same time, since pressure must be compared in order
to make a diagnosis of system operation.
LOW PRESSURE GAUGE - The low pressure gauge is
a compound gauge. It is best used to judge evacuation
effectiveness. A vacuum reading indicates a system
malfunction. For this reason, it is necessary to use a
compound gauge that will indicate both pressure and
vacuum.
During normal operation the low pressure gauge must
always indicate from 10 – 35 psi ( 0.7 – 2.4 bar) after
the system has run 10 – 15 minutes.
HIGH PRESSURE GAUGE - The high pressure gauge
is used to indicate pressures in the high side of the sys-
tem. The gauge must indicate from 0 – 400 psi ( 0 –
27.6 bar) minimum.
During normal operation, the high pressure gauge will
normally indicate from 120 – 310 psi ( 8.3 – 21.4 bar).
See pressure-temperature chart on Air conditioning -
General specification (50.200).
Pressure Test Connection

Connect the manifold gauge set into the air conditioning
system as shown. Make sure that both valves in the
manifold gauge set are closed.
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Air conditioning - Charging

Recovery and charging station connections
1. Clean the external surfaces of the compressor and
hoses. Remove the caps from the service ports on the
suction and pressure hoses.
NOTICE: Do not steam clean any air conditioning system
parts while the system is charged. The heat will cause the
refrigerant to rise to a pressure that could cause the system
to explode.
2. Connect the hoses from the test gauges to the service
ports by turning the knurled knobs on the depressors.
3. Connect the hose from the low pressure gauge to the
port on the suction hose.
4. Connect the hose from the high pressure gauge to the
port on the discharge hose.
NOTICE: Always wear safety goggles when working with
liquid refrigerant. Liquid refrigerant in your eyes could
cause blindness.
5. Make sure the charging station OEM1598 manifold
gauge valves are in the closed position.
6. Start the engine and run at 1500 RPM maximum
speed. Operate the air conditioner system at maximum
cooling setting and blower speed for 15 minutes with
the cab door open. Observe the test gauges and check
the chart on page 13 against the gauge readings.
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Air conditioner system refrigerant recovery

Recovered refrigerant passes through an oil separator
and a filter-drier before entering the refrigerant tank.
The moisture indicator will turn green when dry refrig-
erant passes over it. If possible, run the air condition-
ing system for ten minutes before starting the recovery
process. Turn the system off before proceeding.
1. Clean the external surfaces of the compressor and
hoses. Remove the caps from the service ports on the
suction and pressure hoses.
2. With the charging station manifold gauge valves in the
closed position, connect the hoses from the test gauges
to the service ports. Connect the hose from the low
pressure gauge to the port on the suction hose. Turn
in valve depressor. Connect the hose from the high
pressure gauge to the port on the discharge hose. Turn
in valve depressor.
3. Open the high and low valves.
LEIL13WHL1092AA 1
4. Make certain the refrigerant tank gas and liquid valves

are open.
LEIL13WHL1093AA 2
5. Connect the main power plug to a 115 V 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 complete.
Wait for 5 minutes and observe the manifold pressure
gauges for a pressure rise. If pressure rises above
0 bar (0 psi), depress the hold/cont switch. Then wait
for the compressor to automatically shut OFF.
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6. Drain the oil separator of the Air Conditioning system

oil. Open the air purge valve long enough to let some of
the compressor discharge pressure back into the sep-
arator.
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7. Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the oil
drain valve completely.
LEIL13WHL1096AA 5
8. Fill the Air Conditioning compressor with fresh SP-20

PAG oil equal to the amount in the reservoir.
LEIL13WHL1097AA 6
9. Remove the hoses from the service ports and install

the caps.
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Air conditioner system evacuation and recharching

NOTE: Replace the receiver-drier if one or more of the following conditions occurs before your remove the air and
moisture from the system
A. The system has been opened for service before.
B. Receiver-drier has operated two or more years.
C. Disassembly of compressor shows small particles
of moisture removing material (gold or brown par-
ticles).
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.
10. With the charging station manifold gauge valves in
the closed position, connect the hoses from the test
gauges to the service ports as follows:
1. Connect the hose from the low pressure gauge to
the port on the suction hose.
2. Connect the hose from the high pressure gauge
to the port on the discharge hose.
3. Turn in both thumbscrews to depress the service
valves.
NOTE: The pump on the reclamation unit will not pull a suf-
ficient vacuum to remove air and moisture. Air and mois-
ture are removed from the system by a vacuum pump. A
vacuum pump is the only equipment made to lower the
pressure enough to change the moisture to vapor that can
be removed from the system.
NOTE: Refer to the vacuum pump manufacturer’s user
manual for additional information.
11. Connect the main power plug to a 115 V AC outlet.
Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum of
45 minutes and press the Enter key. The display will
flash once indicating the programmed data has been
accepted.
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12. Press the Charge key. “Program” and “Charge” will

appear on the display.
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13. Program 3.5 lbs and press the enter key. The display
will flash once indicating the programmed data has
been accepted.
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14. Fully open the low and high pressure valves.
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15. Open the red (vapor) and blue (liquid) valves on the
tank.
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16. Press the Vacuum key. “Automatic” will appear on the

display. Vacuum will appear 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.
When the programmed time has elapsed, an auto-
matic hold occurs. Check the low pressure gauge
to see that the Air Conditioning system maintains a
28-29 in. of mercury (Hg). The low pressure gauge
must not increase faster than one inch of mercury (Hg)
in 10 min. A previously charged, leak-free system will
leach refrigerant from compressor oil and raise sys-
tem pressure under vacuum. If the system will not
hold vacuum, a leak exists that must be corrected be- LEIL13WHL1103AA 12
fore recharging can begin.
17. 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”.
LEIL13WHL1100AA 13
18. Completely close the high and low pressure manifold

valves.
NOTICE: Check the OEM equipment manual before per-
forming Step 19 to avoid damaging the recovery unit. The
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 Air Conditioning system is operating.
LEIL13WHL1102AA 14
19. Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting and
blower speed with the doors and windows open.
NOTE: The compressor will not operate if the system pres-
sure is too low or too high. The pressure indicator lamp will
illuminate when the relay is actuated by a low or high pres-
sure and the compressor clutch will disengage. To restart
the compressor, the air conditioner control or blower switch
must be turned to the OFF position and then to the ON po-
sition.
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20. Observe the pressure gauge readings to determine

that the correct amount of refrigerant has entered the
system.
LEIL13WHL1104AA 15
21. Stop the engine, close any open valves and carefully
remove the manifold gauge hoses.
22. Install the caps on the service ports on the suction and
discharge hoses.
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Air conditioning - Service instruction - Troubleshooting
Problem Possible Cause Correction

MECHANICAL See Mechanical Compressor Check
No Cooling (compressor doesn’t run) See Blower and Compressor Clutch
ELECTRICAL
Check
No Cooling (compressor runs) INTERNAL SYSTEM PROBLEM See Pressure Testing
Make sure the heater control is OFF
HEATER and that there is no coolant flow
through the heater core.
Make sure the sealing material is
SEAL
correctly in place.
Not Enough Cooling MECHANICAL See Mechanical Compressor Check
MECHANICAL See Evaporator Heater Core Check
See Blower and Compressor Clutch
ELECTRICAL
Check
REFRIGERANT See Cable Temperature Check
INTERNAL SYSTEM PROBLEM See Pressure Testing
See Blower and Compressor Clutch
ELECTRICAL
Check
Erratic Cooling ELECTRICAL Blower Motor Check
ELECTRICAL Blower Switch Check
ELECTRICAL Compressor Clutch Check
MECHANICAL See Blower Motor Check
System Makes Noise
ELECTRICAL See Compressor Clutch Check
Mechanical Compressor Check

Component Correction
Compressor and Fan Belts Too much belt wear - replace a worn belt, because a
worn belt will cause too much slippage.
Compressor Mounting Brackets 1. Loose bracket mounting bolts - tighten the bolts to the
correct torque.
2. Bracket has cracks or breaks - replace the bracket."
Compressor Clutch 1. The compressor belt will slip on the compressor pulley
if there is compressor seizure. Remove the compressor
for service or replacement.
2. Remove the dust cover and check the air gap on the
compressor clutch. The gap between the front plate
and pulley assembly must be 0.41 – 0.79 mm (0.02 –
0.03 in).
3. Use a socket wrench to slowly rotate the compressor
clockwise. Compressor rotation should be smooth and
not require much effort.
Pulley and Belt Alignment The compressor pulley and the compressor drive pulley
must be aligned within 1.6 mm (0.1 in) of each other.
Use a straight edge to check pulley alignment. Adjust the
compressor mounting bracket if needed.
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Blower and Compressor Clutch Check

Compressor Clutch NOTE: check supply voltage with compressor lead
plugged in and engaged. Voltage drops will not be ap-
parent without current flow.
1. If there is electrical system voltage to the clutch,
check for excessive voltage drop in the ground circuit,
and replace the compressor.
Low and High Pressure Switches Check the high and low pressure switches.
Blower Fuse ( 10 A) Check for damaged blower fuse.
Blower Fan Switch 1. Check switch operation. Switch must give four
different blower speeds: OFF, Low, High, and Purge.
2. Check for loose connections or broken wires. Repair
or replace as necessary.
3. Check resistor board.
Blower Motor 1. Check the wiring to the blower motor. Make repairs or
replace items as necessary.
2. Check motor ground wire. Make sure motor ground
wire is making good contact with mounting bracket.
Temperature Control Switch 1. With key in ON position, turn switch to maximum cold.
Compressor clutch must engage.
NOTE: blower must be operating, since electrical power
to temperature control switch is received from blower
switch.
2. Turn the blower off. Disconnect the wires from the
temperature control. Using an ohmmeter, check the
continuity between switch terminals. If continuity is not
present when switch is on maximum cold, replace switch.
Cab Temperature Check

Air Louvers 1. Make sure louvers and recirculation vents are fully
open for most efficient air conditioning operation. Defrost
louvers must be closed.
2. Check blower; blower must be running.
Air Conditioning NOTICE: use caution when feeling hoses. Hoses become
very hot. Check temperature by slowly reaching for hose
and touching briefly several times with finger tips, increas-
ing the duration with each touch.
1. Feel the air conditioning hoses. The high pressure
hoses (small line) must be warmer than the low pressure
hose (large line).
2. If no temperature difference, the system is low on
refrigerant, or compressor is not working correctly.
Duct Temperature 1. Put a thermometer in the air duct behind the seat
and run the compressor for f i ve minutes to make
temperature stable.
2. Duct temperature must be below 25 °C (77 °F) if the
system is operating at maximum efficiency.
3. If temperature is above 25 °C (77 °F), system is
low on refrigerant, there is a restr iction in the system,
compressor is not working correctly, or air ducts are not
sealed correctly.
NOTE: ambient temperature must be 27 – 43 °C (81 –
109 °F).
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Temperature Sensing Probe Check 1. Turn the engine OFF, key switch ON, blower switch
ON and temperature control switch turned fully clockwise.
2. Remove the temperature sensing probe from the
evaporator.
3. Put the end of the temperature sensing probe in a
container with ice and water.
4. When the sensing tube has cooled to the temperature
of the ice and water mixture, the temperature control
switch should interrupt the current flow to the compressor.
Check for current at the control switch terminals as on
previous page. If current is not interrupted then replace
the control switch.
Visual and Leak Check

Compressor Hoses 1. Make sure that all hose connections are tight.
2. Check hoses for bends or cracks. Replace all hoses
that have damage.
Leak Finding Check 1. Shut off the engine.
NOTICE: when refrigerant comes in contact with an open
flame, it can form dangerous gas. Never breathe these
fumes.
2. Use electronic leak detector 380001327 to inspect
all connections. Use instructions from manufacturer of
leak finding tool.
NOTE: when checking compressor seal for a leak, re-
move 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.
Condenser Make sure the condenser is clean and the seals are in
place. Make sure condenser fans run when temperature
control switch is ON.
Evaporator/Heater Core Check

Make sure heater valve is closed.
1. Inspect the fins on the evaporator/heater core. All the
fins that have bends or damage must be made straight.
2. Inspect the evaporator/heater core for restrictions.
If the core is dry, use compressed air or a brush and
vacuum cleaner. If the core is wet or filled with mud, flush
Evaporator/Heater Core the core with water using a hose without pressure. Make
sure the water drains freely from the evaporator/heater
core. DO NOT USE STEAM.
NOTICE: do not steam clean any air conditioning systems
parts while the system is charged. The heat will cause
the refrigerant to rise to a pressure that could cause the
system to explode
Evaporator/Heater Core Sealing Make sure seals are in place so blower will pull air only
through the evaporator/heater core and not around the
evaporator/heater core.
Filters Make sure the filters are clean.
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Air-conditioning compressor - Remove

WARNING
Escaping refrigerant may cause frostbite!
Always wear protective goggles when handling refrigerant. If you get refrigerant in your eye, immedi-
ately flush your eyes with water for 15 minutes. Seek medical assistance immediately.
W0339A

Discharge the air conditioning system.
Use the handle indicated in figure to open the wide rear
LEIL15WHL0658AB 1
from the left-hand side of machine.
LEIL15WHL0659AB 2
4. Act on the automatic belt tensioner and remove the

drive belt from the engine.
LEIL15WHL0772AA 3
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5. Disconnect the compressor clutch connector from the

engine harness assembly.
LEIL15WHL0772AA 4
6. Disconnect the hose (2) of the low pressure line from

the suction port (compressor to condenser hose) and
the hose (1) of the high pressure line from the discharge
port (cab to compressor hose) of the air-conditioning
compressor.
Immediately install protective caps on the open ports
and lines.
LEIL15WHL0773AA 5
7. Remove the four bolts (1).

Remove the air-conditioning compressor (2) from the
machine.
LEIL15WHL0772AA 6
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Air-conditioning compressor - Install

WARNING
W0339A
1. Place the air-conditioning compressor (2) in position on

the machine.
Install the four bolts (1) to lock the air-conditioning (2)
in position.
LEIL15WHL0772AA 1
2. Carefully remove the protective caps from the high

pressure line and from the compressor.
Install a new O-ring, and connect the hose (1) of the
high pressure line to the discharge port of the compres-
sor.
NOTE: use caution when removing the protective caps.
New compressors have internal pressure when shipped.
3. Carefully remove the protective caps from the low pres-
sure line and from the compressor.
low pressure line to the suction port of the compressor.
Tighten the hoses (1) and (2) to the torque indicated in
Air conditioning - Torque (50.200). LEIL15WHL0773AA 2
4. Act on the automatic belt tensioner and install the drive

belt.
Verify the correct tension using the tool CNH299147.
The correct tension for a new belt is: 623 – 712 N·m
(459.5 – 525.1 lb ft).
Tension for a used belt is: 400 – 534 N·m (295.0 –
393.9 lb ft).
LEIL15WHL0772AA 3
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5. Connect the compressor clutch connector to the engine

harness assembly.
LEIL15WHL0772AA 4

LEIL15WHL0659AB 5
7. Close the wide rear fender panel compartment. Lower

the engine hood.
LEIL15WHL0658AB 6
8. Charge the air conditioning system. Refer to Air con-

ditioning - Charging (50.200).
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Air-conditioning condenser - Remove

WARNING
W0339A

To access the cooling box, use the latch to open fan
door.
LEIL15WHL0698AB 1
3. Disconnect the hose (1) of the high pressure line (cab to

compressor hose) from the air-conditioning condenser
(3).
Disconnect the hose (2) (condenser to dryer hose) from
the air-conditioning condenser (3).
and lines.
LEIL15WHL0774AB 2
4. Remove the four bolts M8x20 (4) and the four washers
(5).
Remove the air-conditioning condenser (3).
LEIL15WHL0773AA 3
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Air-conditioning condenser - Install

WARNING
W0339A
1. Place the air-conditioning condenser (3) in position.

Install the four washers (5) and the four bolts M8x20 (4)
to fix the air-conditioning condenser (3) to the frame.
LEIL15WHL0773AA 1
2. Carefully remove the protective caps from the lines and

from the air-conditioning condenser.
high pressure line to the air-conditioning condenser (3).
low pressure line to the air-conditioning condenser (3).
LEIL15WHL0774AB 2
3. Position the hoses (1) and (2) as indicated.

Tighten the hoses (1) and (2) to the torque indicated in
Air conditioning - Torque (50.200).
LEIL15WHL0776AA 3

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Receiver-dryer - Remove
WARNING
W0339A

Use the handle indicated in figure to open the wide
rear fender panel compartment (right-hand side of the
machine).
LEIL15WHL0775AA 1
from the right-hand side of machine.
LEIL15WHL0703AB 2
4. Disconnect the hose (1) (dryer to cab hose) and the

hose (2) (condenser to dryer hose).
and lines.
LEIL15WHL0777AB 3
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5. Remove the two bolts M8x40 (3), the two washers (4),
the two washers (5) and the two nuts (6).
Remove the two bolts M8x25 (7), the four washers (8)
and the two nuts (9).
Remove the receiver/dryer (10) from the bracket.
LEIL15WHL0778AB 4
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Receiver-dryer - Install
WARNING
W0339A
1. Place the receiver/dryer in position, as indicated.

A. "This side up" decal
B. Flow direction
LEIL15WHL0779AB 1
2. Place the receiver/dryer (10) on the bracket.

Install the two bolts M8x25 (7), the four washers (8) and
the two nuts (9).
Install the two bolts M8x40 (3), the two washers (4), the
two washers (5) and the two nuts (6).
LEIL15WHL0778AB 2
3. .Carefully remove the protective caps from the lines

and from the dryer.
4. Install new O-rings, and connect the hose (1) (dryer to
cab hose) and the hose (2) (condenser to dryer hose)
to the dryer.
5. Tighten the hoses (1) and (2) to the torque indicated in
Air conditioning - Torque (50.200).
LEIL15WHL0777AB 3
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6. Install the side body panel (2) on the right-hand side of

LEIL15WHL0703AB 4
7. Close the wide rear fender panel compartment.

LEIL15WHL0775AA 5

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Air-conditioning evaporator - Remove

3. Turn the timed disconnect switch in the OFF position.
4. Before changing any air conditioning components, be
sure to discharge the air conditioning system according
to procedures.
6. Remove the six bolts (arrows) and related washers to
LEIL16WHL1190AB 1

LEIL16WHL1209AB 2
8. Remove the bolts (1) with related washers. Remove

the air cab filter assembly from the machine.
LEIL16WHL1210AB 3
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9. Disconnect the PRH2 connector (1) of the engine and

rear chassis harness. Remove the clamps (2) securing
the wire to the cab frame.
LEIL16WHL1696AB 4
10. Loosen the clamp (2). Disconnect and plug the heater
hoses (1).
LEIL16WHL1241AB 5
11. Disconnect the drain hose (1).

Loosen the nut (4) and remove the clamp plate (3).
Disconnect and plug the air conditioning hoses (2) and
(3).
LEIL16WHL1242AB 6
12. Remove the cover case (1)
LEIL16WHL1243AB 7
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13. Disconnect the electrical connector (3).

Remove the three clamps (2) that hold the air condi-
tioning wire harness (1) on the water drain tank.
LEIL16WHL1244AB 8
14. Loosen the screws (1) and extract the water drain tank
from the cab heater assembly.
LEIL16WHL1245AB 9
15. Remove the case gasket (1) and the water drain tank
gasket (2). Remove the evaporator sensor bracket
(3).
LEIL16WHL1246AB 10
16. Separate the air conditioning evaporator (1) from the

water drain tank (2).
LEIL16WHL1249AB 11
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17. Remove the bolts (1) holding the heat exchanger (2)
on the cab heater assembly.
LEIL16WHL1247AB 12
18. Remove the heater core from the machine.
LEIL16WHL1248AA 13
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Air-conditioning evaporator - Install

1. Place the heat exchanger (2) in the correct position on
the cab heater assembly. Install the bolts (1) to secure
the heat exchanger (2) to the cab heater assembly.
LEIL16WHL1247AB 1
2. Insert the air conditioning evaporator (1) to the water

drain tank (2).
LEIL16WHL1249AB 2
3. Install the case gasket (1), the water drain tank gasket
(2) and the evaporator sensor bracket (3) to the air
conditioning evaporator.
LEIL16WHL1246AB 3
4. Insert the water drain tank (2) from the cab heater as-
sembly. Install the bolts (1) to secure the water drain
tank (2).
LEIL16WHL1245AB 4
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5. Connect the electrical connector (3).

Install the three clamps (2) holding the air conditioning
wire harness (1) on the water drain tank.
LEIL16WHL1244AB 5
6. Install the cover case (1).
LEIL16WHL1243AB 6
7. Install the drain hose (1).

Remove the protective plugs from the air conditioning
hoses (2) and (3).Install the air conditioning hoses (2)
and (3)
Install the nut (4) and the clamp plate (3).
LEIL16WHL1242AB 7
8. Remove the protective plugs from the heater hoses (1).

Install the heater hoses (1)and secure with the clamps
(2).
LEIL16WHL1241AB 8
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9. Connect the PRH2 connector (1) of the engine and rear

chassis harness. Install the clamps (2) securing the
wire to the cab frame.
LEIL16WHL1696AB 9
10. Install the bolts (1) with the relevant to lock the air cab
filter assembly (2) on the cab frame.
LEIL16WHL1210AB 10
LEIL16WHL1209AB 11
12. Use the six mounting bolts and washers to install the
HVAC cover.
LEIL16WHL1190AB 12
13. Charge the Air Conditioning system. Refer to Air con-

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14. Fill the engine cooling system.

15. Fill the hydraulic system
16. Put the timed disconnect switch to ON position
17. Start engine and run engine at low idle. Run engine
at operating temperature for approximately 5 min.
NOTICE: hot coolant can spray out if radiator cap is re-
moved. To remove radiator cap: let system cool, turn to
first notch, then wait until all pressure is released. Scald-
ing can result from fast removal of radiator cap
48083742_EN 31/07/2018
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Index

Air conditioning - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Air conditioning - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air conditioning - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air conditioning - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air conditioning - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Air conditioning - Service instruction - Safety procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Air conditioning - Service instruction - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Air conditioning - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air conditioning - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air conditioning - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air conditioning - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air-conditioning compressor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Air-conditioning compressor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Air-conditioning condenser - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Air-conditioning condenser - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Air-conditioning evaporator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Air-conditioning evaporator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Receiver-dryer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Receiver-dryer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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PRINTED IN ITALY
48083742_EN 31/07/2018
EN
SERVICE MANUAL
Electrical systems

48083742_EN 31/07/2018
55
Contents
Electrical systems - 55
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . . . 55.5
[55.415] Loader arm and bucket control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.530] Camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9
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55
Harnesses and connectors - 100

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Contents
FUNCTIONAL DATA
Electrical components
ECU description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sensor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Diode description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuse description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Voltage source description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Ground description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Speaker description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Power outlet description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Relay description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Load description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lamp description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Motor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Resistor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Switch description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Solenoid description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wiring harnesses
Electrical schematic sheet 03 SH03 - PWR DISTR-BATTERY / STARTER / KEY . . . . . . . . . . . . . . . . . . 36
Electrical schematic sheet 04 SH04 - POWER DISTRIBUTION SFB PWR AND GRNDS . . . . . . . . . . . 40
Electrical schematic sheet 06 SH06 - BATTERY PWR DISTR (FUSE BLOCK LC1) . . . . . . . . . . . . . . . . 42
Electrical schematic sheet 07 SH07 - BATTERY PWR DISTR (FUSE BLOCK LC2) . . . . . . . . . . . . . . . . 44
Electrical schematic sheet 08 SH08 - POWER DISTRIBUTION (FUSE BLOCK LC3) . . . . . . . . . . . . . . . 46
Electrical schematic sheet 09 SH09 - ACCESSORY PWR DIST (FUSE BLOCK LC4) . . . . . . . . . . . . . . 48
Electrical schematic sheet 10 SH10 - IGNITION PWR DISTR (FUSE BLOCK LC5) . . . . . . . . . . . . . . . . 50
Electrical schematic sheet 11 SH11 - PWR DISTR ENG COMPARTMENT (FUSE BLOCK LC6) . . . . . 52
Electrical schematic sheet 12 SH12 - POWER DISTRIBUTION 1 CLEAN GROUND BLK . . . . . . . . . . . 54
Electrical schematic sheet 13 SH13 - POWER DISTRIBUTION 2 CAB GROUND BLK . . . . . . . . . . . . . 56
Electrical schematic sheet 14 SH14 - CAB & CHASSIS GROUND PWR DISTR . . . . . . . . . . . . . . . . . . . 58
Electrical schematic sheet 15 SH15 - POWER DISTRIBUTION 4 ENGINE GROUND BLK . . . . . . . . . . 60
Electrical schematic sheet 16 SH16 - ENGINE CONTROL UNIT 1, GRID HEATER, FILTER HEATER 62
Electrical schematic sheet 17 SH17 - ENGINE CONTROL UNIT 2, AT . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Electrical schematic sheet 18 SH18 - ENGINE CONTROL UNIT 3, AT . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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Electrical schematic sheet 19 SH19 - UCM PWR, GRND, INSTRUMENTATION . . . . . . . . . . . . . . . . . . . 68
Electrical schematic sheet 20 SH20 - UCM VEHICLE DRIVELINE / FAN CONTROL . . . . . . . . . . . . . . . 70
Electrical schematic sheet 21 SH21 - UCM-STEERING AUX JSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Electrical schematic sheet 22 SH22 - UCM-LOADER BOOM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electrical schematic sheet 23 SH23 - PILOT LOADER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Electrical schematic sheet 24 SH24 - CAN STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Electrical schematic sheet 25 SH25 - GEAR CONTROL UNIT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Electrical schematic sheet 26 SH26 - GEAR CONTROL UNIT 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Electrical schematic sheet 27 SH27 - LIGHTING DOME, MAP LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Electrical schematic sheet 28 SH28 - LIGHTING HAZARD WARNING, BLINKERS, DRIVING . . . . . . . 86
Electrical schematic sheet 29 SH29 - LIGHTING REAR TAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Electrical schematic sheet 30 SH30 - OLD EURO LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Electrical schematic sheet 31 SH31 - LIGHTING WORKING LIGHTS CAB ROOF, FRONT AND REAR 92
Electrical schematic sheet 32 SH32 - CAB WIPER / WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Electrical schematic sheet 33 SH33 - HEATING BLOWER HEATER, HVAC . . . . . . . . . . . . . . . . . . . . . . . 96
Electrical schematic sheet 34 SH34 - MIRRORS, HORN BEACON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Electrical schematic sheet 35 SH35 - CABIN RADIO LOUDSPEAKER/12V CNVRTR . . . . . . . . . . . . . 100
Electrical schematic sheet 36 SH36 - REAR DEFROST, BACKUP ALARM . . . . . . . . . . . . . . . . . . . . . . 102
Electrical schematic sheet 37 SH37 - HOOD LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Electrical schematic sheet 38 SH38 - MISCELLANOUS, TELEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Electrical schematic sheet 39 SH39 - MISCELLANOUS, REAR CAMERA . . . . . . . . . . . . . . . . . . . . . . . 108
Wire connectors
Component diagram 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Component diagram 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
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Electrical systems - Harnesses and connectors
Electrical components - ECU description

A-108F - ZF DIAGNOSTIC CONNECTOR (ECU)
Component Type ECU

Wiring frames SHEET 25 SH25 - GEAR CONTROL UNIT 1
Connectors X-ZF_DI (Plug) - DIAGNOSTIC [A-108F] (84364851)
A-AC CONTROL PANEL - DENSO (ECU)
Component Type ECU

Wiring frames SHEET 33 SH33 - HEATING BLOWER HEATER, HVAC
A-DIA - DIAGNOSTIC PLUG (ECU)
Component Type ECU

Wiring frames SHEET 24 SH24 - CAN STRUCTURE
Connectors X-DIA (Plug) - DIAGNOSTIC PORT [A-DIA] (87736919)
A-DISPLAY - (ECU)
Component Type ECU

Wiring frames SHEET 39 SH39 - MISCELLANOUS, REAR CAMERA
A-DRIVER 24V - DENSO (ECU)
Component Type ECU

A-DSP - DISPLAY (ECU)
Component Type ECU

Connectors X-DSP (Receptacle) - DISPLAY [A-DSP] (82016219)
A-ECU - ENGINE CONTROLLER (ECU)
Component Type ECU

Wiring frames SHEET 16 SH16 - ENGINE CONTROL UNIT 1, GRID HEATER, FILTER HEATER
SHEET 17 SH17 - ENGINE CONTROL UNIT 2, AT
SHEET 18 SH18 - ENGINE CONTROL UNIT 3, AT
Connectors X-ECU (Receptacle) - ECU CONNECTOR [A-ECU] (84300197)
A-EH_VLV - ELECTROHYDRAULIC VALVE (ECU)
Component Type ECU

Wiring frames SHEET 22 SH22 - UCM-LOADER BOOM CONTROL
Connectors X-PILOT_ENABLE (Receptacle) - PILOT ENABLE SOLENOID [SH28: A-1]
(87695582) X-BOOM_RAISE (Receptacle) - BOOM RAISE SOLENOID [A-EH_VLV]
(87695582) X-BOOM_LOWER (Receptacle) - BOOM LOWER SOLENOID
[A-EH_VLV] (87695582) X-BUCKET_ROLL (Receptacle) - BUCKET ROLL
SOLENOID [A-EH_VLV] (87695582) X-BUCKET_DUMP (Receptacle) - BUCKET
DUMP SOLENOID [A-EH_VLV] (87695582) X-AUX_1_LEFT (Receptacle) - AUX
1 LEFT [A-EH_VLV] (87695582) X-AUX_1_RIGHT (Receptacle) - AUX 1 RIGHT
[A-EH_VLV] (87695582) X-AUX_2_LEFT (Receptacle) - AUX 2 LEFT [A-EH_VLV]
(87695582) X-AUX_2_RIGHT (Receptacle) - AUX 2 RIGHT [A-EH_VLV] (87695582)
A-HVAC - DENSO (ECU)
Component Type ECU

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A-LIGHT HOLDER 2 - DENSO (ECU)
Component Type ECU

A-LIGHT HOLDER1 - DENSO (ECU)
Component Type ECU

A-MAIN JB CAB - JUNCTION BLOCK INTO CAB (ECU)
Component Type ECU

Wiring frames SHEET 03 SH03 - PWR DISTR-BATTERY / STARTER / KEY
SHEET 06 SH06 - BATTERY PWR DISTR (FUSE BLOCK LC1)
SHEET 07 SH07 - BATTERY PWR DISTR (FUSE BLOCK LC2)
SHEET 08 SH08 - POWER DISTRIBUTION (FUSE BLOCK LC3)
A-ORLACO CAMERA - REAR VIEW CAMERA (ECU)
Component Type ECU

Wiring frames SHEET 39 SH39 - MISCELLANOUS, REAR CAMERA
A-PFNR - PRIMARY FNR (ECU)
Component Type ECU

Wiring frames SHEET 20 SH20 - UCM VEHICLE DRIVELINE / FAN CONTROL
Connectors X-TS2 (Receptacle) - TRANS SHIFTER 2 [A-PFNR] (47702209) X-TS1 (Plug) -
TRANS SHIFTER1 [A-PFNR] (87692817)
A-PMP - DEF PUMP MODULE (ECU)
Component Type ECU

Wiring frames SHEET 18 SH18 - ENGINE CONTROL UNIT 3, AT
Connectors X-PUMP (Receptacle) - DENOX CONTROL UNIT [A-PMP] (47421681)
A-SFB - SMART FUSE BOX (ECU)
Component Type ECU

SHEET 04 SH04 - POWER DISTRIBUTION SFB PWR AND GRNDS
SHEET 24 SH24 - CAN STRUCTURE
SHEET 27 SH27 - LIGHTING DOME, MAP LIGHTS
SHEET 28 SH28 - LIGHTING HAZARD WARNING, BLINKERS, DRIVING
SHEET 29 SH29 - LIGHTING REAR TAILS
SHEET 31 SH31 - LIGHTING WORKING LIGHTS CAB ROOF, FRONT AND REAR
SHEET 32 SH32 - CAB WIPER / WASHER
SHEET 33 SH33 - HEATING BLOWER HEATER, HVAC
SHEET 34 SH34 - MIRRORS, HORN BEACON
SHEET 36 SH36 - REAR DEFROST, BACKUP ALARM
SHEET 39 SH39 - MISCELLANOUS, REAR CAMERA
Connectors X-X6 (Receptacle) - SFB [A-SFB] (47554341)
A-TELE - TELEMATIC MODULE (ECU)
Component Type ECU

Wiring frames SHEET 38 SH38 - MISCELLANOUS, TELEMATICS
Connectors X-X_TEL (Receptacle) - TELEMATICS [SH38: C-6] (87700156)
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A-TERM2 - TERMINATOR (ECU)
Component Type ECU

Connectors X-TERM2 (Receptacle) - TERMINATOR CAN [A-TERM2] (87695580)
A-TERM3 - TERMINATOR (ECU)
Component Type ECU

Connectors X-TERM3 (Receptacle) - TERMINATOR CAN [A-TERM3] (87695580)
A-TERMC - TERMINATOR FOR CAN (ECU)
Component Type ECU

Connectors X-TERM_C (Receptacle) - CONTROLLER AREA NETWORK [A-TERMC] (87695580)
A-TRANS - TRANSMISSION CONTROL UNIT (ECU)
Component Type ECU

SHEET 26 SH26 - GEAR CONTROL UNIT 2
Connectors X-TECM (Receptacle) - TRANS CONTROLLER [SH25: C-6] (84550089)
A-TRC - TRANS CONTROLLER ON TRANNY (ECU)
Component Type ECU

Connectors X-TRC (Receptacle) - TRANS CONTROLLER ON TRANNY CNH [A-TRC]
(47669071)
A-UCM - 47749442 WAS 84328725 (ECU)
Component Type ECU

Wiring frames SHEET 19 SH19 - UCM PWR, GRND, INSTRUMENTATION
SHEET 20 SH20 - UCM VEHICLE DRIVELINE / FAN CONTROL
SHEET 21 SH21 - UCM-STEERING AUX JSS
SHEET 22 SH22 - UCM-LOADER BOOM CONTROL
SHEET 23 SH23 - PILOT LOADER CONTROLS
Connectors X-UCM3B (Receptacle) - UCM [A-UCM] (84130760) X-UCM4B (Receptacle) - UCM
[A-UCM] (82028495) X-UCM2B (Receptacle) - UCM [A-UCM] (82028495)
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Electrical components - Sensor description

B-ACCEL - THROTTLE CONTROL (Sensor)
Component Type Sensor

Connectors X-THRTL (Receptacle) - THROTTLE CONTROL [B-ACCEL] (84403598)
B-BKT_ANG - BUCKET ANGLE (Sensor)

Connectors X-BUA (Receptacle) - BUCKET ANGLE SENSOR [B-BKT_ANG] (84403598)
B-BM_ANG - BOOM ANGLE (Sensor)

Connectors X-BOA (Receptacle) - BOOM ANGLE SENSOR [B-BM_ANG] (84403598)
B-BPP - BRAKE PEDAL ANGLE (Sensor)

Connectors X-BPP (Plug) - BRAKE PEDAL ANGLE [B-BPP] (87710588)
B-C_TS - DOC UPSTREAM TEMP SENSOR (Sensor)

Connectors X-CTS (Receptacle) - DOC UPSTREAM TEMP [B-C_TS] (84532147)
B-DEF_Q - DEF QUALITY SENSOR (Sensor)

Connectors X-DEFQ (Receptacle) - DEF QUALITY SENSOR (UQS) [B-DEF_Q] (84149219)
B-D_TS - SCR DOWNSTREAM TEMP SENSOR (Sensor)

Connectors X-DTS (Receptacle) - SCR DOWNSTREAM TEMP [B-D_TS] (84532147)
B-ES_S - ENGINE SPEED SENSOR (Sensor)

Connectors X-ESS (Receptacle) - SPEED SENSOR ENGINE [B-ES_S] (84364854)
B-FAX - FRONT AXLE OIL TEMP (Sensor)

Connectors X-FAX (Receptacle) - FRONT AXLE TEMP SENSOR [SH20: A-6] (87711966)
B-FM - FILTER MAINTENANCE (Sensor)

Connectors X-FM (Plug) - PRESSURE SWITCH OIL FILTER [B-FM] (82012083)
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B-FSS - FAN SPEED SENSOR (Sensor)

Connectors X-FSS (Receptacle) - FAN SPEED SENSOR [B-FSS] (47696743)
B-GOT - GEAR OIL TEMP (Sensor)

Connectors X-TCOT (Receptacle) - GEAR OIL TEMP [B-GOT] (84364854)
B-HOT - HYD OIL TEMP (Sensor)

Connectors X-HOT (Receptacle) - HYD OIL TEMP [B-HOT] (84607243)
B-HT - HUMIDITY AND AMB TEMP SENSOR (Sensor)

Connectors X-HTS (Receptacle) - HUMIDITY AND TEMP SENSOR [B-HT] (87709809)
B-IS_S - INTERMEDIATE SPEED SENSOR (Sensor)

Connectors X-ISS (Receptacle) - SPEED SENSOR MIDDLE WHEEL CHAIN [B-IS_S] (84364854)
B-JSS - LH JOYSTICK STEERING (Sensor)

Wiring frames SHEET 21 SH21 - UCM-STEERING AUX JSS
Connectors X-JSS_JOY (Receptacle) - JSS LEFT HAND JOYSTICK [B-JSS] (87700107)
B-JSS_CO_2 - JSS CUT OFF SENSOR 2 (Sensor)

Connectors X-JSS_CO_2 (Receptacle) - CUT OFF SENSOR [B-JSS_CO_2] (87694153)
B-NH3 - NH3 SENSOR (Sensor)

Connectors X-NH3 (Receptacle) - NH3 SENSOR [B-NH3] (84146686)
B-NOX_DU - DOC UPSTREAM NOX SENSOR (Sensor)

Connectors X-NOXD (Receptacle) - SCR DOWNSTREAM NOX SENSOR [B-NOX_DU]
(84190317)
B-NOX_SD - SCR DOWNSTREAM NOX SENSOR (Sensor)

Connectors X-NOXS (Receptacle) - DOC UPSTREAM NOX SENSOR [B-NOX_SD] (84190317)
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B-NTC SENSOR - DENSO (Sensor)

B-OSS - OUTPUT SPEED SENSOR (Sensor)

Connectors X-OSS (Plug) - SPEED SENSOR GEAR TRANS [B-OSS] (84062580)
B-PBBS - PARK BRAKE PR SENSOR FUTURE (Sensor)

Connectors X-PBBS (Plug) - PARK BRAKE PRES SENSR [B-PBBS]
B-PBL/PEDAL/DECLTCH - BRAKE PESSURE SENSOR (Sensor)

Connectors X-PLB-PBD (Receptacle) - BRAKE PRES SENSR [B-PBL/PEDAL/DECLTCH]
(84078681)
B-PBW - BRAKE SUPPLY PRESS (Sensor)

Connectors X-PBW (Receptacle) - BRAKE SUPPLY WARNING PRES [B-PBW] (84078681)
B-PRB1 - RED_BRAKE_FRNT (Sensor)

Connectors X-PRB1 (Receptacle) - REDUNDANT BRAKE SW 1 [B-PRB1] (84078681)
B-PRB2 - RED_BRAKE_REAR (Sensor)

Connectors X-PRB2 (Receptacle) - REDUNDANT BRAKE SW 2 [B-PRB2] (84078681)
B-PSS - AUX STEERING PRESSURE (Sensor)

Connectors X-PSS (Receptacle) - STEERING PRESSURE SENSOR [B-PSS] (84078681)
B-PXF - RETURN TO DIG PROX (Sensor)

Wiring frames SHEET 23 SH23 - PILOT LOADER CONTROLS
Connectors X-PXF (Plug) - RETURN TO DIG PROX [B-PXF] (87692858)
B-PXH - HEIGHT CONTROL PROX (Sensor)

Connectors X-PXH (Plug) - HEIGHT CNTRL PROX [B-PXH] (87644909)
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B-PXT - RTD FOR XT (Sensor)

Connectors X-PXT (Plug) - RTD XT [B-PXT] (87644909)
B-RECTD - COOLANT TEMP (Sensor)

Connectors X-RECT (Receptacle) - ENGINE COOLANT TEMP [B-RECTD] (84607243)
B-RFLG - FUEL LEVEL SENSOR (Sensor)

Connectors X-FL (Plug) - FUEL LEVEL [B-RFLG] (82012083)
B-ST_MTN - STEERING WHEEL MOTION (Sensor)

Connectors X-STW (Receptacle) - STEERING WHEEL MOTION SENSOR [B-ST_MTN]
(84563557)
B-TS_S - TURBINE SPEED SENSOR (Sensor)

Connectors X-TSS (Receptacle) - SPEED SENSOR TURBINE [B-TS_S] (84364854)
B-U_LVL - SENSOR TANK LEVEL & TEMP (Sensor)

Connectors X-DTLTS (Plug) - DEF LEVEL / TEMP [B-U_LVL] (84062580)
B-U_TS - SCR UPSTREAM TEMP SENSOR (Sensor)

Connectors X-UTS (Receptacle) - UPSTREAM OF SCR TEMP SENSOR [B-U_TS] (84532147)
B-WIF - WATER IN FUEL (Sensor)

Connectors X-WIF (Receptacle) - WATER IN FUEL [B-WIF] (87709663)
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Electrical components - Diode description

D-SS DIODE - SEC STRG FLYBACK DIODE (Diode)
Component Type Diode

Connectors X-SSD (Plug) - SS FLYBACK DIODE [D-SS DIODE] (87692858)
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Electrical components - Fuse description

F-1F1 - ACCESSORY (Fuse)
Component Type Fuse

Wiring frames SHEET 06 SH06 - BATTERY PWR DISTR (FUSE BLOCK LC1)
F-1F2 - IGNITION (Fuse)
Component Type Fuse

F-1F3 - SFB-D (Fuse)
Component Type Fuse

F-1F4 - SFB-A (Fuse)
Component Type Fuse

F-1F5 - SFB-B (Fuse)
Component Type Fuse

F-1F6 - SFB-A (Fuse)
Component Type Fuse

F-2F1 - UCM-VP (Fuse)
Component Type Fuse

F-2F10 - SPARE (Fuse)
Component Type Fuse

F-2F11 - CAMERA (Fuse)
Component Type Fuse

Component Type Fuse

Component Type Fuse

Component Type Fuse

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F-2F2 - UCM VF2/3 (Fuse)
Component Type Fuse

F-2F3 - UCM VF4/6 (Fuse)
Component Type Fuse

F-2F4 - UCM VS1/VLP (Fuse)
Component Type Fuse

Component Type Fuse

F-2F6 - TECM (Fuse)
Component Type Fuse

F-2F7 - DISPLAY (Fuse)
Component Type Fuse

F-2F8 - DIAGNOSTIC (Fuse)
Component Type Fuse

F-2F9 - HOOD LIFT (Fuse)
Component Type Fuse

F-3F1 - 12V PWR1 (Fuse)
Component Type Fuse

Wiring frames SHEET 08 SH08 - POWER DISTRIBUTION (FUSE BLOCK LC3)
F-3F2 - 12V SPARE (Fuse)
Component Type Fuse

F-3F3 - 12V RADIO (Fuse)
Component Type Fuse

F-3F4 - 12V SPARE (Fuse)
Component Type Fuse

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Component Type Fuse

Component Type Fuse

Component Type Fuse

F-3F8 - 12V CONVERTER (Fuse)
Component Type Fuse

F-4F1 - 24V CIGAR (Fuse)
Component Type Fuse

Wiring frames SHEET 09 SH09 - ACCESSORY PWR DIST (FUSE BLOCK LC4)
Component Type Fuse

Component Type Fuse

F-4F3 - A/C CLUTCH (Fuse)
Component Type Fuse

Component Type Fuse

Component Type Fuse

F-4F6 - BLOWER (Fuse)
Component Type Fuse

F-4F7 - SEAT (Fuse)
Component Type Fuse

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F-4F8 - REAR DEFROST (Fuse)
Component Type Fuse

Component Type Fuse

F-5F1 - DISPLAY WK (Fuse)
Component Type Fuse

Wiring frames SHEET 10 SH10 - IGNITION PWR DISTR (FUSE BLOCK LC5)
F-5F10 - STALK/DIFF (Fuse)
Component Type Fuse

F-5F2 - UCM (Fuse)
Component Type Fuse

F-5F3 - TECM (Fuse)
Component Type Fuse

F-5F4 - TELEMATICS (Fuse)
Component Type Fuse

F-5F5 - SEC STRG (Fuse)
Component Type Fuse

F-5F6 - IMP JOYSTICK (Fuse)
Component Type Fuse

F-5F7 - KEY PAD (Fuse)
Component Type Fuse

F-5F8 - JSS IGN (Fuse)
Component Type Fuse

F-5F9 - REAR PWR (Fuse)
Component Type Fuse

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F-GH - INLINE GH FUSE (Fuse)
Component Type Fuse

Connectors X-GH2 (Plug) - GRID HEATER [F-GH] (84140737) X-GH3 (Plug) - GRID HEATER
RING TERMINAL [F-GH] (84140737)
F-LC6F1 - MAIN ECU (Fuse)
Component Type Fuse

F-LC6F10 - TELE (Fuse)
Component Type Fuse

F-LC6F2 - KEY/HORN (Fuse)
Component Type Fuse

F-LC6F3 - ECU AUX (Fuse)
Component Type Fuse

F-LC6F4 - SCR SENSORS (Fuse)
Component Type Fuse

Wiring frames SHEET 11 SH11 - PWR DISTR ENG COMPARTMENT (FUSE BLOCK LC6)
F-LC6F5 - FFH (Fuse)
Component Type Fuse

F-LC6F6 - EVGT (Fuse)
Component Type Fuse

F-LC6F7 - ECU IGN (Fuse)
Component Type Fuse

F-LC6F9 - FAN (Fuse)
Component Type Fuse

F-MAIN CAB - FUSE (Fuse)
Component Type Fuse

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Electrical components - Voltage source description

G-001 - BATTERY (Voltage source)
Component Type Voltage source

Connectors X-563 (Plug) - BATTERY LUG [G-001] X-567 (Plug) - BATTERY LUG [G-001]
X-P5321 (Plug) - JUMP START [G-001]
G-002 - BATTERY (Voltage source)

Connectors X-564 (Plug) - BATTERY LUG [G-002] X-566 (Plug) - BATTERY POSITIVE [G-002]
X-P5320 (Plug) - JUMP START [G-002]
G-G1 - ALTERNATOR (Voltage source)

Connectors X-ALT (Receptacle) - ALTERNATOR [G-G1] (8602487)
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Electrical components - Ground description

GND-001 - (Ground)
Component Type Ground

GND-017 - (Ground)

Wiring frames SHEET 34 SH34 - MIRRORS, HORN BEACON
GND-018 - (Ground)

GND-019 - (Ground)

GND-025 - (Ground)

GND-029 - (Ground)

Wiring frames SHEET 31 SH31 - LIGHTING WORKING LIGHTS CAB ROOF, FRONT AND REAR
GND-069 - (Ground)

Wiring frames SHEET 36 SH36 - REAR DEFROST, BACKUP ALARM
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Electrical components - Speaker description

H-BU_ALRM - BACKUP ALARM (Speaker)
Component Type Speaker

Connectors X-BU2 (Plug) - BACK UP ALARM [H-BU_ALRM] (84426117) X-BU1 (Plug) - BACK
UP ALARM [H-BU_ALRM] (84426117)
H-HN - HORN (Speaker)

Connectors X-HN2 (Plug) - HORN_GRND [H-HN] (87697629) X-HN1 (Plug) - HORN_PWR
[H-HN] (87697629)
H-LSP1 - LOUDSPEAKER RT (Speaker)

Wiring frames SHEET 35 SH35 - CABIN RADIO LOUDSPEAKER/12V CNVRTR
Connectors X-XLP1 (Receptacle) - LOUDSPEAKER RT [H-LSP1] (84147089)
H-LSP2 - LOUDSPEAKER LF (Speaker)

Connectors X-XLP2 (Receptacle) - LOUDSPEAKER LF [H-LSP2] (84147089)
H-RADIO - 12V RADIO (Speaker)

Connectors X-SPK (Receptacle) - RADIO TO SPKRS [H-RADIO] (87709371) X-RAD
(Receptacle) - RADIO [H-RADIO] (87709660)
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Electrical components - Power outlet description

J-CNVRTR_24-12 - POWER CONVERTER (Power outlet)
Component Type Power outlet

Connectors X-CNV (Receptacle) - 24 TO 12 POWER CONVERTER [SH35: B-4] (87694112)
J-JS+ - JUMP START (Power outlet)

Connectors X-JS+ (Plug) - JUMP START STUD POS [J-JS+]
J-JS- - JUMP START STUD (Power outlet)

Connectors X-JS- (Plug) - JUMP START STUD NEG [J-JS-]
J-PO1 - RH CONSOLE 12V POWER OUTLET (Power outlet)

Connectors X-X-PO1 (Receptacle) - POWER OUTLET [J-PO1] (84398827)
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Electrical components - Relay description

K-3R1 - 12V CONVERTER (Relay)
Component Type Relay

K-3R2 - SEC STEERING (Relay)

K-3R3 - REAR DEFROST (Relay)

K-4KR1 - ACCESSORY (Relay)

K-5KR1 - IGNITION (Relay)

K-GH - GRID HEATER RELAY (Relay)

Connectors X-GHC (Plug) - GRID HEATER CONTROL [K-GH] (82012083)
K-ISOLATOR - ISOLATOR (Relay)

Connectors X-DC2 (Plug) - NON-DISC POWER STUD [K-ISOLATOR] (84140737) X-ISO (Plug)
- ISOLATOR [K-ISOLATOR] (87687242) X-D(S) (Plug) - MASTER DISCONNECT
SWITCHED [K-ISOLATOR] (84163398)
K-JSS_CO_1 - JSS CUT OFF SENSOR 1 (Relay)

Connectors X-JSS_CO_1 (Receptacle) - CUT OFF SENSOR [K-JSS_CO_1] (87694153)
K-LC3R4 - HORN RELAY (Relay)

Connectors X-LC3 (Receptacle) - LOADCENTER 3 [SH35: B-6] (84529039)
K-LC6F3_F4 - T2 OK TO START (Relay)

K-LC6KR3 - ECU AUX (Relay)

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K-LC6KR5 - AC CLUTCH (Relay)

K-LC6R1 - HOOD UP (Relay)

Wiring frames SHEET 37 SH37 - HOOD LIFT
Connectors X-LC6 (Receptacle) - LOADCENTER 6 [SH16: A-3] (84380518)
K-LC6R2 - HOOD DOWN (Relay)

K-LC6R4 - CRANK CONTROL (Relay)

K-LC7R1 - FF HEATER RELAY (Relay)

K-LC7R2 - STARTER RELAY (Relay)

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Electrical components - Load description

L-MH_L - MIRROR HEATER LH (Load)
Component Type Load

Connectors X-MH_L (Receptacle) - MIRROR HEATED LEFT [L-MH_L] (87695582)
L-NA-TAIL - LH REAR TAIL LT NA (Load)
Component Type Load

Wiring frames SHEET 29 SH29 - LIGHTING REAR TAILS
Connectors X-LH-TAIL (Receptacle) - LH REAR TAIL LIGHT NA [L-NA-TAIL] (87694101)
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Electrical components - Lamp description

LMP-BEA_RT - ROTATING BEACON / LED STROBE LIGHT (Lamp)
Component Type Lamp

Connectors X-BEA (Receptacle) - BEACON [LMP-BEA_RT] (84015523)
LMP-CIG_LTR - 24V CIGAR LIGHTER (Lamp)
Component Type Lamp

Connectors X-CL (Receptacle) - CIGAR LIGHTER [LMP-CIG_LTR] (84015523)
LMP-DM - EGRESS/DOME LAMP (Lamp)
Component Type Lamp

Wiring frames SHEET 27 SH27 - LIGHTING DOME, MAP LIGHTS
Connectors X-DM_G (Receptacle) - DOME LIGHT GROUND [LMP-DM] (87688695) X-DM_P
(Receptacle) - DOME LIGHT POSITIVE [LMP-DM] (84015523)
LMP-L-EURO-TAIL - LH REAR TAIL LT EURO (Lamp)
Component Type Lamp

Wiring frames SHEET 30 SH30 - OLD EURO LIGHTING
Connectors X-LH-REAR-TAIL-EURO (Receptacle) - LH REAR TAIL LIGHT EURO
[LMP-L-EURO-TAIL] (87694112)
LMP-LF0 - LEFT FRONT OPT WL (Lamp)
Component Type Lamp

Connectors X-LF2 (Receptacle) - WORK LIGHT OPT [LMP-LF0] (87695582)
LMP-LF_LT - LH FRONT COMBO LIGHT (Lamp)
Component Type Lamp

Wiring frames SHEET 28 SH28 - LIGHTING HAZARD WARNING, BLINKERS, DRIVING
Connectors X-LLF (Plug) - FRONT COMBO LAMP LEFT [LMP-LF_LT] (87694109)
LMP-LF_WL - LEFT FRONT WORK LIGHT (Lamp)
Component Type Lamp

Connectors X-LFWL (Receptacle) - LEFT FRONT WORK LIGHT [LMP-LF_WL] (87695582)
LMP-LPL - LICENSE PLATE LIGHT (Lamp)
Component Type Lamp

Connectors X-LPL (Plug) - LICENSE PLATE LIGHT [LMP-LPL] (87692855)
LMP-LR_WL - LEFT REAR WORK LIGHT (Lamp)
Component Type Lamp

Connectors X-LRWL (Receptacle) - LEFT REAR WORK LIGHT [LMP-LR_WL] (87695582)
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LMP-MH_R - MIRROR HEATER RH (Lamp)
Component Type Lamp

Connectors X-MH_R (Receptacle) - MIRROR HEATED RIGHT [LMP-MH_R] (87695582)
LMP-MPL - MAP LIGHT (Lamp)
Component Type Lamp

Connectors X-MAP (Receptacle) - MAP LIGHT [SH13: C-6] (84058093)
LMP-R-EURO-TAIL - RH REAR TAIL LT EURO (Lamp)
Component Type Lamp

Wiring frames SHEET 30 SH30 - OLD EURO LIGHTING
Connectors X-RH-REAR-TAIL-EURO (Receptacle) - RH-REAR-TAIL-EURO [LMP-R-EURO-TAIL]
(87694112)
LMP-R-NA-TAIL - RH REAR TAIL LT NA (Lamp)
Component Type Lamp

Wiring frames SHEET 29 SH29 - LIGHTING REAR TAILS
Connectors X-RH-TAIL (Receptacle) - RH REAR TAIL [LMP-R-NA-TAIL] (87694101)
LMP-RFO - RIGHT FRONT OPT WL (Lamp)
Component Type Lamp

Connectors X-RF2 (Receptacle) - WORK LIGHT OPTION [LMP-RFO] (87695582)
LMP-RF_LT - RH FRONT COMBO LIGHT (Lamp)
Component Type Lamp

Connectors X-LRF (Plug) - FRONT COMBO LAMP RT [LMP-RF_LT] (87694109)
LMP-RF_WL - RIGHT FRONT WORK LIGHT (Lamp)
Component Type Lamp

Connectors X-RFWL (Receptacle) - RIGHT FRONT WORK LIGHT [LMP-RF_WL] (87695582)
LMP-RR_WL - RIGHT REAR WORK LIGHT (Lamp)
Component Type Lamp

Connectors X-RRWL (Receptacle) - RIGHT REAR WORK LIGHT [LMP-RR_WL] (87695582)
LMP-TTI - TELL TALE INDICATOR (Lamp)
Component Type Lamp

Connectors X-TT (Receptacle) - TELL TALE INDICATOR [LMP-TTI] (87715979)
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Electrical components - Motor description

M-BLOWER 24V - DENSO (Motor)
Component Type Motor

M-FW_M - FRONT WASHER MOTOR (Motor)

Wiring frames SHEET 32 SH32 - CAB WIPER / WASHER
Connectors X-FWW (Receptacle) - FRONT WASHER MOTOR [M-FW_M] (84015523)
M-HD_L_M - HOOD LIFT MOTOR (Motor)

Connectors X-HDM (Receptacle) - HOOD MOTOR [M-HD_L_M] (87711966)
M-RW_M - REAR WASHER MOTOR (Motor)

Connectors X-RWW (Receptacle) - REAR WASHER MOTOR [M-RW_M] (84015523)
M-R_WPR_M - REAR WIPER MOTOR (Motor)

Connectors X-RWM (Plug) - REAR WIPER MOTOR [M-R_WPR_M] (87692862) X-RWM_G
(Plug) - REAR WIPER MOTOR GRND [SH13: C-2] (87693744)
M-SEC_STRG - SECONDARY STEERING MOTOR/PUMP (Motor)

Connectors X-S244 (Plug) - 20157 AUX STRG PWR RT ANGLE CONN [SH21: D-3] X-SSS
(Plug) - SECONDARY STEERING MOTOR [M-SEC_STRG] (84426118) X-S242
(Plug) - GROUND [M-SEC_STRG] (84401307)
M-STEPPER MOTOR 24V - DENSO (Motor)

M-STRT_MTR - STARTER MOTOR (Motor)

Connectors X-ST (Plug) - START SIGNAL TO STARTER [M-STRT_MTR] (84426134)
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Electrical components - Resistor description

R-022 - TERMINATOR (Resistor)
Component Type Resistor

Connectors X-TERM (Receptacle) - TERMINATOR [R-022] (87695580)
R-CERAMIC RESISTOR 24V - DENSO (Resistor)

R-RES-G_HTR - GRID HEATER (Resistor)

Connectors X-GH6 (Plug) - GRID HEATER [R-RES-G_HTR] (87744835) X-GH7 (Plug) - GRID
HEATER [R-RES-G_HTR] (87744835)
R-WND_HTR - REAR WINDSHIELD HEATER ELEMENT (Resistor)

Connectors X-RWHE1 (Receptacle) - REAR WINDOW HEATER [R-WND_HTR] (87688695)
X-RWHE2 (Receptacle) - REAR WINDOW HEATER [SH13: C-3] (87688695)
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Electrical components - Switch description

SW-AC SWITCH - DENSO (Switch)
Component Type Switch

SW-AFS2 - AIR FILTER SWITCH T2/T3 (Switch)

Connectors X-AFS2 (Receptacle) - AIR FILTER SWITCH T2/3 [SW-AFS2] (84607243)
SW-ARM_POS_DWN - LH ARMREST POSITION (Switch)

Connectors X-LH_ARM_DWN (Receptacle) - LH JSS ARM REST DOWN [SW-ARM_POS_DWN]
(84000405)
SW-ARM_POS_UP - LH ARMREST POSITION (Switch)

Connectors X-LH_ARM_UP (Receptacle) - LH JSS ARM REST DOWN [SW-ARM_POS_UP]
(84000405)
SW-A_F_S - AIR FILTER RSTCN SW (Switch)

Connectors X-AFS (Receptacle) - AIR FILTER RSTCN SW [SW-A_F_S] (84607243)
SW-BCK_U_SW - BACKUP ALRM CANCEL SW (Switch)

Connectors X-S_BU (Receptacle) - CANCEL BACKUP ALARM [SW-BCK_U_SW] (87716755)
SW-DEV6223 - JOYSTICK INTERNAL (Switch)

SW-DS - DOOR SWITCH (Switch)

Connectors X-DS (Receptacle) - DOOR SWITCH [SH27: C-6] (87382906)
SW-FNR - JOYSTICK INTERNAL (Switch)

Connectors X-P_JS (Plug) - PILOT LOADER JOYSTICK [SW-FNR] (87694152)
SW-HD_L_SW - HOOD LIFT SWITCH (Switch)

Connectors X-HD (Receptacle) - HOOD LIFT SWITCH [SH3: A-4] (84159859)
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SW-HN_RH_ARM - RH ARMREST HORN SWITCH (Switch)

SW-HN_STLK - RH STALK HORN SWITCH (Switch)

Connectors X-STLK (Receptacle) - STALK LEVER RH [SW-HN_STLK] (84426133)
SW-HORN - (Switch)

Connectors X-HN (Plug) - CAN [SW-HORN] (87311796)
SW-HZD_SW - HAZARD SWITCH (Switch)

Connectors X-S_HZD (Receptacle) - SWITCH HAZARD [SW-HZD_SW] (87716755)
SW-K/D - JOYSTICK INTERNAL (Switch)

SW-KD - KICK DOWN SW (Switch)

SW-KEY - IGNITION SWITCH (Switch)

Connectors X-KEY (Receptacle) - KEY SWITCH [SW-KEY] (87699176)
SW-LOW PRESSURE SWITCH N.C. - DENSO (Switch)

SW-MD - MASTER DISCONNECT (Switch)

SW-MH_SW - MIRROR HEATER SWITCH (Switch)

Connectors X-S_HMR (Receptacle) - SWITCH HEATED MIRRORS [SH13: D-4] (87716755)
SW-PD - SWITCH/KEY PAD (Switch)

Connectors X-SW_PD (Receptacle) - SWITCH PAD [SW-PD] (87694153)
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SW-PHF - HYDRAULIC FILTER SWITCH (Switch)

Connectors X-PHF (Plug) - HYDRAULIC FILTER SENSOR [SW-PHF] (84352277)
SW-POTENTIOMETER FOR MIX - DENSO (Switch)

SW-PRB - ROLL BACK PR SW (Switch)

Connectors X-PRB (Plug) - ROLL BACK PRESSURE SWITCH [SW-PRB] (87692877)
SW-PR_H2 - AC HIGH PRESS SW (Switch)

Connectors X-PRH2 (Plug) - HIGH PRESSURE SWITCH 2 [SH33: C-6] (87688788)
SW-RH_JS - RIGH HAND JOYSTICK or 3 lever (Switch)

SW-ROTARY FOR BLOWER - DENSO (Switch)

SW-R_DEF_SW - REAR DEFROST SWITCH (Switch)

Connectors X-S_RDF (Receptacle) - SWITCH REAR DEFROST [SW-R_DEF_SW] (87716755)
SW-SDM - DIFF LOCK FOOT SWITCH (Switch)

Connectors X-SDM (Plug) - SWITCH DIFF LOCK [SW-SDM] (82012083)
SW-STALK - STALK SWITCH (Switch)

SW-SW_JSS - SWITCH JSS ACTIVATION (Switch)

Connectors X-SW_JSS (Receptacle) - JOYSTICK STEERING SWITCH [SW-SW_JSS]
(87716755)
SW-WPR_SW - REAR WIPER SWITCH (Switch)

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Connectors X-SRWP (Receptacle) - SWITCH REAR WIPER [SW-WPR_SW] (87716755)
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Electrical components - Solenoid description

Y-ACT - AC COMPRESSOR CLUTCH (Solenoid)
Component Type Solenoid

Y-C0V_1 - JSS CUT OFF VALVE 1 (Solenoid)

Connectors X-COV1 (Receptacle) - CUT OFF VALVE SOL [Y-C0V_1] (87695582)
Y-COV_2 - JSS CUT OFF VALVE 2 (Solenoid)

Connectors X-COV2 (Receptacle) - CUT OFF VALVE SOL [Y-COV_2] (87695582)
Y-DL - DIFF LOCK SOLENOID (Solenoid)

Connectors X-YDL (Receptacle) - DIFF LOCK SOL [Y-DL] (87695582)
Y-DSV - DOSING VALVE (Solenoid)

Connectors X-DSR (Receptacle) - UREA DOSING VALVE [Y-DSV] (87709798)
Y-F_F_H - FILTER HEATER (Solenoid)

Connectors X-FFH (Receptacle) - FILTER HEATER [Y-F_F_H] (87679438)
Y-HC DET - (Solenoid)

Y-JSS_STRG_VLV - JOYSTICK STEERING VALVE (Solenoid)

Connectors X-JSV (Receptacle) - JOYSTICK STEERING VALVE [SH21: B-2] (87695592)
Y-RTD DET - (Solenoid)

Y-RTT DET - (Solenoid)

Connectors X-EM (Receptacle) - ELECTROMAGNETIC DETENTS [Y-RTT DET] (87694112)
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Y-SC - SEAT COMPRESSOR (Solenoid)

Connectors X-SC (Plug) - SEAT COMPRESSOR [Y-SC] (87692855)
Y-TNK_HTR - SCR TANK HEATING VALVE (Solenoid)

Connectors X-THV (Receptacle) - SCR TANK HEATING VALVE [Y-TNK_HTR] (84146685)
Y-W_S_H - WATER SEP HEATER (Solenoid)

Connectors X-WSH (Receptacle) - WATER SEPERATOR HEATER [Y-W_S_H] (87679438)
Y-YLS - LOCKUP SOLENOID (Solenoid)

Y-YLV - HEAT LOAD VALVE (Solenoid)

Connectors X-YLV (Receptacle) - HEAT LOAD VALVE [Y-YLV] (87695582)
Y-YPE - COUPLER VALVE SOL. (Solenoid)

Connectors X-YPE (Receptacle) - COUPLER VALVE [Y-YPE] (87695582)
Y-YRC - YRC RIDE CONTROL SOL (Solenoid)

Connectors X-YRC (Receptacle) - RIDE CONTROL SOLENOID [Y-YRC] (84607243)
Y-Y_FC - PWM FAN CONTROL (Solenoid)

Connectors X-YFN (Receptacle) - SOLENOID FAN CONTROL [Y-Y_FC] (87693821)
Y-Y_FR - FAN REVERSER (Solenoid)

Connectors X-YFR (Receptacle) - FAN REVESER SOLENOID [Y-Y_FR] (87695582)
Y-Y_PB - PARKING BRAKE SOLENOID (Solenoid)

Connectors X-YPB (Receptacle) - VALVE PARKING BRAKE [Y-Y_PB] (87695582)
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Y-Y_PL - PILOT LOCK (Solenoid)

Connectors X-YPP (Plug) - PILOT PRESSURE SOLENOID [Y-Y_PL] (87692855)
Y-Y_SS - SEC STEERING SOL. (Solenoid)

Connectors X-YSS (Receptacle) - SEC STEERING VALVE SOL [Y-Y_SS] (87695582)
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Wiring harnesses - Electrical schematic sheet 03 SH03 - PWR

DISTR-BATTERY / STARTER / KEY
Type Component Connector / Link
ECU A-MAIN JB CAB - JUNCTION
BLOCK INTO CAB (ECU)
ECU A-SFB - SMART FUSE BOX X-X6 - SFB [A-SFB]
(ECU) (47554341)
Fuse F-GH - INLINE GH FUSE X-GH2 - GRID HEATER [F-GH]
(Fuse) (84140737) X-GH3 - GRID
HEATER RING TERMINAL
[F-GH] (84140737)
Fuse F-LC6F1 - MAIN ECU (Fuse)
Fuse F-LC6F10 - TELE (Fuse)
Fuse F-LC6F2 - KEY/HORN (Fuse)
Fuse F-LC6F3 - ECU AUX (Fuse)
Fuse F-LC6F5 - FFH (Fuse)
Fuse F-MAIN CAB - FUSE (Fuse)
Voltage source G-001 - BATTERY (Voltage X-563 - BATTERY LUG
source) [G-001] X-567 - BATTERY
LUG [G-001] X-P5321 - JUMP
START [G-001]
Voltage source G-002 - BATTERY (Voltage X-564 - BATTERY LUG [G-002]
source) X-566 - BATTERY POSITIVE
[G-002] X-P5320 - JUMP
START [G-002]
Voltage source G-G1 - ALTERNATOR (Voltage X-ALT - ALTERNATOR [G-G1]
source) (8602487)
Power outlet J-JS+ - JUMP START (Power X-JS+ - JUMP START STUD
outlet) POS [J-JS+]
Power outlet J-JS- - JUMP START STUD X-JS- - JUMP START STUD
(Power outlet) NEG [J-JS-]
Relay K-ISOLATOR - ISOLATOR X-DC2 - NON-DISC POWER
(Relay) STUD [K-ISOLATOR]
(84140737) X-ISO -
ISOLATOR [K-ISOLATOR]
(87687242) X-D(S) - MASTER
DISCONNECT SWITCHED
[K-ISOLATOR] (84163398)
Relay K-LC6R4 - CRANK CONTROL
(Relay)
Relay K-LC7R1 - FF HEATER
RELAY (Relay)
Relay K-LC7R2 - STARTER RELAY
(Relay)
Motor M-STRT_MTR - STARTER X-ST - START SIGNAL TO
MOTOR (Motor) STARTER [M-STRT_MTR]
(84426134)
Switch SW-KEY - IGNITION SWITCH X-KEY - KEY SWITCH
(Switch) [SW-KEY] (87699176)
Switch SW-MD - MASTER
DISCONNECT (Switch)
Connector X-563 X-563 - BATTERY LUG [G-001]
Connector X-566 X-566 - BATTERY POSITIVE
[G-002]
Connector X-ALT X-ALT - ALTERNATOR [G-G1]
(8602487)
Connector X-ALT_B X-ALT_B - ALTERNATOR B+
(84399576)
Connector X-B4 X-B4 - ALTERNATOR TO
STARTER B+ (84401309)
Connector X-BAT-GND X-BAT-GND - BATTERY
GROUND (84140737)
Connector X-CAB_E X-CAB_E - CAB TO ENGINE
[SH7: B-5] (84807216)
Connector X-CAB_E-2 X-CAB_E-2 - CAB TO ENG 2
[SH9: C-2] (87703902)
Connector X-CP X-CP - CAB POWER
(84401295)
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Connector X-CPWR X-CPWR - CAB POWER
(84401295)
Connector X-D(B) X-D(B) - MASTER
DISCONNECT BATTERY
(84140737)
Connector X-D(S) X-D(S) - MASTER
DISCONNECT SWITCHED
[K-ISOLATOR] (84163398)
Connector X-DC2 X-DC2 - NON-DISC POWER
STUD [K-ISOLATOR]
(84140737)
Connector X-ENG X-ENG - ENGINE TO CAB
[SH18: C-6] (87696948)
Connector X-ENG-2 X-ENG-2 - ENGINE TO CAB 2
(87703931)
Connector X-GH1 X-GH1 - GRID HEATER
(84140737)
Connector X-GH2 X-GH2 - GRID HEATER [F-GH]
(84140737)
Connector X-GH3 X-GH3 - GRID HEATER RING
TERMINAL [F-GH] (84140737)
Connector X-ISO X-ISO - ISOLATOR
[K-ISOLATOR] (87687242)
Connector X-JC1 X-JC1 - JUNCTION STUD OF
B+ IN REAR (84399576)
Connector X-JC2 X-JC2 - JUNCTION STUD
OF B+ IN REAR [SH3: C-4]
(84186853)
Connector X-JC3 X-JC3 - JUNCTION STUD OF
B+ IN REAR (84253168)
Connector X-JS+ X-JS+ - JUMP START STUD
POS [J-JS+]
Connector X-JS- X-JS- - JUMP START STUD
NEG [J-JS-]
Connector X-KEY X-KEY - KEY SWITCH
[SW-KEY] (87699176)
Connector X-LC6 X-LC6 - LOADCENTER 6
[SH16: A-3] (84380518)
Connector X-LC7 X-LC7 - LOAD CENTER 7
(84563565)
Connector X-P5320 X-P5320 - JUMP START
[G-002]
Connector X-P5321 X-P5321 - JUMP START
[G-001]
Connector X-ST X-ST - START SIGNAL TO
STARTER [M-STRT_MTR]
(84426134)
Connector X-SW_DISC X-SW_DISC - DISCONNECT
SWITCH [SH37: C-4]
(87694112)
Connector X-UCM2B X-UCM2B - UCM [A-UCM]
(82028495)
Connector X-X3 X-X3 - SFB [SH3: A-1]
(47554344)
Connector X-X4 X-X4 - SFB (47554343)
Connector X-X5 X-X5 - SFB [SH3: D-3]
(47554342)
(84538791)
Connector X-XM1B X-XM1B - STARTER LUG
FROM ISOLATOR (84596842)
Connector X-XM1C X-XM1C - STARTER
(84401295)
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6 5 4 3 2 1
G-G1
ALTERNATOR
CHARGE X-ALT_B
INDICATOR B+
A
15
3 X-ENG
SH3: A-1 M10 PL10, PL23 84401295

PHASE 228 RD 0.8 26 26 228A RD 0.8
L 4 M12 MID 84426142
301 RD 13.0
D X-ALT
239 YE 0.8 17 17 239A YE 0.8 SH3: A-3
SH21: D-3 1
X-XM1C
STARTER MOTOR
D
1990 RD 62.0
X-CAB_E X-B4
K-ISOLATOR CABLE-004 RD 62.0
X-XM1B
X-D(B) ISOLATOR
235 RD 19.0 GND
1
X-CPWR M
IN OUT X-D(S)
1 1
X-DC2 X-ST
OPEN GND K-LC7R2
3 SH15: B-2 STARTER MOTOR GROUND
1 251 BK 0.8 STARTER RELAY
CLOSE M-STRT_MTR
2 X-ISO 7 6
229 RD 5.0 3 2 230 RD 5.0
K-LC6R4
X-ISO CRANK CONTROL 8 5
664 YE 0.8 4 1 197 BK 0.8 SH15: D-2
FROM UCM
32 35
SH20: D-1 663C YE 0.8 X-LC7 ENGINE SPACE X-LC7
SH16: C-3 619A YE 0.8 688A BL 0.8 SH16: C-3

36 31
SH16: B-2 619 YE 0.8 688 BL 0.8 SH16: B-2
FROM ECU
F-LC6F1 TO ECU
1 1 2 5
30.0 A 233 RD 5.0 SH16: D-6
CABLE-003 RD 62.0
MAIN ECU
TIER 4B K-LC7R1
3 1 2 7 F-LC6F3
212 RD 3.0 25.0 A 213 RD 3.0 SH11: A-6
C ECU AUX
FF HEATER RELAY
C
9 1 13 F-LC6F5 11 10
2
416 RD 5.0 30.0 A 417 RD 5.0 421 OR 5.0 SH16: A-2
216A RD 3.0
237A YE 0.8
FFH
ENGINE SPACE
X-LC6 X-LC6 12 9
SH16: A-2 627A RD 0.8 661 BK 0.8 SH16: A-2
SH11: A-6 ENGINE SPACE SH16: A-3

212A RD 3.0 661A BK 0.8
X-LC7 X-LC7 A-MAIN JB CAB
F-MAIN CAB JUNCTION BLOCK INTO CAB
X-JC2 FUSE M10

X-JC3
ENGINE SPACE M8
1
100A 240 RD 19.0
X-JC1 JC4 X-CP
F-GH
X-GH1 INLINE GH FUSE
1 2
CABLE 06 RD 32.0 150.0 A CABLE 05 RD 32.0 SH16: B-3 TO GRID HEATER SH6:A-6, SH7:B-6, SH8:C-6
CABLE09 RD 32.0 X-GH2 X-GH3
X-P5320
1
X-566 A-SFB
SMART FUSE BOX
POS
X-ENG-2
BATTERY
17
G-002
OUT_11_H
250A YE 0.8 F F 250 YE 0.8
ISOLATOR SET
NEG
X-X4
X-JS+ 8 OUT_09_H
G G 237 YE 0.8
X-564 ISOLATOR RESET
B SP-216A X-ENG
X-CAB_E-2
X-X7
B
JUMP START 216D RD 2.0 4 4 216E RD 2.0 SH7: B-5 TO HOOD LIFT MOTOR
CABLE-002 RD 62.0
J-JS+ X-CAB_E
F-LC6F10
TELE
X-ENG-2 217A RD 0.8 SH38: B-6 TO TELEMATICS
20 1 2 24
216B RD 1.0 7.5 A 217 RD 0.8 H H
11 VMCU
219C RD 0.8
F-LC6F2 NON-ISOLATED PWR
2 1 2 6
J-JS- 216C RD 1.0 10.0 A X-X4 8
SH34: C-6 OUT_02_H SH10: A-6
X-567 JUMP START STUD 219D RD 0.8 222 YE 0.8
KEY/HORN TO HORN Ignition Relay V+
RELAY
ENGINE SPACE
X-LC6 X-LC6 219E RD 0.8 SH34: C-6
POS
BATTERY
33 IN_DIG_01_H_WU
G-001
X-JS- ISOLATOR SHUTOFF DETECT

218 RD 0.8
OUT_01_H 11
NEG
226 YE 0.8 SH9: A-6

SW-KEY
Accessory Relay V+
SW-MD IGNITION SWITCH
X-563 X-P5321 MASTER DISCONNECT SP-219A START START 30
B IN_DIG_04_H_WU
220 YE 0.8
IN1 OUT1 B+ RUN KEY SWITCH: CRANK
CABLE08 BK 32.0 6 4 219 RD 0.8 J J 219A RD 0.8 219B RD 0.8 A
OFF RUN 15
5 533 RD 1.0 D 221 YE 0.8 OUT_06_H 192 OR 0.8 SH8: B-6
IN2 OUT2 ACC DC CONVERTER RELAY
SH11: C-2 510 OR 0.8 1 3 X-KEY
31 IN_DIG_03_H_WU
IGN X-CAB_E-2 START ACC
C
Key Switch: Ignition OUT_03_H
5
220B YE 0.8 SH20: D-5
PWR RUN CRANK SIGNAL
CABLE-001 BK 62.0
OFF 32 IN_DIG_02_H_WU
X-SW_DISC X-SW_DISC X-KEY 225 YE 0.8 X-X3
ACC Key Switch: Accesory
A SH37: C-4 A
669 OR 0.8 SH16: C-6
67 IN_ANA_15 OUT_07_H 4
SH3: D-3 239A YE 0.8 228A RD 0.8 SH3: D-3
ALT_CHARGE_INDICATOR ALTERNATOR_EXCITATION
669A OR 0.8 SH16: C-5
X-X7 X-X5
to ecu
IGN PWR
1
X-BAT-GND
ENG BLOCK GROUND
6 5 4 3 2 1
SHT_3 1
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Wiring harnesses - Electrical schematic sheet 04 SH04 - POWER

DISTRIBUTION SFB PWR AND GRNDS
(ECU) (47554341)
(84344499)
Connector X-X2 X-X2 - SFB [SH6: C-1]
(84344499)
(47554344)
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6 5 4 3 2 1
D D
C C
A-SFB
SMART FUSE BOX
GND_1 8
1002 BK 1.0 SH14: C-3
MODULE GROUND
GND_2 5
1006 BK 1.0 SH14: C-3
Redundant GND
X-X4
2 14
SH6: D-1 VSUPA PGND SH14: C-3
169 RD 8.0 1003 BK 1.0
X-X3
1
SH6: C-2 VSUPB
169 RD 8.0
X-X1
B 2
B
SH6: C-2 VSUPC
171 RD 8.0
1
SH6: C-1 VSUPD
172 RD 8.0
X-X2
A A
6 5 4 3 2 1
SHT_4 1
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Wiring harnesses - Electrical schematic sheet 06 SH06 - BATTERY PWR

DISTR (FUSE BLOCK LC1)
Fuse F-1F1 - ACCESSORY (Fuse)
Fuse F-1F2 - IGNITION (Fuse)
Fuse F-1F3 - SFB-D (Fuse)
Fuse F-1F4 - SFB-A (Fuse)
Fuse F-1F5 - SFB-B (Fuse)
Fuse F-1F6 - SFB-A (Fuse)
[SH10: A-6] (47728326)
Connector X-P1031 X-P1031 - B+ ON POWER
STUD (84140737)
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6 5 4 3 2 1
D LC1 D
A-MAIN JB CAB
JUNCTION BLOCK INTO CAB
F-1F6
SFB-A
F1
1 2
50 A 169 RD 8.0 SH4: B-6
F-1F5
SFB-B
E1
1 2
50 A 170 RD 8.0 SH4: B-5
1 1 F-1F4
518 RD 19.0 SFB-A
X-P1031 P1310 D1
1 2
50 A 171 RD 8.0 SH4: B-6
C C
F-1F3
SFB-D
C1
1 2
50 A 172 RD 8.0 SH4: B-5
F-1F2
IGNITION
1 2 B1
50 A 173 RD 5.0 SH10: A-6
F-1F1
ACCESSORY
1 2 A1
50 A 174 RD 5.0 SH9: A-6
B B
X-LC1
A A
SH3:B-1
X-LC1
6 5 4 3 2 1
SHT_6 1
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Wiring harnesses - Electrical schematic sheet 07 SH07 - BATTERY PWR

Fuse F-2F1 - UCM-VP (Fuse)
Fuse F-2F10 - SPARE (Fuse)
Fuse F-2F11 - CAMERA (Fuse)
Fuse F-2F2 - UCM VF2/3 (Fuse)
Fuse F-2F3 - UCM VF4/6 (Fuse)
Fuse F-2F4 - UCM VS1/VLP (Fuse)
Fuse F-2F6 - TECM (Fuse)
Fuse F-2F7 - DISPLAY (Fuse)
Fuse F-2F8 - DIAGNOSTIC (Fuse)
Fuse F-2F9 - HOOD LIFT (Fuse)
[SH7: B-3] (87733581)
Connector X-P1002 X-P1002 - B+ POWER STUD
(84140737)
(84140737)
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6 5 4 3 2 1
LC2
A-MAIN JB CAB
D JUNCTION BLOCK INTO CAB D
F-2F1
4.0 MAX UCM-VP
1B 1 1A
2 SH19: D-6
526 RD 1.0 20 A 465 RD 1.0
F-2F2
UCM VF2/3
1 2B 1 2A
2 SH19: D-6
527 RD 3.0 20 A 448 RD 3.0
X-P1196
F-2F3
UCM VF4/6
3B 1 2 3A
528 RD 3.0 20 A 454 RD 3.0 SH19: D-6
F-2F4
UCM VS1/VLP
4B 1 2 4A
529 RD 3.0 15 A 461 RD 3.0 SH19: D-6
C F-2F5
SPARE
C
5B 1 2 5A
0A
F-2F6
TECM
6B 1 2 6A
7.5 A 165 RD 1.0 SH25: D-6
F-2F7
DISPLAY
1 7B 1 2 7A
532 RD 3.0 10 A 805 RD 0.8 SH24: C-6
X-P1002
F-2F8
DIAGNOSTIC
8B 1 2 8A
5A 798 RD 0.8 SH24: C-5
SH3:B-1
F-2F9
HOOD LIFT
9B 1 2 9A
SH3: B-3 216E RD 2.0 20 A 205 RD 2.0 SH37: D-6
B F-2F10 B
SPARE
10B 1 2 10A
0A
F-2F11
CAMERA
1 2 11A
5A 125 OR 0.8 SH39: B-6
11B
F-2F12
SPARE
12B 1 2 12A
SH10: A-1 878C OR 3.0 0A
F-2F13
SPARE
13B 1 2 13A
0A
F-2F14
SPARE
1 2
0A
A A
X-LC2
X-LC2
20 FUSE SLOTS IN BOX
6 5 4 3 2 1
SHT_7 1
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DISTRIBUTION (FUSE BLOCK LC3)
Fuse F-3F1 - 12V PWR1 (Fuse)
Fuse F-3F2 - 12V SPARE (Fuse)
Fuse F-3F3 - 12V RADIO (Fuse)
Fuse F-3F4 - 12V SPARE (Fuse)
Fuse F-3F8 - 12V CONVERTER
(Fuse)
Relay K-3R1 - 12V CONVERTER
(Relay)
Relay K-3R2 - SEC STEERING
(Relay)
Relay K-3R3 - REAR DEFROST
(Relay)
[SH35: B-6] (84529039)
(84140737)
(47554344)
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6 5 4 3 2 1
SH35: B-4
LC3
A-MAIN JB CAB
JUNCTION BLOCK INTO CAB
F-3F1
D F1_9
12V PWR1 D
1 2 F1_13
10 A 750 OR 1.0 SH35: A-3
F-3F2
SP-6199 12V SPARE
F2_10
1 2 F2_14
20 A
F-3F3
12V RADIO
F3_11
1 2 F3_15
748 OR 2.0 10 A 753 OR 0.8 SH35: B-5
F-3F4
12V SPARE
F4_12
1 2 F4_16
20 A
F-3F5
SPARE
F5_5
2 F5_1
1
0A
F-3F6
SPARE
F6_6
F6_2
C 1
541 RD 2.0
1
0.0 A
2
C
X-P1009
F-3F7
SPARE
F7_7
2 F7_3
1
0A
F-3F8
12V CONVERTER
F8_8
SH3:B-1 1 2 F8_4
917 RD 3.0 20 A 191 RD 3.0 SH8: B-5
K-3R1
12V CONVERTER
87A R1_87A
R1_30
30
SH8: B-2 191 RD 3.0 R1_87
87
746 OR 3.0 SH35: B-6
R1_86 86 85 R1_85
SH3: A-1 192 OR 0.8 954F BK 0.8 SH13: A-2
K-3R2
SEC STEERING
87A R2_87A
B SH10: C-2 182 OR 0.8
R2_30 30
R2_87
B
87
441 OR 0.8 SH21: B-3
R2_86 86 85 R2_85
SH21: C-2 183 YE 0.8 954R BK 0.8 SH13: A-4
K-3R3
REAR DEFROST
87A R3_87A
R3_30 30
SH9: B-1 877 OR 2.0 R3_87
87
801 OR 2.0 SH36: D-2
R3_86 86 85 R3_85
SH36: D-3 120 YE 0.8 954M BK 0.8 SH13: A-3
3R4
HORN
87A
30
87
86 85 ON HORN SHT 34
A X-LC3
A
X-LC3
6 5 4 3 2 1
SHT_8 1
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Wiring harnesses - Electrical schematic sheet 09 SH09 - ACCESSORY

PWR DIST (FUSE BLOCK LC4)
Fuse F-4F1 - 24V CIGAR (Fuse)
Fuse F-4F3 - A/C CLUTCH (Fuse)
Fuse F-4F6 - BLOWER (Fuse)
Fuse F-4F7 - SEAT (Fuse)
Fuse F-4F8 - REAR DEFROST
(Fuse)
Relay K-4KR1 - ACCESSORY
(Relay)
[SH35: C-6] (87733595)
(47554344)
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6 5 4 3 2 1
874 OR 3.0
920 OR 3.0
919 OR 3.0
D D
LC4
F-4F1
24V CIGAR
1 2 1A
1B
4.0 MAX 15 A 743 OR 2.0 SH35: C-6
F-4F2
SPARE
SP-6201 2A
2B 1 2
0A
F-4F3
A/C CLUTCH
1 2 3A
3B 5A SH11: A-6
875 OR 1.0
F-4F4
SPARE
C 4B 1
0A
2 4A
C
F-4F5
SPARE
1 2 5A
5B 0A
F-4F6
BLOWER
1 2 6A
6B 25 A SH33: D-4
876 OR 3.0
F-4F7
SEAT
1 2 7A
7B 15 A SH35: D-6
742 OR 2.0
F-4F8
REAR DEFROST
1 2 8A
8B 20 A SH8: B-6
877 OR 2.0
B F-4F9 B
SPARE
1 2 9A
9B 0A
F-4F10
SPARE
10B 1 2 10A
0A
K-4KR1
ACCESSORY
87A
30 30
SH6: B-2
87 87
86 86 85 85
SH3: A-1 226 YE 0.8 954A BK 0.8 SH13: B-2
A X-LC4 X-LC4 A
6 5 4 3 2 1
SHT_9 1
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Wiring harnesses - Electrical schematic sheet 10 SH10 - IGNITION PWR

Fuse F-5F1 - DISPLAY WK (Fuse)
Fuse F-5F10 - STALK/DIFF (Fuse)
Fuse F-5F2 - UCM (Fuse)
Fuse F-5F3 - TECM (Fuse)
Fuse F-5F4 - TELEMATICS (Fuse)
Fuse F-5F5 - SEC STRG (Fuse)
Fuse F-5F6 - IMP JOYSTICK (Fuse)
Fuse F-5F7 - KEY PAD (Fuse)
Fuse F-5F8 - JSS IGN (Fuse)
Fuse F-5F9 - REAR PWR (Fuse)
Relay K-5KR1 - IGNITION (Relay)
[SH10: D-1] (87733595)
Connector X-ZF_DI X-ZF_DI - DIAGNOSTIC
[A-108F] (84364851)
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6 5 4 3 2 1
878B OR 3.0
878A OR 3.0
D D
LC5
F-5F1
DISPLAY WK
1B 1A
1 2
5A 806 OR 0.8 SH24: C-6
F-5F2
SH19: D-6
UCM
2B 2A
1 2
5A 466 OR 0.8
F-5F3
19D OR 0.8 SH20: C-4
TECM
3B 3A SP-19C
1 2
7.5 A 19C OR 2.0 19E OR 0.8 SH25: D-5
19F OR 0.8 SH25: C-2
F-5F4
19G OR 0.8 SH26: A-2
TELEMATICS
4B 4A
C 1
5A
2
168 OR 0.8 SH38: B-5 C
F-5F5
SEC STRG
5B 5A
1 2
7.5 A 182 OR 0.8 SH8: B-6
F-5F6
IMP JOYSTICK
6B 6A
1 2
7.5 A 792 OR 0.8 SH24: A-3
F-5F7
KEY PAD
7B 7A
1 2
5A 807 OR 0.8 SH24: D-5
F-5F8
JSS IGN
8B 8A SP-799
1 2
10 A 799 OR 0.8 799B OR 0.8 SH21: A-4
B F-5F9 799A OR 0.8 SH24: A-6

B
REAR PWR
9B 9A
1 2
15 A 850 OR 2.0 SH11: C-5
F-5F10
STALK/DIFF
SP-19H
10B 1 2 10A
5A 19H OR 0.8 19M OR 0.8 SH20: B-6
19J OR 0.8 SH24: C-5
878C OR 3.0 SH7: A-6

K-5KR1
IGNITION
87A
30 30
SH6: B-2 173 RD 5.0 SP-878
87 87
878 OR 5.0
86 86 85 85
SH3: B-1 222 YE 0.8 954H BK 0.8 SH13: A-4
A X-LC5 X-LC5 A
6 5 4 3 2 1
SHT_10 1
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Wiring harnesses - Electrical schematic sheet 11 SH11 - PWR DISTR ENG

COMPARTMENT (FUSE BLOCK LC6)
Fuse F-LC6F4 - SCR SENSORS
(Fuse)
Fuse F-LC6F6 - EVGT (Fuse)
Fuse F-LC6F7 - ECU IGN (Fuse)
Fuse F-LC6F9 - FAN (Fuse)
Relay K-LC6KR3 - ECU AUX (Relay)
Relay K-LC6KR5 - AC CLUTCH
(Relay)
[SH7: B-5] (84807216)
[SH9: C-2] (87703902)
[SH18: C-6] (87696948)
(87703931)
[SH16: A-3] (84380518)
Connector X-SW_DISC X-SW_DISC - DISCONNECT
SWITCH [SH37: C-4]
(87694112)
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6 5 4 3 2 1
LC6
IN ENGINE COMPARTMENT
LC6F1
MAIN ECU
1 2
30 A
LC6F2 SHOWN ON
KEYHORN
1 2
SHEET 3
D 10 A
D
LC6F3 LC6F3_F4_REF
ECU AUX TIER 2 OK TO START
1 2
3 25 A 7
30 87
4 7 SHOWN ON
SHEET 16
F-LC6F4 86 85
200J RD 3.0 SH18: A-6
SCR SENSORS 8 3
4 1 2 8
20 A 200 RD 3.0 SH18: A-6
LC6F5
FFH
1 2 SHOWN ON
30 A
SHEET 3
F-LC6F6
202A RD 1.0 SH18: B-5
10 EVGT
SP-214 14
1 2 TIER 2 ONLY
214A RD 3.0 20 A 202 RD 3.0 SH18: A-4
10 A EVGT
X-ENG SH17: D-4

850E OR 0.8
F-LC6F7
C IGN PWR SP-850A

11 1
ECU IGN
2 15
C
SH10: B-1 850 OR 2.0 1 1 850A OR 2.0 850B OR 0.8 5A 510 OR 0.8 SH3: A-6
F-LC6F8
X-CAB_E SPARE
12 1 2
-A
16
F-LC6F9 SH20: A-2

FAN 852B OR 0.8
SP-852
19 1 2 23
850D OR 0.8 7.5 A 852 OR 0.8 852C OR 0.8 SH20: B-2
F-LC6F10
TELE
SHOWN ON
1 2
7.5 A SHEET 3
X-LC6 X-LC6
214 RD 3.0
214C RD 3.0
LC6KR1 87A
HOOD UP 30
87
B 86 85 SHOWN ON B
SHEET 37
LC6KR2 87A
HOOD DOWN 30
87
86 85
SH3: C-4 212A RD 3.0

K-LC6KR3
TIER 2
ECU AUX PL2326 EVGT
30 30 87
SH3: C-2 213 RD 3.0 33
SH16: A-3 627F RD 0.8 29

34 86 85
SH16: B-3 620 WH 0.8 645 BK 0.8 SH16: B-3
SH16: A-2 627D RD 0.8 645A BK 0.8 SH16: B-3
LC6KR4
CRANK
CONTROL 30 87
SHOWN ON
SHEET 3
86 85
A A
X-CAB_E-2 X-ENG-2
ACC PWR
K-LC6KR5 87A
AC CLUTCH 187A YE 1.0 SH33: B-6
18 30
SH9: C-2 875 OR 1.0 K K 875A OR 1.0 25
87
187 YE 1.0 SH33: B-6
86 85 17
LOAD CENTER 7
26
SH33: C-6 211B YE 1.0 254 BK 0.8 SH12: A-4 SHOWN ON
SHEET 3
X-LC6 X-LC6
6 5 4 3 2 1
SHT_11 1
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DISTRIBUTION 1 CLEAN GROUND BLK
[SH7: B-5] (84807216)
[SH18: C-6] (87696948)
Connector X-GND_CENG1 X-GND_CENG1 - GROUND
CLEAN ENG BLOCK
(84140737)
Connector X-GND_CENG2 X-GND_CENG2 - GROUND
CLEAN ENG BLOCK [SH12:
A-4] (84140737)
Connector X-SP_PK_CLN X-SP_PK_CLN - SPLICE
PACK CLEAN GRND [SH25:
C-1] (87352746)
Connector X-TURBO_2 X-TURBO_2 - ENGINE
HARNESS INTERFACE T2
[SH18: B-5] (87694583)
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6 5 4 3 2 1
A
SH38: B-1 912 BK 0.8
B
SH24: D-5 916 BK 0.8
C
D SH24: B-6 871 BK 0.8 D
D
SH24: C-4 945 BK 0.8
E
SH33: D-4 256 BK 0.8
F
857 BK 2.0
G CLEAN
SH25: C-1 946 BK 0.8 GROUND
IN
CAB
H
SH25: D-2 856 BK 0.8
J
SH25: D-2 855 BK 0.8
C SH38: B-3 287 BK 0.8

K
C
M
X-ENG
3 3
X-SP_PK_CLN
X-CAB_E
B 857A BK 2.0
B
1
SH18: B-5 203A BK 1.0 X-GND_CENG1
SH18: A-4 203 BK 3.0
CHASSIS
CLEAN
GROUND
ON ENGINE
BLOCK
SH16: C-1 603 BK 5.0
SH11: A-2 254 BK 0.8

X-GND_CENG2
A SH18: A-6 201 BK 3.0 A

SH18: A-6 201K BK 3.0
6 5 4 3 2 1
SHT_12 1
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DISTRIBUTION 2 CAB GROUND BLK
Connector X-CG3 X-CG3 - CAB GROUND RH
HEADLINER [SH13: D-5]
(84149207)
Connector X-CG4 X-CG4 - CAB GROUND
[SH24: B-6] (84149207)
[SH35: B-6] (84529039)
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6 5 4 3 2 1
A
SH36: C-4 955A BK 0.8
B
SH34: A-4 955J BK 0.8
C
SH34: A-6 955K BK 0.8
D D
D
SH39: B-6 955AD BK 0.8
F
SH36: C-6 955R BK 0.8
H
SH27: C-2 955N BK 0.8
CAB
GROUND
SH27: C-6
J ROPS BACK
955P BK 0.8
TUBE
K
SH27: C-2 955Q BK 0.8
C C
L
SH32: C-1 955V BK 1.0
M
SH34: A-5 954B BK 0.8
SH31: C-3 X-CG3

949 BK 2.0
SH36: D-2 272 BK 2.0
1 RH HEADLINER
SH31: B-3 953 BK 2.0
CG1
STUD
SH33: C-2 903 BK 2.5
SH35: C-1 271 BK 0.8
SH36: C-4 958 BK 0.8

A
SH9: A-1 954A BK 0.8
B
SH21: A-3 955X BK 0.8
B SH35: D-1 955L BK 2.0

C B
D
SH28: C-3 954D BK 1.0
E
SH24: B-6 954E BK 0.8
F
SH8: B-1 954F BK 0.8
SH36: C-5 954T BK 0.8

SP-954L
G
SH36: B-5 954G BK 0.8 954L BK 0.8
SH36: B-6 955S BK 0.8

H
SH10: A-1 954H BK 0.8
CAB
GROUND
J
SH21: A-4 954J BK 0.8
A K A
SH24: A-3 954K BK 1.0
SH8: B-2 954R BK 0.8

SP-954S ROPS BACK
M
SH8: A-1 954M BK 0.8 954S BK 0.8
TUBE STUD
X-CG4
6 5 4 3 2 1
SHT_13 1
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Wiring harnesses - Electrical schematic sheet 14 SH14 - CAB & CHASSIS

GROUND PWR DISTR
Connector X-GND_FRNT X-GND_FRNT - CHASSIS
GROUND (84140737)
Connector X-GND_GRL X-GND_GRL - GROUND
GRILL TERMINAL (84140737)
Connector X-GND_PED X-GND_PED - GROUND
PEDESTAL RING [SH14: B-6]
(84140737)
Connector X-GND_RR X-GND_RR - CHASSIS
GROUND (84140737)
Connector X-GND_RR2 X-GND_RR2 - CHASSIS
GROUND [SH28: B-2]
(84426126)
Connector X-GND_RR3 X-GND_RR3 - SEC STRG
CHASSIS GRND [SH14: B-4]
(84426126)
Connector X-GND_RR4 X-GND_RR4 - (84140737)
Connector X-GRD_WIF X-GRD_WIF - WATER IN
FUEL GRND (84426120)
Connector X-SSG X-SSG - SECONDARY
STEERING GROUND RING
[SH21: C-1] (84401307)
Connector X-X31CF1-2 X-X31CF1-2 - CAB GROUND
BLOCK (84122130)
Connector X-X31CF1-3 X-X31CF1-3 - CAB GROUND
BLOCK (84122130)
Connector X-X31CF2-1 X-X31CF2-1 - STEERING
COLUMN GROUND
(84122130)
Connector X-X31CF2-2 X-X31CF2-2 - STEERING
COLUMN GROUND
(84122130)
Connector X-YSS X-YSS - SEC STEERING
VALVE SOL [Y-Y_SS]
(87695582)
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6 5 4 3 2 1
SH32: A-5 279 BK 2.0
CONTINUED ON
SHT 13
D D
SH35: A-1 275 BK 1.0
1
SH32: D-1 103 BK 2.0
CG2
SH35: C-1 957 BK 2.0
SH35: B-5 276 BK 2.0
CAB STUD
GROUND
SH35: B-5 277 BK 2.0
SH4: B-2 1002 BK 1.0
C 1 C
SH4: B-2 1006 BK 1.0
CG5
SH4: B-2 1003 BK 1.0

CONTINUED ON
SHT 19
1
STRAP1 - 50.0
X-X31CF2-1
BIG BRAIDED STRAP
CAB BOTTOM
GROUND
B B
1
1
SH28: D-1 X-X31CF2-2
955U BK 1.0 1
X-GND_PED SH21: C-1 185 BK 62.0
X-SSG
SH20: B-2 1
PEDESTAL 391A BK 1.0
X-GND_RR4
GROUND 1
SH21: B-1 184 BK 0.8 1 1
X-GND_RR3 CABLE_ENG_GRND BK 62.0
X-X31CF1-3 X-X31CF1-2
1 GRND CABLE
SH28: B-2 624D BK 2.0
X-GND_RR2
1
1
SH23: C-5 293 BK 0.8
RR4
1 GND_RR5 ENGINE BLOCK
GROUND
X-GND_RR REAR FRAME
GROUND
313 BK 2.0
1
SH15: C-2 281 BK 1.0
X-GRD_WIF
CONTINUED ON
X-GND_GRL 1
SHT 3, 12, AND 15
WATER IN FUEL
BODY GROUND
ON GRILL
A 1 A
061 BK 5.0
X-GND_FRNT
FRONT FRAME
GROUND
6 5 4 3 2 1
SHT_14 1
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DISTRIBUTION 4 ENGINE GROUND BLK
Connector X-BU1 X-BU1 - BACK UP ALARM
[H-BU_ALRM] (84426117)
Connector X-GND_ENG1 X-GND_ENG1 - GROUND
ENG BLOCK [SH16: A-1]
(84140737)
ENG BLOCK [SH15: C-3]
(84140737)
ENG BLOCK [SH29: B-3]
(84140737)
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6 5 4 3 2 1
SH16: A-1 195 BK 2.0

D D
1
SH3: C-2 197 BK 0.8
X-GND_ENG1
SH16: A-1 196 BK 2.0
SH16: B-5 198 BK 0.8
C C
SH14: A-5 281 BK 1.0
X-GND_ENG3
SH20: A-1 204 BK 0.8
1
SH37: C-1 208 BK 2.0
SH29: C-1 243 BK 0.8

ENG_EURO_PL10-20
B FROM PL10-20 BU SH36: C-1

ENG_PL10-20
244 BK 0.8
B
X-GND_ENG4
SH29: B-3 242 BK 1.0
1
SH3: D-5 251 BK 0.8
ENGINE BLOCK GROUND
A A
6 5 4 3 2 1
SHT_15 1
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Wiring harnesses - Electrical schematic sheet 16 SH16 - ENGINE

CONTROL UNIT 1, GRID HEATER, FILTER HEATER
ECU A-ECU - ENGINE X-ECU - ECU CONNECTOR
CONTROLLER (ECU) [A-ECU] (84300197)
Sensor B-ACCEL - THROTTLE X-THRTL - THROTTLE
CONTROL (Sensor) CONTROL [B-ACCEL]
(84403598)
Relay K-GH - GRID HEATER RELAY X-GHC - GRID HEATER
(Relay) CONTROL [K-GH] (82012083)
Relay K-LC6F3_F4 - T2 OK TO
START (Relay)
Resistor R-RES-G_HTR - GRID X-GH6 - GRID HEATER
HEATER (Resistor) [R-RES-G_HTR] (87744835)
X-GH7 - GRID HEATER
[R-RES-G_HTR] (87744835)
Connector X-001 X-001 - GRID HEATER
CABLE GRND ON ENGINE
(84398003)
[SH7: B-5] (84807216)
[SH9: C-2] (87703902)
Connector X-DIA X-DIA - DIAGNOSTIC PORT
[A-DIA] (87736919)
Connector X-ECU X-ECU - ECU CONNECTOR
[A-ECU] (84300197)
Connector X-EDC7 X-EDC7 - ENGINE
CONTROLLER T2/3 [SH18:
C-5] (84160698)
[SH18: C-6] (87696948)
(87703931)
Connector X-FFH X-FFH - FILTER HEATER
[Y-F_F_H] (87679438)
[R-RES-G_HTR] (87744835)
[R-RES-G_HTR] (87744835)
Connector X-GHC X-GHC - GRID HEATER
CONTROL [K-GH] (82012083)
[SH16: A-3] (84380518)
Connector X-THRTL X-THRTL - THROTTLE
CONTROL [B-ACCEL]
(84403598)
Connector X-WSH X-WSH - WATER
SEPERATOR HEATER
[Y-W_S_H] (87679438)
Solenoid Y-F_F_H - FILTER HEATER X-FFH - FILTER HEATER
(Solenoid) [Y-F_F_H] (87679438)
Solenoid Y-W_S_H - WATER SEP X-WSH - WATER
HEATER (Solenoid) SEPERATOR HEATER
[Y-W_S_H] (87679438)
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6 5 4 3 2 1
2
233F RD 1.0
3
233G RD 1.0
8
233H RD 1.0
9
233J RD 1.0
X-EDC7
5
D SH3: C-2
SP-233 A-ECU 603F BK 1.0 D
233 RD 5.0 233A RD 1.0 1 1 6
ENGINE CONTROLLER
603G BK 1.0
233B RD 1.0 25 25
10
233C RD 1.0 26 26 603H BK 1.0
11
233D RD 1.0 49 49 603J BK 1.0
233E RD 1.0 73 73
X-EDC7
3 3 603A BK 1.0
GROUND
5 5 603B BK 1.0
SH3: A-4 SP-603
669 OR 0.8 69 69
28 28 603C BK 1.0 603 BK 5.0 SH12: A-2
KEY SW POWER FROM DISCONNECT
SP-669A 40
SH3: A-4 669A OR 0.8 669B OR 0.8 29 29
669C OR 0.8 SH20: D-6 52 52 603D BK 1.0
SP-643F 75 75 603E BK 1.0 603K BK 0.8 SH17: D-5

29
643G BK 0.8 643F BK 0.8
76 76
B-ACCEL X-EDC7 X-ECU

X-ENG-2
THROTTLE CONTROL 643E BK 0.8
C X-ENG
C
F 643C BK 0.8 E E 643D BK 0.8 SH17: C-4 20 20 303 WH 0.8 SH24: B-4
60 160
D 408 WH 0.8 D D 408A WH 0.8 LOW IDLE POSITION SW
B 651H BL 0.8 C C 651K BL 0.8 80 180 X-CAB_E
89
THROTTLE PEDAL SNSR1 GND 303A WH 0.8
A 409 YE 0.8 A A 409A YE 0.8 79 179
C 471B PK 0.8 B B 471K PK 0.8 THROTTLE SIGNAL 1
37
619A YE 0.8 SH3: C-4
66 166
X-THRTL 48 5v SENSOR SUPPLY 2D
X-CAB_E-2 17
408B WH 0.8 688A BL 0.8 SH3: C-3
78 X-EDC7
651P BL 0.8 19 19 619 YE 0.8 SH3: C-4
CRANK CONTROL RELAY
79 88 88 688 BL 0.8 SH3: C-3
409B YE 0.8 CRANK CONTROL RELAY
77
471P PK 0.8
X-EDC7
FROM UCM SH20: D-1 663B YE 0.8 6363
OK TO START FROM VEHICLE
20 20 620 WH 0.8 SH11: A-5
AUX RELAY CONTROL
45 45 645 BK 0.8 SH11: A-2

32
K-LC6F3_F4 21E YE 0.8 AUX RELAY CONTROL
T2 OK TO START 51
B 4 87 X-EDC7
645A BK 0.8 SH11: A-2
B
30 7
X-EDC7
8 86 85 3
SH20: D-1 663D YE 0.8 198 BK 0.8 SH15: D-2
FROM UCM X-LC6 X-LC6
X-ECU K-GH
X-ECU
GRID HEATER RELAY
THESE PINS ARE ALSO USED SH3: B-3
ON SHT 3 FOR ECU AUX FUSE 87A
AND SHT 11 FOR SCR SENSOR 30
FUSE. TIER 4B MACHINES ONLY. CABLE 05 RD 32.0 R-RES-G_HTR
87 GH5
GH4 GRID HEATER
CABLE_06 RD 32.0
12 674A WH 0.8 86 85 P N
74 74 674 WH 0.8 1 2 CABLE_07 BK 32.0
GRID RELAY CNTRL HI
ENGINE CONTROLER CONNECTOR X-GHC ENGINE SPACE X-GHC X-GH6 X-GH7
IS 84595906 RIGHT EXIT ON PL23 83 83 683 BL 0.8
IS 84300197 LEFT EXIT ON ALL OTHERS. GRID RELAY CNTRL LO
75 683B BL 0.8 X-001
GROUND ON ENGINE
627F RD 0.8 SH11: A-5 BLOCK NEAR GRID HEATER
627D RD 0.8 SH11: A-5

Y-F_F_H GROUND
13 627E RD 0.8 FILTER HEATER
X-EDC7 SH3: C-1 SP-421
1 2
27 27 627 RD 0.8 627A RD 0.8 421 OR 5.0 421A OR 2.0 A B 196 BK 2.0 SH15: D-3
A B+ FOR AIR FILTER RS + FFH SIGNAL SP-627 SH3: C-2 A
TIER 2 AND TIER 3 ENGINES X-FFH X-FFH
627B RD 0.8 SH17: A-6
Y-W_S_H
FFH 61 61 661 BK 0.8 SH3: C-1 WATER SEP HEATER
1 2
X-ECU 421B OR 2.0 B A 195 BK 2.0 SH15: D-3
36 661A BK 0.8 SH3: C-1 X-WSH X-WSH

PL2326
NO FFH GROUND
X-EDC7
6 5 4 3 2 1
SHT_16 1
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Wiring harnesses - Electrical schematic sheet 17 SH17 - ENGINE CONTROL UNIT 2, AT

Type Component Connector / Link Type Component Connector / Link
ECU A-ECU - ENGINE X-ECU - ECU CONNECTOR Connector X-EDC7 X-EDC7 - ENGINE
CONTROLLER (ECU) [A-ECU] (84300197) CONTROLLER T2/3 [SH18:
Sensor B-C_TS - DOC UPSTREAM X-CTS - DOC UPSTREAM C-5] (84160698)
TEMP SENSOR (Sensor) TEMP [B-C_TS] (84532147) Connector X-HTS X-HTS - HUMIDITY AND
Sensor B-D_TS - SCR X-DTS - SCR DOWNSTREAM TEMP SENSOR [B-HT]
DOWNSTREAM TEMP TEMP [B-D_TS] (84532147) (87709809)
SENSOR (Sensor) Connector X-LEV1 X-LEV1 - INLINE TO DEF
Sensor B-HT - HUMIDITY AND AMB X-HTS - HUMIDITY AND LEVEL & TEMP (84062580)
TEMP SENSOR (Sensor) TEMP SENSOR [B-HT] Connector X-LEV2 X-LEV2 - INLINE TO DEF
(87709809) LEVEL & TEMP (87680689)
Sensor B-U_LVL - SENSOR TANK X-DTLTS - DEF LEVEL / TEMP Connector X-SCR1 X-SCR1 - INLINE TO SCR
LEVEL & TEMP (Sensor) [B-U_LVL] (84062580) SENSORS HARNESS
Sensor B-U_TS - SCR UPSTREAM X-UTS - UPSTREAM OF SCR (87695592)
TEMP SENSOR (Sensor) TEMP SENSOR [B-U_TS] Connector X-SCR2 X-SCR2 - INLINE FROM
(84532147) SCR SENSORS HARNESS
Sensor B-WIF - WATER IN FUEL X-WIF - WATER IN FUEL (87695724)
(Sensor) [B-WIF] (87709663) Connector X-THV X-THV - SCR TANK HEATING
Switch SW-A_F_S - AIR FILTER X-AFS - AIR FILTER RSTCN VALVE [Y-TNK_HTR]
RSTCN SW (Switch) SW [SW-A_F_S] (84607243) (84146685)
Connector X-AFS X-AFS - AIR FILTER RSTCN Connector X-UTS X-UTS - UPSTREAM OF SCR
SW [SW-A_F_S] (84607243) TEMP SENSOR [B-U_TS]
Connector X-CTS X-CTS - DOC UPSTREAM (84532147)
TEMP [B-C_TS] (84532147) Connector X-WIF X-WIF - WATER IN FUEL
Connector X-DSR X-DSR - UREA DOSING [B-WIF] (87709663)
VALVE [Y-DSV] (87709798) Solenoid Y-DSV - DOSING VALVE X-DSR - UREA DOSING
Connector X-DTLTS X-DTLTS - DEF LEVEL / TEMP (Solenoid) VALVE [Y-DSV] (87709798)
[B-U_LVL] (84062580) Solenoid Y-TNK_HTR - SCR TANK X-THV - SCR TANK HEATING
Connector X-DTS X-DTS - SCR DOWNSTREAM HEATING VALVE (Solenoid) VALVE [Y-TNK_HTR]
TEMP [B-D_TS] (84532147) (84146685)
[A-ECU] (84300197)
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6 5 4 3 2 1
42
613A YE 0.8
A-ECU
ENGINE CONTROLLER
B-WIF 696B TN 0.8 Y-DSV
X-EDC7 X-SCR2
WATER IN FUEL DOSING VALVE
1 2
1 MC18 MC18 MC19 MC19 IN OUT
1 613 YE 0.8 13 113 196 96
696 TN 0.8 5 5 696A TN 0.8
WATER IN FUEL SW O_T_RL10
D 2 2
603K BK 0.8 SH16: C-1 X-DSR X-DSR D
643B BK 0.8
123 623A WH 0.8
23 623 WH 0.8 6 6
O_T_RH01
MC19
3 3 850E OR 0.8 SH11: C-4 X-SCR1
623B WH 0.8
X-WIF
B-HT
643D BK 0.8 SH16: C-4
HUMIDITY AND AMB TEMP SENSOR
1 690 OR 0.8 90 190

COMMON SUPPLY
2 615 YE 0.8 15 115

HUMIDITY SENSOR
3 643A BK 0.8 643 BK 0.8 43 143

COMMON GROUND
SP-643
4 642 YE 0.8 40 140
AIR TEMPERATURE SENSOR
X-HTS
C 632 YE 0.8 32 132

I_A_AN24
C
B-U_TS
SCR UPSTREAM TEMP SENSOR
1 T 2
610A BK 0.8
P N
X-UTS X-UTS
609B YE 0.8
X-SCR2
109
609A YE 0.8 10 10 609 YE 0.8 9
I_A_AN22
B-D_TS
SCR DOWNSTREAM TEMP SENSOR
1 T 2
610C BK 0.8 9 9 610B BK 0.8
P N
X-DTS X-DTS 610G BK 0.8
B-C_TS
DOC UPSTREAM TEMP SENSOR 610F BK 0.8
1 2
T 10 110
610E BK 0.8 7 7 610D BK 0.8 610 BK 0.8
P N COMMON GROUND
SP-610
X-CTS X-CTS
B 616A YE 0.8 8 8 616 YE 0.8 16 116 B

I_A_AN13
X-SCR1
616B YE 0.8
B-U_LVL
SENSOR TANK LEVEL & TEMP
X-LEV1
31 131 I_A_AN12
1 1 631A YE 0.8 1 1 631 YE 0.8
SCR LEVEL SENSOR
8 108 I_A_AN25
3 3 608A PK 0.8 3 3 608 YE 0.8
SCR TEMP SENSOR
SP-639
2 2 639B BL 0.8 2 2 639A BL 0.8 39 139
639 BL 0.8
G_R_AN12
X-DTLTS X-LEV2
Y-TNK_HTR
639C BL 0.8 SH18: C-4
SCR TANK HEATING VALVE
O_S_RL12 172 672 BL 0.8 3 3 1 1

SW-A_F_S 72
SCR TANK HEATING VALVE
AIR FILTER RSTCN SW
X-THV X-THV
P
SH18: D-4 650C OR 0.8
1 IN OUT 2
SH16: A-2 627B RD 0.8 637 YE 0.8 37 137
MC17
I_S_DIG04
X-AFS X-AFS
A A
X-ECU X-ECU
PL2326 CIRCUITS
TIER 2 AND TIER 3 ENGINES
6 5 4 3 2 1
SHT_17 1
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Wiring harnesses - Electrical schematic sheet 18 SH18 - ENGINE

CONTROL UNIT 3, AT
ECU A-ECU - ENGINE X-ECU - ECU CONNECTOR
CONTROLLER (ECU) [A-ECU] (84300197)
ECU A-PMP - DEF PUMP MODULE X-PUMP - DENOX CONTROL
(ECU) UNIT [A-PMP] (47421681)
ECU A-TERMC - TERMINATOR X-TERM_C - CONTROLLER
FOR CAN (ECU) AREA NETWORK [A-TERMC]
(87695580)
Sensor B-DEF_Q - DEF QUALITY X-DEFQ - DEF QUALITY
SENSOR (Sensor) SENSOR (UQS) [B-DEF_Q]
(84149219)
Sensor B-NH3 - NH3 SENSOR X-NH3 - NH3 SENSOR
(Sensor) [B-NH3] (84146686)
Sensor B-NOX_DU - DOC X-NOXD - SCR
UPSTREAM NOX SENSOR DOWNSTREAM NOX
(Sensor) SENSOR [B-NOX_DU]
(84190317)
Sensor B-NOX_SD - SCR X-NOXS - DOC UPSTREAM
DOWNSTREAM NOX NOX SENSOR [B-NOX_SD]
SENSOR (Sensor) (84190317)
Connector X-CAN X-CAN - CAN (87696093)
Connector X-DEF1 X-DEF1 - INLINE TO
DEF QUALITY SENSOR
(87694153)
Connector X-DEF2 X-DEF2 - INLINE FROM
DEF QUALITY SENSOR
(87694154)
Connector X-DEFQ X-DEFQ - DEF QUALITY
SENSOR (UQS) [B-DEF_Q]
(84149219)
[A-ECU] (84300197)
Connector X-EDC7 X-EDC7 - ENGINE
CONTROLLER T2/3 [SH18:
C-5] (84160698)
[SH16: A-3] (84380518)
Connector X-NH3 X-NH3 - NH3 SENSOR
[B-NH3] (84146686)
Connector X-NOXD X-NOXD - SCR
DOWNSTREAM NOX
SENSOR [B-NOX_DU]
(84190317)
Connector X-NOXS X-NOXS - DOC UPSTREAM
NOX SENSOR [B-NOX_SD]
(84190317)
Connector X-PUMP X-PUMP - DENOX CONTROL
UNIT [A-PMP] (47421681)
Connector X-SCR1 X-SCR1 - INLINE TO SCR
SENSORS HARNESS
(87695592)
Connector X-SCR2 X-SCR2 - INLINE FROM
SCR SENSORS HARNESS
(87695724)
Connector X-TERM_C X-TERM_C - CONTROLLER
AREA NETWORK [A-TERMC]
(87695580)
Connector X-TURBO X-TURBO - INTERFACE
WIRING HARNESS PLUG C
[SH12: B-3] (84152563)
Connector X-TURBO_2 X-TURBO_2 - ENGINE
HARNESS INTERFACE T2
[SH18: B-5] (87694583)
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6 5 4 3 2 1
TERMC
ECU TERMINATOR FOR CAN
MC66 MC66
ENGINE CONTROLLER MC1 A
650A OR 0.8 CANC_HK YE 0.8 A
200G OR 1.0
B
PMP CANC_LK GN 0.8 B
DEF PUMP MODULE

TERM_C
MC15 84 184 O_T_RL13
D 10
684 YE 0.8
MC15 SCR PUMP MOTOR D
9
9 10
689 GY 0.8
8 89 189 G_G_RL13
8 SCR PUMP MOTOR
SCR PUMP MOTOR MC15 SP650
MC16 50 150 O_V_RH11
SH18: D-6 650B OR 0.8 650 OR 0.8
MC16 11 11 COMMON BATTERY PLUS
SH18: D-5 650B OR 0.8 650C OR 0.8 SH17: A-2
12 12 85 185 O_T_RL16
685 GY 0.8
SCR REVERTING VALVE
MC1
MC16
SCR REVERTING VALVE
PUMP NOX_SD
2 2 68 168 V_V_5VSS1D
668 PK 0.8 SCR DOWNSTREAM NOX SENSOR
4 COMMON SUPPLY
4 SH17: A-4
639C BL 0.8 1
3 3 1
200G OR 1.0
SCR PRESSURE SENSOR 7 107 I_A_AN23 2

607 YE 0.8 2
SCR PRESSURE SENSOR
MC3 MC3 4
PUMP CANC_HJ YE 0.8 4
CAN2_HC YE 0.8
SPL_CANC_HG
3
CANC_LJ GN 0.8 3
MC4
CAN2_LC GN 0.8
SPL_CANC_LG
NOXS
CANC_HG YE 0.8
CANC_LG GN 0.8
NOX_DU
CAN_1
MC14 MC14 46 146 DOC UPSTREAM NOX SENSOR
SH24: C-1 CAN_H YE 0.8 1
B_D_CANH0 200F OR 1.0 1
C SH24: C-1 CAN_L GN 0.8
47 147
2
C
35 201F BK 1.0 2
SH24: C-1 MC63 MC63 B_D_CANL0
CAN_H7 YE 0.8 5
201G BK 0.8 5
200G OR 1.0
34
MC4
SH24: C-1 CAN_L7 GN 0.8 MC5 4
200F OR 1.0
201H BK 1.0
CANC_HF YE 0.8 4
SPL_CANC_HE
EDC7
3
CANC_LF GN 0.8 3
MC6
MC5
SPL_CANC_LE NOXD
CANC_HE YE 0.8
CANC_LE GN 0.8
MC13 MC13 71 171
1 671 YE 0.8
B_D_CANH1
95 195
2 695 GN 0.8 B_D_CANL1
PROTOTYPES ONLY NH3
CAN ECU NH3 SENSOR
CAN SPL_200D 1
200E OR 1.0 101
MC65
CAN2_HB YE 0.8 53 4
SPL_201D 201E BK 1.0 104
MC6
CAN2_LB GN 0.8 52
MC7 MC7 2
SPL_CANC_HC CANC_HD YE 0.8 102
TIER 2, PL2326
ONLY EDC7 CANC_LD GN 0.8
3
103
MC65
SPL_CANC_LC NH3
200D RD 2.0
B B
201D BK 2.0
CANC_HC YE 0.8
SP2HC
CANC_LC GN 0.8
6
202A RD 1.0 SH11: C-2 SP2LC
CANC_HM YE 0.8
5
203A BK 1.0 SH12: B-2
MC64
201J BK 1.0
7 MC64
CAN2_HA YE 0.8
MC8
1
SCR2
CAN2_LA GN 0.8
CANC_LM GN 0.8
12 12
11 11
4
1 1
TURBO_2
4
12 PIN
MC12
SCR1
201B BK 2.0
200B RD 2.0
PL23PL26 ONLY
CANC_HB YE 0.8
SH11: D-2 200J RD 3.0 200H OR 1.0
CANC_LB GN 0.8
DEF_Q
DEF1
DEF QUALITY SENSOR
3 3
SH11: D-2 200 RD 3.0 200A OR 1.0 4 4 200C OR 1.0
SP200
CLEAN SH12: A-3 201K BK 3.0 SP201
6 6
GROUND SH12: A-3 201 BK 3.0 201A BK 1.0 1 1 201C BK 1.0
MC12
SPL_CAN_H1 MC11 MC9 MC9 4
1 4
202 RD 3.0 SH11: C-2 CANC_HA YE 0.8 3 3 CANC_HZ YE 0.8
5 5
2
CANC_LA GN 0.8 2 2 CANC_LZ GN 0.8
A TO FPT
203 BK 3.0 SH12: B-3
SPL_CAN_L1 DEF2 DEFQ
A
ENGINE
MC10
HARNESS
6 MC10
CANC_H YE 0.8
5
CANC_L GN 0.8
TURBO
6 5 4 3 2 1
SHT_18 1
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Wiring harnesses - Electrical schematic sheet 19 SH19 - UCM PWR, GRND, INSTRUMENTATION
ECU A-UCM - 47749442 WAS X-UCM3B - UCM [A-UCM] Connector X-LC2 X-LC2 - LOADCENTER 2
84328725 (ECU) (84130760) X-UCM4B - [SH7: B-3] (87733581)
UCM [A-UCM] (82028495) Connector X-PBW X-PBW - BRAKE SUPPLY
X-UCM2B - UCM [A-UCM] WARNING PRES [B-PBW]
(82028495) (84078681)
Sensor B-HOT - HYD OIL TEMP X-HOT - HYD OIL TEMP Connector X-PHF X-PHF - HYDRAULIC
(Sensor) [B-HOT] (84607243) FILTER SENSOR [SW-PHF]
Sensor B-PBL/PEDAL/DECLTCH - X-PLB-PBD - BRAKE PRES (84352277)
BRAKE PESSURE SENSOR SENSR [B-PBL/PEDAL/ Connector X-PHF23 X-PHF23 - HYDRAULIC
(Sensor) DECLTCH] (84078681) FILTER SENSOR PL23
Sensor B-PBW - BRAKE SUPPLY X-PBW - BRAKE SUPPLY (82012083)
PRESS (Sensor) WARNING PRES [B-PBW] Connector X-PLB-PBD X-PLB-PBD - BRAKE PRES
(84078681) SENSR [B-PBL/PEDAL/
Sensor B-PRB1 - RED_BRAKE_FRNT X-PRB1 - REDUNDANT DECLTCH] (84078681)
(Sensor) BRAKE SW 1 [B-PRB1] Connector X-PRB1 X-PRB1 - REDUNDANT
(84078681) BRAKE SW 1 [B-PRB1]
Sensor B-PRB2 - X-PRB2 - REDUNDANT (84078681)
RED_BRAKE_REAR (Sensor) BRAKE SW 2 [B-PRB2] Connector X-PRB2 X-PRB2 - REDUNDANT
(84078681) BRAKE SW 2 [B-PRB2]
Sensor B-RECTD - COOLANT TEMP X-RECT - ENGINE COOLANT (84078681)
(Sensor) TEMP [B-RECTD] (84607243) Connector X-RECT X-RECT - ENGINE COOLANT
Sensor B-RFLG - FUEL LEVEL X-FL - FUEL LEVEL [B-RFLG] TEMP [B-RECTD] (84607243)
SENSOR (Sensor) (82012083) Connector X-SP_PK1 X-SP_PK1 - SPLICE PACK
Switch SW-PHF - HYDRAULIC X-PHF - HYDRAULIC (87693718)
FILTER SWITCH (Switch) FILTER SENSOR [SW-PHF] Connector X-SP_PK2 X-SP_PK2 - SPLICE PACK
(84352277) (87693718)
Connector X-BTM X-BTM - BOTTOM TO CAB Connector X-TRANS X-TRANS - TRANSMISSION
STD (87704523) TO CAB (87696949)
Connector X-CAB_B X-CAB_B - CAB TO BOTTOM Connector X-UCM1A X-UCM1A - UCM (82016219)
[SH21: B-3] (87696945) Connector X-UCM1B X-UCM1B - UCM [SH22: A-6]
Connector X-CAB_E X-CAB_E - CAB TO ENGINE (87410946)
[SH7: B-5] (84807216) Connector X-UCM2A X-UCM2A - UCM (82028493)
Connector X-CAB_TR X-CAB_TR - CAB TO Connector X-UCM2B X-UCM2B - UCM [A-UCM]
TRANSMISSION [SH26: (82028495)
A-2] (87696944) Connector X-UCM3A X-UCM3A - UCM (84130757)
Connector X-ENG X-ENG - ENGINE TO CAB Connector X-UCM3B X-UCM3B - UCM [A-UCM]
[SH18: C-6] (87696948) (84130760)
Connector X-FL X-FL - FUEL LEVEL [B-RFLG] Connector X-UCM4A X-UCM4A - UCM (82028493)
(82012083)
Connector X-HOT X-HOT - HYD OIL TEMP (82028495)
[B-HOT] (84607243)
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6 5 4 3 2 1
A-UCM
47749442 WAS 84328725
6 A
GND_SIGNAL 1 937 BK 0.8
SP-448
7
SH7: C-2 448 RD 3.0 448A RD 1.0 24VF3 X-UCM1A
13 24VF3_1
448B RD 1.0 9 B
GND_SIGNAL_2 H
938 BK 0.8
X-UCM2A
1 X-UCM1B
448C RD 1.0 24VF2
8 24VF2_1
448D RD 1.0 26 C
D SP-454
X-UCM4A
GND_SIGNAL_4 939 BK 0.8 D
X-SP_PK1
7 X-UCM2A
SH7: C-3 454 RD 3.0 454A RD 1.0 24VF6
13 24VF6_1
454B RD 1.0 26 D
GND_SIGNAL_5 940 BK 0.8
X-UCM3A
SH7: C-1 461 RD 3.0
8
454C RD 1.0 24VF4
9 24VF4_1
SH7: D-1 465 RD 1.0 454D RD 1.0 34 E
GND_SIGNAL_6 941 BK 0.8
SP-461 2
SH10: C-2 466 OR 0.8 461A RD 1.0 24VS1
3 24VS1_1 X-UCM2B
461B RD 1.0
433A YE 0.8
X-UCM3B GND_SIGNAL_7 20 F
942 BK 0.8
2
B-RECTD 461C RD 1.0 24VLP
COOLANT TEMP GND_SIGNAL_8
X-UCM4B
1 T 2 20 26 G
482T BL 0.8 24 VP 943 BK 0.8
SUPPLY GND
X-RECT X-RECT SP-466 X-UCM3A X-SP_PK1
26 24 VB
466A OR 0.8
14 GND_SIGNAL_9 26 A
466B OR 0.8 24VA 929 BK 0.8
SH20: A-5 482N BL 0.8
X-UCM1A
X-ENG
12 34 B
B-RFLG 5 5 12 GND_SIGNAL_12
433 YE 0.8 930 BK 0.8
FUEL LEVEL SENSOR COOLANT TEMP H
SP-482R
482R BL 0.8 9 9 X-UCM3B
SIG GND
2 1 482M BL 0.8
C GND_SIGNAL_13 20
931 BK 0.8
C L C
X-FL X-FL
11
633A YE 0.8 8 8 633 YE 0.8 11
FUEL LEVEL M
26 D
GND_SIGNAL_14
634A YE 0.8 932 BK 0.8
X-SP_PK2
X-CAB_E
B-HOT X-UCM4A
HYD OIL TEMP
X-TRANS 32 E
GND_SIGNAL_15
1 933 BK 0.8
T 2
482S BL 0.8 18
SUPPLY GND 18
30 30 634 YE 0.8
HYD OIL TEMP
X-HOT X-HOT
34 F
GND_SIGNAL_16
934 BK 0.8
X-UCM4A
PL23/26 ONLY X-UCM4B
SW-PHF
HYDRAULIC FILTER SWITCH 2 236 YE 0.8
ECU_GND_SENSE 7 G
1 391G BK 0.8 935 BK 1.0
BODY P
GROUND X-PHF23 CAB GROUND
IN OUT 1 17 K STUD 2
636A YE 0.8 23 23 AN_33 950 BK 1.0
636 YE 0.8
X-PHF SWITCH, HYDRAULIC FILTER RES (PL23)
SH20: B-1 X-UCM3A
J
B-PRB1
482G BL 0.8
RED_BRAKE_FRNT 1
SP-482A UCM_GND
X-SP_PK2
PWR GND
SH19: A-1 486R PK 0.8 B A 482D BL 0.8 482A BL 0.8 3 3
B B
OUT 15
X-PRB1 C 443A YE 0.8 1 1 443 YE 0.8 AN_02
PRESSURE, BRAKE ACCUMULATOR PRB1
482B BL 0.8
X-PRB1
B-PRB2
RED_BRAKE_REAR
17
24 24 638 YE 0.8 AN_07
PWR GND PRESSURE, BRAKE ACCUMULATOR PRB2
SH19: A-1 486S PK 0.8 B A 482E BL 0.8
OUT X-CAB_TR
X-PRB2 C 638B YE 0.8
X-TRANS
TO FRONT X-PRB2
EH CNTRL SH22: C-5 482J BL 0.8 486R PK 0.8 SH19: B-6
1 GND_SIGNAL
482 BL 0.8 SP-486
SP-482 2
5V GND1 5VREF1 OUT
AUX SH21: D-4 482F BL 0.8 486 PK 0.8 486B PK 0.8 26 26 486N PK 0.8 486S PK 0.8 SH19: B-6
5VREF1 OUT
5VREF1
SP-486N
X-UCM1A
B-PBW
BRAKE SUPPLY PRESS X-CAB_TR
X-BTM
486A PK 0.8
SP-482H
PWR GND
SH19: A-1 486F PK 0.8 B A 482K BL 0.8 482H BL 0.8 10 10 482C BL 0.8
X-BTM
X-PBW
OUT 10 AN_03
486U PK 0.8 SH21: D-4 AUX
C 640A YE 0.8 6 6 640 YE 0.8
482L BL 0.8
PRESSURE, BRAKE SUPPLY PBW SP-486D

X-PBW 8 8 486D PK 0.8 486E PK 0.8 SH22: C-5
A B-PBL/PEDAL/DECLTCH X-UCM1A A
BRAKE PESSURE SENSOR
X-CAB_B
PWR GND
SH19: A-1 486G PK 0.8 B A 486F PK 0.8 SH19: A-6
X-UCM1B
X-PLB-PBD
OUT 20 AN_10
C 641A YE 0.8 7 7 641 YE 0.8
PRESSURE, BRAKE LIGHT /DECLUTCH PBL/PBD
486G PK 0.8 SH19: A-6
X-PLB-PBD
X-CAB_B
6 5 4 3 2 1
SHT_19 1
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Wiring harnesses - Electrical schematic sheet 20 SH20 - UCM VEHICLE DRIVELINE / FAN CONTROL
ECU A-PFNR - PRIMARY FNR X-TS2 - TRANS SHIFTER 2 Connector X-FRNT X-FRNT - FRONT TO
(ECU) [A-PFNR] (47702209) X-TS1 - BOTTOM STD (87704426)
TRANS SHIFTER1 [A-PFNR] Connector X-FSS X-FSS - FAN SPEED SENSOR
(87692817) [B-FSS] (47696743)
ECU A-UCM - 47749442 WAS X-UCM3B - UCM [A-UCM] Connector X-LC6 X-LC6 - LOADCENTER 6
84328725 (ECU) (84130760) X-UCM4B - [SH16: A-3] (84380518)
UCM [A-UCM] (82028495) Connector X-PBBS X-PBBS - PARK BRAKE PRES
X-UCM2B - UCM [A-UCM] SENSR [B-PBBS]
(82028495) Connector X-PED_2 X-PED_2 - PEDESTAL TO
Sensor B-BPP - BRAKE PEDAL X-BPP - BRAKE PEDAL CAB 2 (87705114)
ANGLE (Sensor) ANGLE [B-BPP] (87710588) Connector X-SDM X-SDM - SWITCH DIFF LOCK
Sensor B-FAX - FRONT AXLE OIL X-FAX - FRONT AXLE [SW-SDM] (82012083)
TEMP (Sensor) TEMP SENSOR [SH20: A-6] Connector X-TRANS X-TRANS - TRANSMISSION
(87711966) TO CAB (87696949)
Sensor B-FSS - FAN SPEED SENSOR X-FSS - FAN SPEED SENSOR Connector X-TS1 X-TS1 - TRANS SHIFTER1
(Sensor) [B-FSS] (47696743) [A-PFNR] (87692817)
Sensor B-PBBS - PARK BRAKE PR X-PBBS - PARK BRAKE PRES Connector X-TS2 X-TS2 - TRANS SHIFTER 2
SENSOR FUTURE (Sensor) SENSR [B-PBBS] [A-PFNR] (47702209)
Switch SW-AFS2 - AIR FILTER X-AFS2 - AIR FILTER SWITCH Connector X-UCM1A X-UCM1A - UCM (82016219)
SWITCH T2/T3 (Switch) T2/3 [SW-AFS2] (84607243)
Connector X-UCM2A X-UCM2A - UCM (82028493)
Switch SW-SDM - DIFF LOCK FOOT X-SDM - SWITCH DIFF LOCK
SWITCH (Switch) [SW-SDM] (82012083)
(82028495)
Connector X-AFS2 X-AFS2 - AIR FILTER SWITCH
T2/3 [SW-AFS2] (84607243)
Connector X-BPP X-BPP - BRAKE PEDAL
(84130760)
ANGLE [B-BPP] (87710588)
Connector X-BTM X-BTM - BOTTOM TO CAB
STD (87704523) Connector X-UCM4B X-UCM4B - UCM [A-UCM]
(82028495)
Connector X-BTM_F X-BTM_F - BOTTOM TO
FRONT STD (87696087) Connector X-YDL X-YDL - DIFF LOCK SOL
[Y-DL] (87695582)
Connector X-CAB_B X-CAB_B - CAB TO BOTTOM
[SH21: B-3] (87696945) Connector X-YFN X-YFN - SOLENOID FAN
CONTROL [Y-Y_FC]
(87693821)
[SH7: B-5] (84807216)
Connector X-YFR X-YFR - FAN REVESER
SOLENOID [Y-Y_FR]
[SH9: C-2] (87703902)
(87695582)
Connector X-CAB_P2 X-CAB_P2 - CAB TO
Connector X-YLV X-YLV - HEAT LOAD VALVE
PEDESTAL 2 [SH27: B-2]
[Y-YLV] (87695582)
(87705101)
Connector X-YPB X-YPB - VALVE PARKING
Connector X-CAB_TR X-CAB_TR - CAB TO
BRAKE [Y-Y_PB] (87695582)
TRANSMISSION [SH26:
A-2] (87696944) Solenoid Y-DL - DIFF LOCK SOLENOID X-YDL - DIFF LOCK SOL
(Solenoid) [Y-DL] (87695582)
[SH18: C-6] (87696948) Solenoid Y-YLV - HEAT LOAD VALVE X-YLV - HEAT LOAD VALVE
(Solenoid) [Y-YLV] (87695582)
(87703931) Solenoid Y-Y_FC - PWM FAN X-YFN - SOLENOID FAN
CONTROL (Solenoid) CONTROL [Y-Y_FC]
Connector X-FAN X-FAN - FAN SPEED SENSOR
(87693821)
JUMPER [SH11: C-1]
(87694112) Solenoid Y-Y_FR - FAN REVERSER X-YFR - FAN REVESER
(Solenoid) SOLENOID [Y-Y_FR]
Connector X-FAN2 X-FAN2 - FAN SPEED
(87695582)
SENSOR JUMPER
(87694152) Solenoid Y-Y_PB - PARKING BRAKE X-YPB - VALVE PARKING
SOLENOID (Solenoid) BRAKE [Y-Y_PB] (87695582)
Connector X-FAX X-FAX - FRONT AXLE
TEMP SENSOR [SH20: A-6]
(87711966)
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6 5 4 3 2 1
A-UCM
CRANK REQUEST
47749442 WAS 84328725
SH3: A-1 220B YE 0.8
TO ECU
14
AN_26
KEY SWITCH CRANK X-ENG
X-UCM3A SP-663A 663D YE 0.8 SH16: B-6
X-UCM2B
HSD_PWM_01 5
663 YE 0.8 15 15 663A YE 0.8 663B YE 0.8 SH16: B-5
CRANK REQUEST
D SW-AFS2
HSD_LP_05 7 X-CAB_E D
AIR FILTER SWITCH T2/T3
P X-ENG
HSD_LP_01 9
134 YE 0.8 SH28: D-3
1 IN OUT 2 17 WARNING INDICATOR LED
SH16: C-5 AN_17 SH3: C-4
669C OR 0.8 319A YE 0.8 18 18 319 YE 0.8 663C YE 0.8
AIR FILTER REST SW T2
X-UCM4B
X-AFS2 X-AFS2
X-CAB_E
CRANK CONTROL
RELAY PWR
A-PFNR
PRIMARY FNR
X-PED_2 11 AN_18
1 1 679 YE 0.8
A Stalk FNR R
3rd AND 4th B B 16 AN_19
407A YE 0.8 2 2 680 YE 0.8
C Stalk FNR N
1ST AND 4TH C 406A YE 0.8
D 10 AN_20
3 3 686 YE 0.8
Stalk FNR F
X-TS2 X-UCM2A
4 4 406 YE 0.8
5 5 407 YE 0.8
X-BTM
Y-Y_PB
C IGN PWR A1 A
B
4029 OR 0.8 6 6 19D OR 0.8 SH10: C-2
22 AN_25
Gear Select 1_4
PARKING BRAKE SOLENOID C
FORWARD SIGNAL B1
683A YE 0.8 27
REVERSE SIGNAL C1 C X-CAB_P2 HSD_HP_01 P N
679A YE 0.8 388 WH 0.8 18 18 388A WH 0.8 1 2
D PARK BRAKE SOLENOID
NEUTRAL SIGNAL D1 680A YE 0.8
21 AN_27 X-YPB X-YPB
X-UCM3B
X-TS1 Gear Select 3_4
B-BPP X-UCM2B
BRAKE PEDAL ANGLE
LSD_HP_04 22
GND 389 WH 0.8 19 19 389A BK 0.8
PWR PARK BRAKE RETURN
SH22: C-5 471E PK 0.8 2 1 651B BL 0.8 SH22: C-5
X-BTM
X-UCM1A
X-BPP
OUT 16
3 15 15 AN_04
402A YE 0.8 402 YE 0.8
ANGLE, BRAKE PEDAL BPP
X-CAB_B
X-BPP X-UCM1A
X-CAB_B Y-DL
DIFF LOCK SOLENOID
X-TRANS
HSD_HP_04 1 1 2
390 WH 0.8 27 27 390A WH 0.8
DIFF LOCK IN OUT
SW-SDM X-UCM3B X-YDL X-YDL
DIFF LOCK FOOT SWITCH
24 SP-391A
SIG GND
SH10: B-2 1 2 AN_37 SH14: B-3
19M OR 0.8 401 WH 0.8 391A BK 1.0 391B BK 0.8
DIFF LOCK FOOT SWITCH
X-SDM X-SDM
B X-UCM3B 391E BK 0.8 SH32: C-1
TO WASH B
MOTORS
391F BK 0.8 SH32: C-1
X-ENG-2 391G BK 0.8 PL23 HYD FILTER GRND SH19: B-6

X-FAN
B-FSS LSD_HP_06 22
X-ENG
FAN SPEED SENSOR HEAT LOAD VALVE 582 BR 0.8 M M 582A BR 0.8 1 1 582B BR 0.8
X-FAN SH21: C-5
677M PK 0.8 28 28 677L PK 0.8 Y-YLV
3 3 677N PK 0.8 3 3 30 HEAT LOAD VALVE
2 2 FIN_05
400B YE 0.8 4 4 400A YE 0.8 16 16 400 YE 0.8
FAN SPEED SENSOR IN OUT
852C OR 0.8 2 2 852A OR 0.8 1 2
1 1 482V BL 0.8 5 5 SH11: C-1
X-CAB_E X-YLV
X-UCM4B X-YLV
X-FAN2 X-FAN2
X-FSS
482N BL 0.8 SH19: C-6 NOT USING
B-PBBS
PARK BRAKE PR SENSOR FUTURE Y-Y_FR
FAN REVERSER
P X-BTM
maybe future SH11: C-2 852B OR 0.8 1
P N
2
1 2 5
1 2 AN_08
16 16 3686 YE 0.8
PRESSURE, PARK BRAKE X-YFR X-YFR
X-PBBS X-PBBS LSD_HP_07 21
X-UCM1A 692 BR 0.8 N N 692A BR 0.8
X-CAB_B FAN REVERSER
Y-Y_FC
PWM FAN CONTROL
A A
HSD_PWM_15 25 P N
B-FAX 392 YE 0.8 P P 392A YE 0.8 A B 392A YE 0.8
X-FRNT X-BTM FAN CONTROL
SH22: C-6 651N BL 0.8 FRONT AXLE OIL TEMP
2 X-UCM2A X-YFN X-YFN
1 1 17 X-CAB_E-2
2 T 17
SH22: C-6 651G BL 0.8 687B YE 0.8 A A 687A YE 0.8 17 17 687 YE 0.8
AXLE OIL TEMP
X-FAX X-FAX X-UCM4A

X-BTM_F X-CAB_B
PL2326 ONLY
6 5 4 3 2 1
SHT_20 1
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Wiring harnesses - Electrical schematic sheet 21 SH21 - UCM-STEERING AUX JSS

ECU A-UCM - 47749442 WAS X-UCM3B - UCM [A-UCM] Connector X-JSS_FR X-JSS_FR - JSS FRAME
84328725 (ECU) (84130760) X-UCM4B - HARNESS TO CAB
UCM [A-UCM] (82028495) (87694152)
X-UCM2B - UCM [A-UCM] Connector X-JSS_JOY X-JSS_JOY - JSS LEFT
(82028495) HAND JOYSTICK [B-JSS]
Sensor B-JSS - LH JOYSTICK X-JSS_JOY - JSS LEFT (87700107)
STEERING (Sensor) HAND JOYSTICK [B-JSS] Connector X-JSV X-JSV - JOYSTICK
(87700107) STEERING VALVE [SH21:
Sensor B-JSS_CO_2 - JSS CUT OFF X-JSS_CO_2 - CUT OFF B-2] (87695592)
SENSOR 2 (Sensor) SENSOR [B-JSS_CO_2] Connector X-LFT_2 X-LFT_2 - LEFT JS TO CAB
(87694153) (87700105)
Sensor B-PSS - AUX STEERING X-PSS - STEERING Connector X-LFT_A X-LFT_A - JSS TO CAB L
PRESSURE (Sensor) PRESSURE SENSOR [B-PSS] ARMREST (87700155)
(84078681) Connector X-LH_ARM_DWN X-LH_ARM_DWN - LH
Diode D-SS DIODE - SEC STRG X-SSD - SS FLYBACK DIODE JSS ARM REST DOWN
FLYBACK DIODE (Diode) [D-SS DIODE] (87692858) [SW-ARM_POS_DWN]
Relay K-JSS_CO_1 - JSS CUT OFF X-JSS_CO_1 - CUT OFF (84000405)
SENSOR 1 (Relay) SENSOR [K-JSS_CO_1] Connector X-LH_ARM_UP X-LH_ARM_UP - LH
(87694153) JSS ARM REST DOWN
Motor M-SEC_STRG - SECONDARY X-S244 - 20157 AUX STRG [SW-ARM_POS_UP]
STEERING MOTOR/PUMP PWR RT ANGLE CONN (84000405)
(Motor) [SH21: D-3] X-SSS - Connector X-PSS X-PSS - STEERING
SECONDARY STEERING PRESSURE SENSOR [B-PSS]
MOTOR [M-SEC_STRG] (84078681)
(84426118) X-S242 - GROUND Connector X-S242 X-S242 - GROUND
[M-SEC_STRG] (84401307) [M-SEC_STRG] (84401307)
Switch SW-ARM_POS_DWN - LH X-LH_ARM_DWN - LH Connector X-S244 X-S244 - 20157 AUX STRG
ARMREST POSITION (Switch) JSS ARM REST DOWN PWR RT ANGLE CONN
[SW-ARM_POS_DWN] [SH21: D-3]
(84000405) Connector X-S245 X-S245 - GROUND (84426118)
Switch SW-ARM_POS_UP - LH X-LH_ARM_UP - LH Connector X-SSD X-SSD - SS FLYBACK DIODE
ARMREST POSITION (Switch) JSS ARM REST DOWN [D-SS DIODE] (87692858)
[SW-ARM_POS_UP]
Connector X-SSS X-SSS - SECONDARY
(84000405)
STEERING MOTOR
Switch SW-SW_JSS - SWITCH JSS X-SW_JSS - JOYSTICK [M-SEC_STRG] (84426118)
ACTIVATION (Switch) STEERING SWITCH
Connector X-SST X-SST - SEC STRG TO
[SW-SW_JSS] (87716755)
TRANS (87694152)
Connector X-SW_JSS X-SW_JSS - JOYSTICK
STD (87704523)
STEERING SWITCH
Connector X-BTS X-BTS - BOTTOM TO SEC [SW-SW_JSS] (87716755)
STRG [SH19: A-1] (87694112)
[SH21: B-3] (87696945)
Connector X-CAB_JSS X-CAB_JSS - CAB TO JSS
(82028495)
FRAME HARNESS [SH24:
A-6] (87694112) Connector X-UCM3A X-UCM3A - UCM (84130757)
Connector X-CAB_L X-CAB_L - CAB TO JSS L Connector X-UCM3B X-UCM3B - UCM [A-UCM]
ARMREST (87700156) (84130760)
Connector X-CAB_L2 X-CAB_L2 - CAB TO LEFT Connector X-UCM4B X-UCM4B - UCM [A-UCM]
JSS (87696138) (82028495)
Connector X-COV1 X-COV1 - CUT OFF VALVE Connector X-YSS X-YSS - SEC STEERING
SOL [Y-C0V_1] (87695582) VALVE SOL [Y-Y_SS]
(87695582)
Connector X-COV2 X-COV2 - CUT OFF VALVE
SOL [Y-COV_2] (87695582) Solenoid Y-C0V_1 - JSS CUT OFF X-COV1 - CUT OFF VALVE
VALVE 1 (Solenoid) SOL [Y-C0V_1] (87695582)
Connector X-JSS_CO_1 X-JSS_CO_1 - CUT OFF
SENSOR [K-JSS_CO_1] Solenoid Y-COV_2 - JSS CUT OFF X-COV2 - CUT OFF VALVE
(87694153) VALVE 2 (Solenoid) SOL [Y-COV_2] (87695582)
Connector X-JSS_CO_2 X-JSS_CO_2 - CUT OFF Solenoid Y-Y_SS - SEC STEERING X-YSS - SEC STEERING
SENSOR [B-JSS_CO_2] SOL. (Solenoid) VALVE SOL [Y-Y_SS]
(87694153) (87695582)
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6 5 4 3 2 1
X-SST
486W PK 0.8 2 2 486U PK 0.8 SH19: A-1

B-PSS
AUX STEERING PRESSURE SH19: A-6 A-UCM
SH3: D-3
47749442 WAS 84328725
PWR GND
D B A 482P BL 0.8 3 3 482F BL 0.8
X-BTM
D
X-PSS
OUT 8 AN_01
C 176B YE 0.8 4 4 176A YE 0.8 11 11 176 YE 0.8
PRESSURE, AUXILIARY STEERING
X-PSS X-UCM1A
X-BTS X-CAB_B
K-JSS_CO_1
JSS CUT OFF SENSOR 1
1990 RD 62.0
GND
PWR
677G PK 0.8 1 2 967G BL 0.8
3 X-JSS_FR
OUT 12 AN_32
4 676A YE 0.8 2 2 676 YE 0.8
JSS COV SENSOR 1
X-JSS_CO_1 M-SEC_STRG
X-JSS_CO_1
B-JSS_CO_2 SECONDARY STEERING MOTOR/PUMP
JSS CUT OFF SENSOR 2 X-UCM3A
SP-677A GND SP-967A SP-967

1 PWR 2 20 GND_SIGNAL_3 1 PWR
677F PK 0.8 967F BL 0.8 967A BL 0.8 4 4 967 BL 0.8 967B BL 0.8 GND
5V REF GRND 3 1
X-S244 M 185 BK 62.0 SH14: B-3
X-UCM2A X-S242
3 1
OUT 4 15 AN_40 A 1
273A YE 0.8 6 6 273 YE 0.8 180A BK 1.0
JSS COV SENSOR 2
X-JSS_CO_2 X-JSS_CO_2 SP-677 X-S245
X-UCM3B X-SSS
677A PK 0.8 3 3 677 PK 0.8
4 5VREF3 OUT
X-CAB_JSS 677B PK 0.8
5VREF3
441D OR 1.0
C X-UCM1A
D-SS DIODE
SEC STRG FLYBACK DIODE
C
B-JSS N
X-JSS_JOY SH20: B-4 677L PK 0.8 441E OR 1.0 C
LH JOYSTICK STEERING P1
1 X-LFT_A A
677D PK 0.8 7 7 677C PK 0.8
P2
180 BK 1.0 B
3
967D BL 0.8 6 6 967C BL 0.8
X-SSD
HSD_LP_03 8
183 YE 0.8 SH8: B-6
X-UCM4B
X-BTM
Y-Y_SS
X-SST
6 SEC STEERING SOL.
651M BL 0.8 3 3 651L BL 0.8 SH22: C-5
P N
SH8: B-2 441 OR 0.8 12 12 441A OR 0.8 1 1 441B OR 1.0 441C OR 1.0 1 2
4
471L PK 0.8 1 1 471J PK 0.8 SH22: C-5
SP-441B
X-YSS X-YSS
2 18
184 BK 0.8
2 2 AN_15
670A YE 0.8 670 YE 0.8
JSS ACTIVIATION SW JSS JOYSTICK 1
INTERNAL 5 12 X-BTS
5 5 AN_16
630A YE 0.8 630 YE 0.8
JSS JOYSTICK 2 X-CAB_B
X-UCM2A
DEUTSCH_DTM SERIES_4-WAY_RECEP HSG

SW-ARM_POS_UP
SH14: B-4
LH ARMREST POSITION
OUT1
B 799K OR 0.8 1
IN
2
B
OUT2 12
3 4 4 AN_30
675A GY 0.8 675 GY 0.8 Y-COV_2
X-LH_ARM_UP JSS ARM UP
JSS CUT OFF VALVE 2
X-LH_ARM_UP
1 2
854B WH 0.8
SW-ARM_POS_DWN
LH ARMREST POSITION X-COV2 X-COV2
TO JSS
STRG VALVE SH24: A-5 854A WH 0.8 SP-854A
OUT1 Y-C0V_1
2 JSS CUT OFF VALVE 1
IN
799J OR 0.8 1 20
OUT2 AN_29 1 2
3 673A TN 0.8 8 8 673 TN 0.8 854 WH 0.8
X-LH_ARM_DWN JSS ARM DWN
X-LH_ARM_DWN X-UCM2B X-COV1 X-COV1
SP-799A
799G OR 0.8 10 10 799B OR 0.8 SH10: B-1
SW-SW_JSS
SWITCH JSS ACTIVATION
955AB BK 0.8
799H OR 0.8
SP-954
10 P N 9
954C BK 0.8 954 BK 0.8 11 11 954J BK 0.8 SH13: A-5 X-JSS_FR
16 955AC BK 0.8
1 3 AN_38
678A WH 0.8 9 9 678 WH 0.8 SP-955Y
JSS ACT NO
SH13: B-3 955X BK 0.8 5 5 955Y BK 0.8
2
A IN
A
2 1 23 AN_39 X-CAB_JSS TO STRG
682A YE 0.8 12 12 682 YE 0.8 955Z BK 0.8 SH24: A-5
JSS ACT NC WHEEL MOTION
8 P1 N1 7 X-CAB_L
954N BK 0.8 X-LFT_2
4 4 X-UCM3B 955AA BK 0.8 SH24: A-6 TO JSS
DEUTSCH_DTM SERIES_4-WAY_RECEP HSG STRG VALVE
3 3
X-SW_JSS X-SW_JSS
981K VT 0.8 2 2 981J VT 0.8 SH27: A-2
16 HSP_LP_04
691A WH 0.8 1 1 691 WH 0.8
JSS INDICATOR
X-CAB_L2
X-UCM4B SH19:A-4
6 5 4 3 2 1
SHT_21 1
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Wiring harnesses - Electrical schematic sheet 22 SH22 - UCM-LOADER BOOM CONTROL

ECU A-EH_VLV - ELECTROHY- X-PILOT_ENABLE - PILOT Connector X-BTM X-BTM - BOTTOM TO CAB
DRAULIC VALVE (ECU) ENABLE SOLENOID STD (87704523)
[SH28: A-1] (87695582) Connector X-BTM_EH X-BTM_EH - BOTTOM TO
X-BOOM_RAISE - BOOM CAB EH (84281075)
RAISE SOLENOID Connector X-BTM_F X-BTM_F - BOTTOM TO
[A-EH_VLV] (87695582) FRONT STD (87696087)
X-BOOM_LOWER - BOOM Connector X-BTM_FEH X-BTM_FEH - BOTTOM TO
LOWER SOLENOID FRONT EH (87700160)
[A-EH_VLV] (87695582)
Connector X-BUA X-BUA - BUCKET ANGLE
X-BUCKET_ROLL -
SENSOR [B-BKT_ANG]
BUCKET ROLL SOLENOID
(84403598)
[A-EH_VLV] (87695582)
X-BUCKET_DUMP - Connector X-BUCKET_DUMP X-BUCKET_DUMP -
BUCKET DUMP SOLENOID BUCKET DUMP SOLENOID
[A-EH_VLV] (87695582) [A-EH_VLV] (87695582)
X-AUX_1_LEFT - AUX 1 Connector X-BUCKET_ROLL X-BUCKET_ROLL - BUCKET
LEFT [A-EH_VLV] (87695582) ROLL SOLENOID [A-EH_VLV]
X-AUX_1_RIGHT - AUX (87695582)
1 RIGHT [A-EH_VLV] Connector X-CAB_B X-CAB_B - CAB TO BOTTOM
(87695582) X-AUX_2_LEFT [SH21: B-3] (87696945)
- AUX 2 LEFT [A-EH_VLV] Connector X-CAB_EH X-CAB_EH - CAB TO
(87695582) X-AUX_2_RIGHT BOTTOM EH (87700159)
- AUX 2 RIGHT [A-EH_VLV] Connector X-FAX X-FAX - FRONT AXLE
(87695582) TEMP SENSOR [SH20: A-6]
ECU A-UCM - 47749442 WAS X-UCM3B - UCM [A-UCM] (87711966)
84328725 (ECU) (84130760) X-UCM4B - Connector X-FRNT X-FRNT - FRONT TO
UCM [A-UCM] (82028495) BOTTOM STD (87704426)
X-UCM2B - UCM [A-UCM] Connector X-FRNT_EH X-FRNT_EH - FRONT TO
(82028495) BOTTOM EH (87700170)
Sensor B-BKT_ANG - BUCKET X-BUA - BUCKET ANGLE Connector X-PILOT_ENABLE X-PILOT_ENABLE - PILOT
ANGLE (Sensor) SENSOR [B-BKT_ANG] ENABLE SOLENOID [SH28:
(84403598) A-1] (87695582)
Sensor B-BM_ANG - BOOM ANGLE X-BOA - BOOM ANGLE Connector X-PRB X-PRB - ROLL BACK
(Sensor) SENSOR [B-BM_ANG] PRESSURE SWITCH
(84403598) [SW-PRB] (87692877)
Switch SW-PRB - ROLL BACK PR X-PRB - ROLL BACK Connector X-UCM1A X-UCM1A - UCM (82016219)
SW (Switch) PRESSURE SWITCH
Connector X-UCM1B X-UCM1B - UCM [SH22: A-6]
[SW-PRB] (87692877)
(87410946)
Connector X-AUX_1_LEFT X-AUX_1_LEFT - AUX 1 LEFT
[A-EH_VLV] (87695582)
(82028495)
Connector X-AUX_1_RIGHT X-AUX_1_RIGHT - AUX
1 RIGHT [A-EH_VLV]
(84130760)
(87695582)
Connector X-AUX_2_LEFT X-AUX_2_LEFT - AUX 2 LEFT
[A-EH_VLV] (87695582) Connector X-UCM4B X-UCM4B - UCM [A-UCM]
(82028495)
Connector X-AUX_2_RIGHT X-AUX_2_RIGHT - AUX
2 RIGHT [A-EH_VLV] Connector X-YPE X-YPE - COUPLER VALVE
(87695582) [Y-YPE] (87695582)
Connector X-BOA X-BOA - BOOM ANGLE Connector X-YRC X-YRC - RIDE CONTROL
SENSOR [B-BM_ANG] SOLENOID [Y-YRC]
(84403598) (84607243)
Connector X-BOOM_LOWER X-BOOM_LOWER - BOOM Solenoid Y-YPE - COUPLER VALVE X-YPE - COUPLER VALVE
LOWER SOLENOID SOL. (Solenoid) [Y-YPE] (87695582)
[A-EH_VLV] (87695582) Solenoid Y-YRC - YRC RIDE CONTROL X-YRC - RIDE CONTROL
Connector X-BOOM_RAISE X-BOOM_RAISE - BOOM SOL (Solenoid) SOLENOID [Y-YRC]
RAISE SOLENOID (84607243)
[A-EH_VLV] (87695582)
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A-UCM
47749442 WAS 84328725
D D
FRONT CHASSIS
X-BTM_FEH X-CAB_EH
B-BM_ANG
BOOM ANGLE
15 AN_14
R R R R A-EH_VLV
BOOM LIFT PRESSURE
N1 ELECTROHYDRAULIC VALVE
P1 X-CAB_EH X-BTM_FEH
B A 651F BL 0.8
OUT1 19 AN_09
C 647B YE 0.8 S S 647A YE 0.8 S S 647 YE 0.8 HSD_HP_02 18 344 WH 0.8 A A 344A WH 0.8 A A 344B WH 0.8 1
BOOM ANGLE 1 PILOT ENABLE PILOT ENABLE
SH28: A-1 624E BK 0.8 2 SOLENOID PST
P2 N2 X-UCM3B
F E 482X BL 0.8
X-PILOT_ENABLE
OUT2 22 AN_12
D 648B YE 0.8 T T 648A YE 0.8 T T 648 YE 0.8 X-BOOM_RAISE
471G PK 0.8
BOOM ANGLE 2
486K PK 0.8
X-BOA X-BOA X-BTM_EH HSD_PWM_10 1

7 340 WH 0.8 B B 340A WH 0.8 B B 340B WH 0.8 BOOM RAISE
BOOM RAISE D
482U BL 0.8 P P 339C BR 0.8 2 SOLENOID
X-UCM4A
SP-570E
486H PK 0.8 Q Q 482J BL 0.8 SH19: A-6 LSD_HP_01 2 339 BR 0.8 C C 339A BR 0.8 C C 339B BR 0.8 SP-339B
from std frnt BOOM ENABLE
X-FRNT_EH bulkhead X-UCM1B
486E PK 0.8 SH19: A-1 339D BR 0.8 2
SP-486F BOOM LOWER B
HSD_PWM_11 6 341 WH 0.8 D D 341A WH 0.8 D D 341B WH 0.8 1 SOLENOID
BOOM LOWER
SP-471F X-UCM4A X-BOOM_LOWER
SH21: B-4 651L BL 0.8
TO JSS
SH21: B-4 471J PK 0.8 HSD_PWM_16 17 346 WH 0.8 E E 346A WH 0.8 E E 346B WH 0.8 1 BUCKET ROLL
BUCKET ROLL SOLENOID C
347C BR 0.8 2
FRONT_PL23_PILOT X-UCM3B
C SH20: A-6 651N BL 0.8 471E PK 0.8 SH20: C-6
LSD_HP_02 30 347 BR 0.8 F F 347A BR 0.8 F F 347B BR 0.8 SP-347B
X-BUCKET_ROLL C
471H PK 0.8
SH20: A-6 TO BUCKET ENABLE

486L PK 0.8
651G BL 0.8
TO FAX SH20: C-5
BPP X-UCM1B
2
X-FRNT 651B BL 0.8 347D BR 0.8 BUCKET DUMP
HSD_PWM_17 SOLENOID A
25 350 WH 0.8 G G 350A WH 0.8 G G 350B WH 0.8 1
X-BTM X-UCM1B BUCKET DUMP
SP-651A SP-651
1 GND_SIGNAL_1 X-BUCKET_DUMP
B-BKT_ANG 651D BL 0.8 V V 651C BL 0.8 651A BL 0.8 3 3 651J BL 0.8 651 BL 0.8
SP-651D 5V GND2
BUCKET ANGLE X-BTM_F
HSD_PWM_18
SP-471 32 351 WH 0.8 H H 351A WH 0.8 H H 351B WH 0.8 1
3 5VREF2 OUT AUX1 LEFT AUX 1 LEFT SOLENOID E
471F PK 0.8 V V 471D PK 0.8 471C PK 0.8 4 4 471A PK 0.8 471 PK 0.8 X-UCM3B 352C BR 0.8 2
P1 N1 5V REF2
B A 651E BL 0.8 SP-471C
X-CAB_B X-UCM1A LSD_HP_03 X-AUX_1_LEFT
10 352 BR 0.8 J J 352A BR 0.8 J J 352B BR 0.8 SP-352B
OUT1 21 AN_11 AUX1 ENABLE
C 653B YE 0.8 W W 653A YE 0.8 W W 653 YE 0.8 BUCKET ANGLE 1 X-UCM1B
352D BR 0.8 2
P2 N2 HSD_PWM_19 AUX 1 RIGHT SOLENOID F
F E 482W BL 0.8 33 355 WH 0.8 K K 355A WH 0.8 K K 355B WH 0.8 1
AUX1 RIGHT
654B YE 0.8
OUT2 23 AN_13 X-UCM3B X-AUX_1_RIGHT
D X X 654A YE 0.8 X X 654 YE 0.8 BUCKET ANGLE 2
X-BUA
X-FRNT_EH X-BTM_FEH HSD_PWM_08
19 356 WH 0.8 L L 356A WH 0.8 L L 356B WH 0.8 1
X-BTM_EH X-CAB_EH X-UCM1B AUX2 LEFT AUX 2 LEFT SOLENOID G
X-BUA 357C BR 0.8 2
X-UCM4A
LSD_HP_05 X-AUX_2_LEFT
21 357 BR 0.8 M M 357A BR 0.8 M M 357B BR 0.8 SP-357B
AUX2 ENABLE
X-UCM1A
357D BR 0.8 2
HSD_PWM_09 AUX 2 RIGHT SOLENOID H
AUX2 RIGHT 13 360 WH 0.8 N N 360A WH 0.8 N N 360B WH 0.8 1
X-UCM4A X-AUX_2_RIGHT
X-BTM_EH X-FRNT_EH
B B
SW-PRB
ROLL BACK PR SW
P X-FRNT X-BTM
B 2 1 A 24
SH28: A-2 U U 13 13 FIN_DI_09
624F BK 0.8 291B YE 0.8 291A YE 0.8 291 YE 0.8
X-PRB X-PRB
X-BTM_F
X-UCM4B
X-CAB_B
XT MACHINES ONLY
REQUIRED WITH RIDE CONTROL SH28: A-2 624C BK 0.8
Y-YRC
X-FRNT
YRC RIDE CONTROL SOL
X-BTM
MC21 MC21 34 HSD_HP_06 6 OUT
SH24: C-1 CAN_HT YE 0.8
CAN1_HI
366 WH 0.8 5 5 366A WH 0.8 P P 366B WH 0.8 1 IN 2
CAN RIDE CONTROL VALVE
X-YRC X-YRC
25 Y-YPE
SH24: C-1 CAN1 LO COUPLER VALVE SOL.
CAN_LT GN 0.8
CAN
HSD_HP_05 7 IN OUT
X-UCM1B 367 WH 0.8 14 14 367A WH 0.8 R R 367B WH 0.8 1 2
COUPLER VALVE
X-YPE X-YPE
MC20 MC20 1
SH24: B-1 CAN2_HI
CANB_HK WH 0.8 4
CAN LSD_HP_08
COUPLER VALVE RETURN 368 BR 0.8 9 9 368A BR 0.8 S S 368B BR 0.8
10
A SH24: B-1 CANB_LK BL 0.8
CAN2_LO
CAN
X-UCM3B
X-CAB_B
A
X-UCM2B X-BTM_F
SH19:A-4
6 5 4 3 2 1
SHT_22 1
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Wiring harnesses - Electrical schematic sheet 23 SH23 - PILOT LOADER CONTROLS

ECU A-UCM - 47749442 WAS X-UCM3B - UCM [A-UCM] Connector X-EM X-EM - ELECTROMAGNETIC
84328725 (ECU) (84130760) X-UCM4B - DETENTS [Y-RTT DET]
UCM [A-UCM] (82028495) (87694112)
X-UCM2B - UCM [A-UCM] Connector X-FRNT X-FRNT - FRONT TO
(82028495) BOTTOM STD (87704426)
Sensor B-PXF - RETURN TO DIG X-PXF - RETURN TO DIG Connector X-HN X-HN - CAN [SW-HORN]
PROX (Sensor) PROX [B-PXF] (87692858) (87311796)
Sensor B-PXH - HEIGHT CONTROL X-PXH - HEIGHT CNTRL Connector X-KDD X-KDD - KICK DOWN SW
PROX (Sensor) PROX [B-PXH] (87644909) (84146428)
Sensor B-PXT - RTD FOR XT (Sensor) X-PXT - RTD XT [B-PXT] Connector X-KDS X-KDS - CAN (87311796)
(87644909) Connector X-PXF X-PXF - RETURN TO DIG
Switch SW-DEV6223 - JOYSTICK PROX [B-PXF] (87692858)
INTERNAL (Switch) Connector X-PXH X-PXH - HEIGHT CNTRL
Switch SW-FNR - JOYSTICK X-P_JS - PILOT LOADER PROX [B-PXH] (87644909)
INTERNAL (Switch) JOYSTICK [SW-FNR] Connector X-PXT X-PXT - RTD XT [B-PXT]
(87694152) (87644909)
Switch SW-HORN - (Switch) X-HN - CAN [SW-HORN] Connector X-P_JS X-P_JS - PILOT LOADER
(87311796) JOYSTICK [SW-FNR]
Switch SW-K/D - JOYSTICK (87694152)
INTERNAL (Switch) Connector X-UCM2B X-UCM2B - UCM [A-UCM]
Switch SW-KD - KICK DOWN SW (82028495)
(Switch) Connector X-UCM3B X-UCM3B - UCM [A-UCM]
Connector X-A_RT3 X-A_RT3 - RIGHT ARM PILOT (84130760)
(87694152) Connector X-UCM4B X-UCM4B - UCM [A-UCM]
Connector X-A_RT_2A X-A_RT_2A - ARM REST (82028495)
RIGHT PILOT 2 (84278761) Connector X-YPP X-YPP - PILOT PRESSURE
Connector X-A_RT_2B X-A_RT_2B - ARM REST SOLENOID [Y-Y_PL]
RIGHT PILOT 2 (84281913) (87692855)
Connector X-A_RT_P X-A_RT_P - ARM REST Solenoid Y-HC DET - (Solenoid)
RIGHT HAND PILOT Solenoid Y-RTD DET - (Solenoid)
(87694112) Solenoid Y-RTT DET - (Solenoid) X-EM - ELECTROMAGNETIC
Connector X-BTM X-BTM - BOTTOM TO CAB DETENTS [Y-RTT DET]
STD (87704523) (87694112)
Connector X-BTM_F X-BTM_F - BOTTOM TO Solenoid Y-Y_PL - PILOT LOCK X-YPP - PILOT PRESSURE
FRONT STD (87696087) (Solenoid) SOLENOID [Y-Y_PL]
Connector X-CAB_B X-CAB_B - CAB TO BOTTOM (87692855)
[SH21: B-3] (87696945)
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B-PXT
RTD FOR XT
C PWR GND B
792K OR 0.8 293C BK 0.8
A-UCM
X-PXT
D OUTPUT A
294C YE 0.8 D
X-PXT
B-PXF 47749442 WAS 84328725
RETURN TO DIG PROX X-FRNT

X-BTM
C PWR OUTPUT A 23 FIN_DI_08
792E OR 0.8 294B YE 0.8 B B 29 29
X-PXF
GROUND B
293A BK 0.8
X-PXF
SP-792D
792D OR 0.8 W W 30 30
B-PXH
HEIGHT CONTROL PROX
SP-293
C PWR GND B SH14: A-3
792F OR 0.8 293B BK 0.8 293 BK 0.8
X-PXH
OUTPUT A 3 FIN_DI_07
295B YE 0.8 X X 31 31
X-PXH
C C
X-BTM_F X-CAB_B
PILOT SINGLE AXIS X-UCM4B
1 310A LB 0.8
2 677K PK 0.8 OPTION NOT OFFERED

3 967K BL 0.8
X-A_RT_2B
FNR 4
SIGNAL SP-677H
5 677J PK 0.8 677H PK 0.8 9 9
SP-967H
SW-KD 6 967J BL 0.8 967H BL 0.8 10 10

KICK DOWN SW X-A_RT3
14 AN_42
11 11
IN OUT 1 FNR SIGNAL
2
22 AN_41
311A WH 0.8 12 12
2 FNR SIGNAL
4
X-UCM3B
X-KDD X-KDS
PILOT JOYSTICK
309B YE 0.8
SW-FNR
F 2 23 AN_23
B 306A WH 0.8 3 3
FORWARD B
IN N 3 16 AN_22
307A YE 0.8 4 4
NEUTRAL
R 4 24 AN_21
308A GY 0.8 5 5
REVERSE
X-A_RT_2B Y-RTD DET
3 P N 4
6 6 297A WH 0.8 954V BK 0.8
IN OUT 6 15 AN_24
309A YE 0.8 2 2
KICKDOWN
2 P N 5
7 7 298A WH 0.8 954W BK 0.8
X-P_JS Y-HC DET
SW-K/D
X-A_RT_2A SP-954U
N
1
P
X-P_JS
X-UCM2B 1 6
8 8 299A WH 0.8 954X BK 0.8
X-EM
Y-RTT DET X-EM
8
SH19:A-4
0.
BK
792H OR 0.8
4Y
95
1
792G OR 0.8
PILOT LOCK
SW-HORN TO RH ARM REST CAB_AR A P N B
2 SHEET 24 1 1 344E YE 0.8
1 5
4 2 113E BR 0.8
PIN 5 TO SHT 34 X-YPP Y-Y_PL X-YPP
X-HN
X-HN X-A_RT_2A
A 2
A
X-A_RT_P
954U BK 1.0
SOLID BLUE COMMON TO

JOYSTICK AND SINGLE AXIS
6 5 4 3 2 1
SHT_23 1
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Wiring harnesses - Electrical schematic sheet 24 SH24 - CAN STRUCTURE

ECU A-DIA - DIAGNOSTIC PLUG X-DIA - DIAGNOSTIC PORT Connector X-ENG X-ENG - ENGINE TO CAB
(ECU) [A-DIA] (87736919) [SH18: C-6] (87696948)
ECU A-DSP - DISPLAY (ECU) X-DSP - DISPLAY [A-DSP] Connector X-JSS_CAN X-JSS_CAN - CAN
(82016219) (87695580)
ECU A-SFB - SMART FUSE BOX X-X6 - SFB [A-SFB] Connector X-JSS_COM X-JSS_COM - JSS FRAME
(ECU) (47554341) TO CAB CAN (87695723)
ECU A-TERM2 - TERMINATOR X-TERM2 - TERMINATOR Connector X-JSS_FR X-JSS_FR - JSS FRAME
(ECU) CAN [A-TERM2] (87695580) HARNESS TO CAB
ECU A-TERM3 - TERMINATOR X-TERM3 - TERMINATOR (87694152)
(ECU) CAN [A-TERM3] (87695580) Connector X-JSV X-JSV - JOYSTICK
Sensor B-ST_MTN - STEERING X-STW - STEERING STEERING VALVE [SH21:
WHEEL MOTION (Sensor) WHEEL MOTION SENSOR B-2] (87695592)
[B-ST_MTN] (84563557) Connector X-PED X-PED - PEDESTAL TO CAB
Resistor R-022 - TERMINATOR X-TERM - TERMINATOR (87700156)
(Resistor) [R-022] (87695580) Connector X-SFB_XCP X-SFB_XCP - DIAG
Switch SW-PD - SWITCH/KEY PAD X-SW_PD - SWITCH PAD (87696093)
(Switch) [SW-PD] (87694153) Connector X-STLK X-STLK - STALK LEVER RH
Switch SW-RH_JS - RIGH HAND [SW-HN_STLK] (84426133)
JOYSTICK or 3 lever (Switch) Connector X-STW X-STW - STEERING
Switch SW-STALK - STALK SWITCH WHEEL MOTION SENSOR
(Switch) [B-ST_MTN] (84563557)
Connector X-A_RT X-A_RT - ARM REST RIGHT Connector X-SW_PD X-SW_PD - SWITCH PAD
(87694112) [SW-PD] (87694153)
Connector X-CAB_AR X-CAB_AR - CAB TO RH ARM Connector X-TERM X-TERM - TERMINATOR
REST (87694152) [R-022] (87695580)
Connector X-CAB_E X-CAB_E - CAB TO ENGINE Connector X-TERM2 X-TERM2 - TERMINATOR
[SH7: B-5] (84807216) CAN [A-TERM2] (87695580)
Connector X-CAB_JSS X-CAB_JSS - CAB TO JSS Connector X-TERM3 X-TERM3 - TERMINATOR
FRAME HARNESS [SH24: CAN [A-TERM3] (87695580)
A-6] (87694112) Connector X-X7 X-X7 - SFB [SH3: A-3]
Connector X-CAB_P X-CAB_P - CAB TO (84538791)
PEDESTAL [SH20: D-2] Connector X-X_TEL X-X_TEL - TELEMATICS
(87700155) [SH38: C-6] (87700156)
Connector X-DIA X-DIA - DIAGNOSTIC PORT Solenoid Y-JSS_STRG_VLV - X-JSV - JOYSTICK
[A-DIA] (87736919) JOYSTICK STEERING VALVE STEERING VALVE [SH21:
Connector X-DSP X-DSP - DISPLAY [A-DSP] (Solenoid) B-2] (87695592)
(82016219)
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SW-PD
SW-STALK SWITCH/KEY PAD

MC34
SH25: C-6
STALK SWITCH
SH10: B-1
TO TRANS
807 OR 0.8 1 1
IGN PWR CONTROLLER
916 BK 0.8 2 2
3
D D
8
GROUND SH25: C-6
MC28
X-STLK
3 3
CAN HI
MC24
955F BK 0.8
SH12: D-5 4 4
CAN LO
X-SW_PD
CAN_HE YE 0.8
19K OR 0.8
CAN_LE GN 0.8
MC36
CAN_HR YE 0.8
SH38: B-6
CAN_HK YE 0.8
TO
CAN_LR GN 0.8
SH28: D-1
TELEMATICS
CAN_LK GN 0.8
SH38: C-6
SH37
CAN_LC GN 0.8
CAN_HC YE 0.8
X-PED
TO
MC34
9 9 19J OR 0.8 SH10: A-1
ECU
R-022 X-ENG
TERMINATOR
SP-HP SP-HL SP-HJ MC30 SP-HF MC32 SP-HD SP-HB SP-HA SH18: C-6
MC22 MC25 MC29 SP-HH MC37 MC38 MC14
MC35
A CAN_HS YE 0.8 CAN_HP YE 0.8 10 10 CAN_HN YE 0.8 CAN_HL YE 0.8 CAN_HJ YE 0.8 CAN_HH YE 0.8 CAN_HF YE 0.8 CAN_HD YE 0.8 CAN_HB YE 0.8 CAN_HA YE 0.8 14 14 CAN_H YE 0.8
SP-LF SP-LD SP-LB
B CAN_LS GN 0.8 CAN_LP GN 0.8 11 11 CAN_LN GN 0.8 CAN_LL GN 0.8 CAN_LJ GN 0.8 CAN_LH GN 0.8 CAN_LF GN 0.8 CAN_LD GN 0.8 CAN_LB GN 0.8 CAN_LA GN 0.8 13 13 CAN_L GN 0.8
SP-LH
MC23 SP-LL MC26 SP-LJ SP-LA SH18: C-6
SP-LP
C CAN_LI GN 0.8
CAN_HM YE 0.8
CAN_HG YE 0.8
CAN_HT YE 0.8
CAN_LG GN 0.8
CAN_H7 YE 0.8
CAN_LM GN 0.8
X-CAB_P X-CAB_E
X-TERM CAN_HI YE 0.8 SH18: C-5
SH7: B-2
CAN_LT GN 0.8
798 RD 0.8 CAN_L7 GN 0.8
C
MC31
945 BK 0.8 SH12: D-3 CANB_HK WH 0.8 SH18: C-5 C
CANB_LK BL 0.8
X-DIA
MC33
MC27
A
B
MC21
X-X7
1
5
1
B
FUSED POWER
D
CAN LO
C
CAN HIGH
A
GROUND
A-DSP SH22: A-6
2 2
DISPLAY
6
13 13
CAN_A_L
CAN_A_H
CAN_A_T
SH7: B-1 805 RD 0.8 CAN CAN CAN SH22: A-6
B+
15
TO
15
SH10: D-1 806 OR 0.8
IGN WAKE
MC20 UCM
CANB_HK WH 0.8 SH22: A-6
11 11 A-SFB
SH12: D-4 871 BK 0.8 A-DIA
SIGNALGRND SMART FUSE BOX
DIAGNOSTIC PLUG
14 14
SH13: B-6 CANB_LK BL 0.8 SH22: A-5
CAN_B_T
CAN_B_H
CAN_B_L
954E BK 0.8
GROUND
CAN LO
CAN HI
X-DSP
CAN 2 LO
CAN 2 HI
ISO K
H
J
CAN CAN CAN
X-DIA
X-X7
5
E
J
F
5
3
2
1
6
X-DSP
CANB_LK BL 0.8
CANB_HK WH 0.8
MC44
MC42
303 WH 0.8
X-SFB_XCP
MC39
CANB_HD WH 0.8
CANB_LF BL 0.8 2
CANB_HB WH 0.8
CANB_LD BL 0.8
CANB_LB BL 0.8 CANB_HF WH 0.8 1
B SH16: C-1
B
MC20
MC39
A-TERM2
TERMINATOR SP-B_HJ
MC40 SP-B_HE MC50
MC41 MC41 MC46
A CANB_HA WH 0.8 CANB_HC WH 0.8 CANB_HE WH 0.8 CANB_HJ WH 0.8
SP-B_HC SP-B_HM
SP-B_LJ
B CANB_LA BL 0.8 CANB_LC BL 0.8 CANB_LE BL 0.8 CANB_LJ BL 0.8
C MC40 SP-B_LC SP-B_LE MC43 MC43 SP-B_LM
X-TERM2 X-A_RT SH34:D-5
MC47
X-JSS_FR
799F OR 0.8 MC47
799A OR 0.8 1 1 799C OR 0.8 SP-799C 3 3 CANB_HI WH 0.8
SW-RH_JS
SH10: B-2 3
799E OR 0.8 8
B-ST_MTN
X-CAB_JSS Y-JSS_STRG_VLV SH21: A-1 955Z BK 0.8 4 4 4 CANB_LI BL 0.8
SH21: A-1 955AA BK 0.8 7 6 854A WH 0.8 SH21: B-2 RIGH HAND JOYSTICK
JOYSTICK STEERING or 3 lever
VALVE STEERING WHEEL 1 1 792 OR 0.8 SH10: B-2
MC61 1 MOTION
MC62 MC68
5
10
2 2 2 954K BK 1.0 SH13: A-6
9 4
CANB_HR WH 0.8
CANB_HT WH 0.8
CANB_LR BL 0.8
X-JSV X-STW X-CAB_AR

X-JSV
CANB_LT BL 0.8
CANB_HW WH 0.8
A A
CANB_LW BL 0.8
MC68
A-TERM3 OPTION
X-JSS_CAN
TERMINATOR
MC60 MC60 SP-B_LS SP-B_LP MC51 MC51 MC50
MC59 SP-B_LV MC67
CANB_LU BL 0.8 CANB_LS BL 0.8 CANB_LV BL 0.8 CANB_LP BL 0.8 B B CANB_LO BL 0.8
B B
SP-B_HS MC67 SP-B_HP

A
A CANB_HU WH 0.8 CANB_HS WH 0.8 CANB_HV WH 0.8 CANB_HP WH 0.8 A A CANB_HO WH 0.8
C MC59 SP-B_HV C C
X-JSS_COM
X-TERM3
6 5 4 3 2 1
SHT_24 1
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Wiring harnesses - Electrical schematic sheet 25 SH25 - GEAR CONTROL

UNIT 1
ECU A-108F - ZF DIAGNOSTIC X-ZF_DI - DIAGNOSTIC
CONNECTOR (ECU) [A-108F] (84364851)
ECU A-TRANS - TRANSMISSION X-TECM - TRANS
CONTROL UNIT (ECU) CONTROLLER [SH25: C-6]
(84550089)
ECU A-TRC - TRANS X-TRC - TRANS
CONTROLLER ON TRANNY CONTROLLER ON TRANNY
(ECU) CNH [A-TRC] (47669071)
TRANSMISSION [SH26:
A-2] (87696944)
Connector X-SP_PK_CLN X-SP_PK_CLN - SPLICE
PACK CLEAN GRND [SH25:
C-1] (87352746)
Connector X-TECM X-TECM - TRANS
CONTROLLER [SH25: C-6]
(84550089)
Connector X-TRANS X-TRANS - TRANSMISSION
TO CAB (87696949)
Connector X-TRC X-TRC - TRANS
CONTROLLER ON TRANNY
CNH [A-TRC] (47669071)
Connector X-YLS X-YLS - TRANS LOCKUP
SOLENOID (82012083)
Connector X-ZF_DI X-ZF_DI - DIAGNOSTIC
[A-108F] (84364851)
Solenoid Y-YLS - LOCKUP SOLENOID
(Solenoid)
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A-TRANS
TRANSMISSION CONTROL UNIT
SP-165
23 23 1 1
SH7: C-3 165 RD 1.0 165A RD 0.8 856 BK 0.8 SH12: C-5
TECM B+ CLEAN GROUND
68 2
GROUNDS
68 2 SH12: C-4
165B RD 0.8 855 BK 0.8
TECM B+ CLEAN GROUND
D D
Y-YLS
X-TRANS
45 LOCKUP SOLENOID
SH10: C-2 19E OR 0.8 45
TECM IGN PWR 50
50 419 BR 0.8 15 15 419A BR 0.8 1
LOCKUP N P
SP-420C
53
53 420 WH 0.8 420C WH 0.8 25 25 420A WH 0.8 2
PWR VPSL
X-YLS
PLUG_2W_SUPERSEAL 1.5_BK_SLD_FEM TERMS
8 8
X-CAB_TR
420B WH 0.8
PWR_VSP2
946 BK 0.8 SH12: C-6
A-108F
ZF DIAGNOSTIC CONNECTOR
15
15 37D WH 0.8 2 2 3 3
DIAGNOSTIC SIG
18
18 167 SIL 0.8 4 4 1 1
C SH24: D-3
MC34
CAN_LE GN 0.8
MC34 26 26
CAN LO
DIAGNOSTIC SIG C
X-ZF_DI X-ZF_DI
25 25
SH24: D-3 CAN_HE YE 0.8
CAN HI
SH10: C-2 19F OR 0.8
67 67
43 43
64 64
65 65
63 63
A-TRC
TRANS CONTROLLER ON TRANNY
22 22
B B
PL2326 ONLY
X-TRANS
56 1
56 834A TN 0.8 1
834 TN 0.8 16 16
SOL Y1 CLUTCH K4
834B TN 0.8
10 836B TN 0.8 2
10 2
836 TN 0.8 17 17 836A TN 0.8
SOL Y2 CLUTCH KR
32 3
32 3
837 TN 0.8 18 18 837A TN 0.8
SOL Y3 CLUTCH K1
55 4
55 4
838 TN 0.8 19 19 838A TN 0.8
SOL Y4 CLUTCH K3
9 5
9 5
839 TN 0.8 20 20 839A TN 0.8
SOL Y5 CLUTCH KV
6 6
51 51 21 21 840A TN 0.8
SOL Y6 CLUTCH K2
SP-841
7 7
13 13 841 WH 0.8 841A WH 0.8 22 22 841C WH 0.8
SW PWR VPS1
VSP1 PWR
12 12 841B WH 0.8
A VSP1 PWR
A
842 YE 0.8 8 8
39 39 5 5 842A YE 0.8
TEMP SEND VALVE BODY TEMP SIG
9 9
VALVE BODY TEMP RET
X-CAB_TR
X-TRC
X-TECM X-TECM
697D BL 0.8 SH26: C-5
6 5 4 3 2 1
SHT_25 1
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Wiring harnesses - Electrical schematic sheet 26 SH26 - GEAR CONTROL

UNIT 2
ECU A-TRANS - TRANSMISSION X-TECM - TRANS
CONTROL UNIT (ECU) CONTROLLER [SH25: C-6]
(84550089)
Sensor B-ES_S - ENGINE SPEED X-ESS - SPEED SENSOR
SENSOR (Sensor) ENGINE [B-ES_S] (84364854)
Sensor B-FM - FILTER X-FM - PRESSURE SWITCH
MAINTENANCE (Sensor) OIL FILTER [B-FM] (82012083)
Sensor B-GOT - GEAR OIL TEMP X-TCOT - GEAR OIL TEMP
(Sensor) [B-GOT] (84364854)
Sensor B-IS_S - INTERMEDIATE X-ISS - SPEED SENSOR
SPEED SENSOR (Sensor) MIDDLE WHEEL CHAIN
[B-IS_S] (84364854)
Sensor B-OSS - OUTPUT SPEED X-OSS - SPEED SENSOR
SENSOR (Sensor) GEAR TRANS [B-OSS]
(84062580)
Sensor B-TS_S - TURBINE SPEED X-TSS - SPEED SENSOR
SENSOR (Sensor) TURBINE [B-TS_S]
(84364854)
TRANSMISSION [SH26:
A-2] (87696944)
Connector X-ESS X-ESS - SPEED SENSOR
ENGINE [B-ES_S] (84364854)
Connector X-FM X-FM - PRESSURE SWITCH
OIL FILTER [B-FM] (82012083)
Connector X-ISS X-ISS - SPEED SENSOR
MIDDLE WHEEL CHAIN
[B-IS_S] (84364854)
Connector X-OSS X-OSS - SPEED SENSOR
GEAR TRANS [B-OSS]
(84062580)
Connector X-TCOT X-TCOT - GEAR OIL TEMP
[B-GOT] (84364854)
Connector X-TECM X-TECM - TRANS
CONTROLLER [SH25: C-6]
(84550089)
TO CAB (87696949)
Connector X-TSS X-TSS - SPEED SENSOR
TURBINE [B-TS_S]
(84364854)
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TRANS CAB_T A-TRANS

TRANSMISSION CONTROL UNIT
X-TRANS
423A WH 0.8 31 31 423 WH 0.8 17 17

FILTER MAINTENANCE
B-FM
FILTER MAINTENANCE
D P
D
1 2
1 2
X-FM X-FM
697C BL 0.8
SH25: A-1 697D BL 0.8
B-GOT
GEAR OIL TEMP
SP-697A
1 1 2 2 697B BL 0.8 697A BL 0.8 12 12 697 BL 0.8 46 46
TRANS SIGNL RETURN
X-TCOT X-TCOT
425A WH 0.8 13 13 425 YE 0.8 49 49

TCO TEMP SENDER
C C
B-ES_S
ENGINE SPEED SENSOR
MC52 MC56
MC52 MC56
1 1 699A YE 0.8 7 7 699 YE 0.8 19 19
ENGINE SPEED
2 2 702D BL 0.8 2 2 702E BL 0.8
X-ESS
B-TS_S
TURBINE SPEED SENSOR
MC57
MC53 MC53 MC57
1 1 700A YE 0.8 8 8 700 YE 0.8 41 41
TURBINE SPEED
2 2 702C BL 0.8 14 14 702F BL 0.8
X-TSS
B-IS_S
INTERMEDIATE SPEED SENSOR
MC54 MC58 MC58
MC54
1 1 701A YE 0.8 9 9 701 YE 0.8 42 42
INTERMEDIATE SPEED
2 2 702B BL 0.8 11 11 702A BL 0.8 702 BL 0.8 3 3
SP-702A SPEED SENSOR GRND
X-ISS
B LOCATE SPLICE
NEAR TCU
B
B-OSS
OUTPUT SPEED SENSOR 28 28
PWR GND
3 1 703A BL 0.8 28 28 703 BL 0.8 4 4
OUTPUT SPEED GRND
X-OSS
OUT
2 578 YE 0.8 10 10 578A YE 0.8 62 62
OUTPUT SPEED SIGNAL
X-OSS
19T_H OR 0.8 29 29 19G OR 0.8 SH10: C-2
X-CAB_TR
A A
X-TECM
6 5 4 3 2 1
SHT_26 1
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Wiring harnesses - Electrical schematic sheet 27 SH27 - LIGHTING

DOME, MAP LIGHTS
(ECU) (47554341)
Lamp LMP-DM - EGRESS/DOME X-DM_G - DOME LIGHT
LAMP (Lamp) GROUND [LMP-DM]
(87688695) X-DM_P - DOME
LIGHT POSITIVE [LMP-DM]
(84015523)
Lamp LMP-LPL - LICENSE PLATE X-LPL - LICENSE PLATE
LIGHT (Lamp) LIGHT [LMP-LPL] (87692855)
Lamp LMP-MPL - MAP LIGHT X-MAP - MAP LIGHT [SH13:
(Lamp) C-6] (84058093)
Switch SW-DS - DOOR SWITCH X-DS - DOOR SWITCH [SH27:
(Switch) C-6] (87382906)
Connector X-AIR X-AIR - HVAC CONSOLE
[SH27: C-2] (84309048)
[SH7: B-5] (84807216)
Connector X-DM_G X-DM_G - DOME LIGHT
GROUND [LMP-DM]
(87688695)
Connector X-DM_P X-DM_P - DOME LIGHT
POSITIVE [LMP-DM]
(84015523)
Connector X-DS X-DS - DOOR SWITCH [SH27:
C-6] (87382906)
[SH18: C-6] (87696948)
Connector X-ENG_H X-ENG_H - ENGINE TO
HOOD (87700321)
Connector X-E_HD X-E_HD - ENGINE TO HOOD
EURO [SH29: B-1] (87692858)
Connector X-HD_E X-HD_E - HOOD EURO TO
EURO ENG HARN (87644909)
Connector X-HD_N X-HD_N - HOOD TO ENG
(87700325)
Connector X-LPL X-LPL - LICENSE PLATE
LIGHT [LMP-LPL] (87692855)
Connector X-MAP X-MAP - MAP LIGHT [SH13:
C-6] (84058093)
(47554344)
(47554342)
Connector X-X6 X-X6 - SFB [A-SFB]
(47554341)
(84538791)
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D D
A-SFB
SMART FUSE BOX
LMP-MPL
MAP LIGHT
OUT_05_H 18 P N
MAP LIGHT 147 VT 0.8 A C 955Q BK 0.8 SH13: C-6
X-X3
X-MAP X-MAP
SW-DS
DOOR SWITCH
IN OUT 80
IN_DIG_09_L_WU LMP-DM
SH13: C-5 955P BK 0.8 2 1 151 YE 0.8
LH Door Ajar Switch EGRESS/DOME LAMP
C X-DS X-DS X-X7
OUT_02_H_PWM
X-X6
17 1 P1
C
EGRESS/DOME LIGHT 148 VT 0.8 N
OUT_47_H_CS_L 12 1 955N BK 0.8 SH13: C-4
2 P2
DOME LAMP 149 OR 0.8
15 W X-DM_G
X-X5 X-DM_P
OUT_05_H_PWM 8
285 VT 0.8 SH33: D-3
Console Panel Illumination
X-X6
LMP-LPL
LICENSE PLATE LIGHT
X-ENG X-ENG_H
OUT_50_H_CS 17 P N
280 VT 0.8 25 25 280A VT 0.8 8 8 280B VT 0.8 A B
License Plate Light
X-X3 X-CAB_E SH29:B-3 X-HD_N X-LPL X-LPL
280C VT 0.8 280T VT 0.8
X-E_HD
ENG_EURO_PL10-20 ENG_EURO_PL10-20
242D BK 0.8
A A 280D VT 0.8
SH29: B-1 242T BK 0.8
C C 243D BK 0.8
B B ENG_EURO_PL10-20
X-HD_E
243C BK 0.8 SH29: C-1
ENG_EURO_PL10-20
B SP-981
B
SH29: B-1
OUT_01_H_PWM 2
981 VT 0.8 981E VT 0.8 SH36: C-6
Switch Back Lighting
X-X4
981D VT 0.8 SH32: C-5
981F VT 0.8 SH34: A-6
981G VT 0.8 SH36: C-6
COLOR:
GREEN NA PL10-26 ENGINE HARNESS 981J VT 0.8 SH21: A-4

A 3399FF
A
NA PL10-26 HOOD HARNESS
33CC00 EURO PL10-20 ENGINE HARNESS
BROWN EURO PL23-26 LIGHT/HOOD HARNESS
006600
PL23-26 ENGINE HARNESS
3399FF PL23-26 NA HOOD HARNESS
6 5 4 3 2 1
SHT_27 1
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HAZARD WARNING, BLINKERS, DRIVING
(ECU) (47554341)
Lamp LMP-LF_LT - LH FRONT X-LLF - FRONT COMBO
COMBO LIGHT (Lamp) LAMP LEFT [LMP-LF_LT]
(87694109)
Lamp LMP-RF_LT - RH FRONT X-LRF - FRONT COMBO
COMBO LIGHT (Lamp) LAMP RT [LMP-RF_LT]
(87694109)
Lamp LMP-TTI - TELL TALE X-TT - TELL TALE INDICATOR
INDICATOR (Lamp) [LMP-TTI] (87715979)
Switch SW-HZD_SW - HAZARD X-S_HZD - SWITCH HAZARD
SWITCH (Switch) [SW-HZD_SW] (87716755)
STD (87704523)
Connector X-BTM_F X-BTM_F - BOTTOM TO
FRONT STD (87696087)
[SH21: B-3] (87696945)
Connector X-CAB_P X-CAB_P - CAB TO
PEDESTAL [SH20: D-2]
(87700155)
Connector X-FRNT X-FRNT - FRONT TO
BOTTOM STD (87704426)
Connector X-LLF X-LLF - FRONT COMBO
LAMP LEFT [LMP-LF_LT]
(87694109)
Connector X-LRF X-LRF - FRONT COMBO
LAMP RT [LMP-RF_LT]
(87694109)
Connector X-PED X-PED - PEDESTAL TO CAB
(87700156)
Connector X-PG X-PG - PEDESTAL GROUND
[SH28: B-6] (87705607)
Connector X-SRWP X-SRWP - SWITCH REAR
WIPER [SW-WPR_SW]
(87716755)
Connector X-S_HZD X-S_HZD - SWITCH HAZARD
[SW-HZD_SW] (87716755)
Connector X-TT X-TT - TELL TALE INDICATOR
[LMP-TTI] (87715979)
(47554344)
(47554342)
(47554341)
(84538791)
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LMP-TTI
TELL TALE INDICATOR A 955T BK 0.8
X-CAB_P X-PED
B 955H BK 0.8 SH28: B-5
LEFT
188 VT 0.8 1 1 188A VT 0.8 2
C 955G BK 0.8 SH32: B-5
D 955F BK 0.8 SH24: D-6

RIGHT
2 2 189A VT 0.8 5
A-SFB E 955E BK 0.8 SH28: C-5
GND
D SMART FUSE BOX 1
SH32: B-5
D
WARNING F 955D BK 0.8
SH20: D-2 134 YE 0.8 5 5 134A YE 0.8 4 X-TT
G 955W BK 0.8 SH32: B-6
OUT_08_H
29 IN_DIG_05_L_WU 9 HIGH H 955U BK 1.0 SH14: B-6
DRIVING LIGHTS LOW BEAM LH TURN TELTALE
132C VT 0.8 3 3 132G VT 0.8 3
X-X7
78 IN_DIG_20_L K 955C BK 0.8 SH28: B-6
DRIVING LIGHTS HIGH BEAM
CAN INPUT
OUT_04_H X-TT
77 IN_DIG_21_L 16 189 VT 0.8 L 955M BK 0.8 SH32: B-6
DRIVING LIGHTS FLASH TO PASS RH TURN TELTALE
J
X-X5 PEDESTAL X-PG
954D BK 1.0 7 7 955B BK 1.0 LMP-LF_LT
LH FRONT COMBO LIGHT
SH13: B-5 X-BTM X-FRNT
OUT_09_H_CS 133B VT 0.8 LOW

21 133 VT 0.8 22 22 133A VT 0.8 F F 2
LH LOW BEAM LAMP
X-X5
27 IN_DIG_07_L_WU SP-132
POSITION TAIL LIGHTS SWITCH OUT_06_H_CS HIGH
4 132 VT 0.8 132A VT 0.8 20 20 132D VT 0.8 C C 132E VT 0.8 3
CAN INPUT LH HIGH BEAM LAMP
X-X4 GND
1
76 IN_DIG_22_L SP-127
LH TURN SWITCH OUT_16_H_CS POSTN X-LLF
6 127 VT 0.8 127A VT 0.8 23 23 127B VT 0.8 H H 127C VT 0.8 4
IN_DIG_23_L LH POSITION/TAIL
75
RH TURN SWITCH X-X6
C OUT_10_H_CS
LH FRONT TURN
12 136 VT 0.8 24 24 136B VT 0.8 J J 136C VT 0.8 5
TURN
C
X-LLF
X-X4
LMP-RF_LT
X-PED X-CAB_P RH FRONT COMBO LIGHT
SW-HZD_SW
HAZARD SWITCH LOW
OUT_04_H_CS 13 26
138 VT 0.8 26 138A VT 0.8 L L 138B VT 0.8 2
RH LOW BEAM LAMP
P1 N1
8 7 955E BK 0.8 SH28: D-1
X-X5
OUT1 IN_DIG_06_L_WU HIGH
OUT_02_H_CS 10 137B VT 0.8
3 141A YE 0.8 6 6 141 YE 0.8 28 137 VT 0.8 25 25 137A VT 0.8 K K 3
HAZARD SWITCH RH HIGH BEAM LAMP X-LRF
IN GND
2 X-X4 1
SP-130
OUT2 POSTN
OUT_17_H_CS 3 130 VT 0.8 130D VT 0.8 27 27 130E VT 0.8 M M 130F VT 0.8 4
X-X7 RH POSITION/TAIL
P2 N2
10 9 955H BK 0.8 SH28: D-1 X-X6
CAB BOTTOM FRONT_STD
981B VT 0.8
CAB HARNESS TURN

X-S_HZD X-S_HZD OUT_13_H_CS 15 135 VT 0.8 28 28 135D VT 0.8 N N 135E VT 0.8 5
RH FRONT TURN
X-X5 X-LRF
X-BTM_F
X-CAB_B
130A VT 0.8
OUT_01_H_CS_L
269 BK 0.8 8 8 269A BK 0.8 16
HAZARD INDICATOR
X-X3
B 955C BK 0.8 SH28: D-1

127D VT 0.8 SH29: C-5
B
TO TAIL
SH32: C-6 SH29: B-5 LIGHTS
TO BACKLIGHTING
624A BK 1.0
SP-624D
SH14: A-3 624D BK 2.0 624 BK 1.0
SH22: A-1 624C BK 0.8 624E BK 0.8 SH22: D-2
624B BK 0.8 SH34: D-2

SH22: B-6 624F BK 0.8
A A
NOTE:
MARKER LIGHTS = POSITION LIGHTS.
6 5 4 3 2 1
SHT_28 1
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Wiring harnesses - Electrical schematic sheet 29 SH29 - LIGHTING REAR

TAILS
(ECU) (47554341)
Load L-NA-TAIL - LH REAR TAIL LT X-LH-TAIL - LH REAR
NA (Load) TAIL LIGHT NA [L-NA-TAIL]
(87694101)
Lamp LMP-R-NA-TAIL - RH REAR X-RH-TAIL - RH REAR TAIL
TAIL LT NA (Lamp) [LMP-R-NA-TAIL] (87694101)
[SH7: B-5] (84807216)
[SH18: C-6] (87696948)
HOOD (87700321)
ENG BLOCK [SH29: B-3]
(84140737)
(87700325)
Connector X-LH-TAIL X-LH-TAIL - LH REAR
TAIL LIGHT NA [L-NA-TAIL]
(87694101)
Connector X-RH-TAIL X-RH-TAIL - RH REAR TAIL
[LMP-R-NA-TAIL] (87694101)
(47554344)
(47554342)
(47554341)
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6 5 4 3 2 1
D D
A-SFB
SMART FUSE BOX
ENG_EURO_PL10-20 FROM PL10-20 LPL

X-ENG L-NA-TAIL
126E VT 0.8 LH REAR TAIL LT NA
X-ENG_H PL10-PL26 243C BK 0.8 SH27: B-2
ENG_NA HOOD_NA 2
OUT_19_H_CS
2
126A VT 0.8
STOP ENG_EURO_PL10-20
126 VT 0.8 10 10 2 2 126B VT 0.8 SP-243
LH Brake 243A BK 0.8 243 BK 0.8
C X-X6 ENG_EURO_PL10-20 C
127J VT 0.8 3
ENG_EURO_PL10-20
TAIL GND
SH28: B-3 127D VT 0.8 12 12 127E VT 0.8 6 6 127F VT 0.8 1 SH15: B-2
ENG_EURO_PL10-20 X-LH-TAIL
18
128E VT 0.8 4 TURN
OUT_12_H_CS 128 VT 0.8 22 22 128A VT 0.8 3 3 128B VT 0.8
LH Rear Turn Lamp
X-X5
242C BK 1.0
X-LH-TAIL
LMP-R-NA-TAIL
RH REAR TAIL LT NA
ENG_EURO_PL10-20
129E VT 0.8 2
12 STOP
OUT_20_H_CS 129A VT 0.8 7 7 129B VT 0.8
RH Brake
129 VT 0.8 21 21 ENG_EURO_PL10-20
X-X3 ENG_EURO_PL10-20 243B BK 0.8
130J VT 0.8 3 TAIL GND HOOD_PL23
SH28: B-3 130A VT 0.8 11 11 130B VT 0.8 5 5 130C VT 0.8 1 242B BK 1.0 242F BK 0.8 SH36: C-1
SP-242A
ENG_EURO_PL10-20 X-RH-TAIL FROM PL2326 BU

131F VT 0.8 4 HOOD_NA
9 TURN
OUT_11_H_CS 131 VT 0.8 6 6 131A VT 0.8 4 4 131B VT 0.8 242D BK 0.8 SH27: B-1
RH Rear Turn Lamp
X-X4 X-RH-TAIL
FROM PL2326 LPL
X-CAB_E HOOD_NA
B 1 1 242A BK 1.0
242T BK 0.8 SH27: B-3
B
X-HD_N
TRKY
SH30:B-3, SH27:B-2
242 BK 1.0 SH15: B-3
COLOR:
GREEN NA PL10-26 ENGINE HARNESS

A 3399FF
A
33CC00
EURO PL10-20 ENGINE HARNESS
BROWN EURO PL23-26 LIGHTHOOD HARNESS
006600 PL23-26 ENGINE HARNESS
3399FF
PL23-26 NA HOOD HARNESS
6 5 4 3 2 1
SHT_29 1
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Wiring harnesses - Electrical schematic sheet 30 SH30 - OLD EURO

LIGHTING
Lamp LMP-L-EURO-TAIL - LH X-LH-REAR-TAIL-EURO
REAR TAIL LT EURO (Lamp) - LH REAR TAIL LIGHT
EURO [LMP-L-EURO-TAIL]
(87694112)
Lamp LMP-R-EURO-TAIL - RH X-RH-REAR-TAIL-EURO
REAR TAIL LT EURO (Lamp) - RH-REAR-TAIL-EURO
[LMP-R-EURO-TAIL]
(87694112)
[SH7: B-5] (84807216)
Connector X-EHD_23 X-EHD_23 - ENG TO PL23
HOOD (87694154)
[SH18: C-6] (87696948)
HOOD (87700321)
Connector X-HD_23 X-HD_23 - HOOD PL23
(87694153)
(87700325)
Connector X-LH-REAR-TAIL-EURO X-LH-REAR-TAIL-EURO
- LH REAR TAIL LIGHT
(87694112)
Connector X-RH-REAR-TAIL-EURO X-RH-REAR-TAIL-EURO
- RH-REAR-TAIL-EURO
[LMP-R-EURO-TAIL]
(87694112)
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6 5 4 3 2 1
LMP-L-EURO-TAIL
LH REAR TAIL LT EURO
1 STOP
126D VT 0.8
D 2 TURN
X-LH-REAR-TAIL-EURO D
GND
128D VT 0.8 5
3 TAIL
127H VT 0.8
4 REVERSE
X-LH-REAR-TAIL-EURO
EURO
PL23-PL26
SH29:B-3
X-ENG X-ENG_H
10 10 2 2
242L BK 0.8
C C
12 12 6 6
22 22 3 3
124K VT 0.8
CONTINUES ON CONTINUES ON 242M BK 0.8
PREVIOUS SHT PREVIOUS SHT
NO LONGER 21 21
11 11
7
5
7
5
SP-242H
B
USED. 6
X-CAB_E
6 4
1
4
242H BK 0.8
242J BK 0.8
B
X-HD_N
242K BK 0.8
X-EHD_23
2 2 124H VT 0.8
SP-124H
X-HD_23
SH36:C-2
LMP-R-EURO-TAIL
RH REAR TAIL LT EURO
129D VT 0.8
STOP
1
131E VT 0.8
TURN
2
GND
130H VT 0.8 5
TAIL X-RH-REAR-TAIL-EURO
3
124J VT 0.8
A 4
REVERSE
A
X-RH-REAR-TAIL-EURO
COLOR:
GREEN
NA PL10-26 ENGINE HARNESS
3399FF EURO PL10-20 ENGINE HARNESS
33CC00 EURO PL23-26 LIGHTHOOD HARNESS
TURKEY TO FOLLOW EU,
BROWN PL23-26 ENGINE HARNESS BUT WITH T3 ENGINE
006600
PL23-26 NA HOOD HARNESS
3399FF
6 5 4 3 2 1
SHT_30 1
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WORKING LIGHTS CAB ROOF, FRONT AND REAR
(ECU) (47554341)
Ground GND-029 - (Ground) GND-029
Lamp LMP-LF0 - LEFT FRONT OPTX-LF2 - WORK LIGHT OPT
WL (Lamp) [LMP-LF0] (87695582)
Lamp LMP-LF_WL - LEFT FRONT X-LFWL - LEFT FRONT
WORK LIGHT (Lamp) WORK LIGHT [LMP-LF_WL]
(87695582)
Lamp LMP-LR_WL - LEFT REAR X-LRWL - LEFT REAR
WORK LIGHT (Lamp) WORK LIGHT [LMP-LR_WL]
(87695582)
Lamp LMP-RFO - RIGHT FRONT X-RF2 - WORK LIGHT
OPT WL (Lamp) OPTION [LMP-RFO]
(87695582)
Lamp LMP-RF_WL - RIGHT FRONT X-RFWL - RIGHT FRONT
WORK LIGHT (Lamp) WORK LIGHT [LMP-RF_WL]
(87695582)
Lamp LMP-RR_WL - RIGHT REAR X-RRWL - RIGHT REAR
WORK LIGHT (Lamp) WORK LIGHT [LMP-RR_WL]
(87695582)
Connector X-CAB_R X-CAB_R - CAB TO ROOF
(87695891)
Connector X-LF2 X-LF2 - WORK LIGHT OPT
[LMP-LF0] (87695582)
Connector X-LFO X-LFO - WORK LIGHT
OPTION (87695584)
Connector X-LFWL X-LFWL - LEFT FRONT
WORK LIGHT [LMP-LF_WL]
(87695582)
Connector X-LRWL X-LRWL - LEFT REAR
WORK LIGHT [LMP-LR_WL]
(87695582)
Connector X-RF2 X-RF2 - WORK LIGHT
OPTION [LMP-RFO]
(87695582)
Connector X-RFO X-RFO - WORK LIGHT
OPTION (87695584)
Connector X-RFWL X-RFWL - RIGHT FRONT
WORK LIGHT [LMP-RF_WL]
(87695582)
Connector X-ROOF X-ROOF - ROOF TO CAB
(87700325)
Connector X-RRWL X-RRWL - RIGHT REAR
WORK LIGHT [LMP-RR_WL]
(87695582)
(47554344)
(84538791)
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6 5 4 3 2 1
A-SFB
D SMART FUSE BOX X-ROOF LMP-LF_WL D

LEFT FRONT WORK LIGHT
2 1 P N 2
OUT_26_H_CS
111 VT 1.0 1 1 111A VT 1.0 949C BK 1.0
LEFT FRONT WORK LIGHT
111D VT 1.0 X-LFWL X-LFWL 949F BK 1.0
1 1 2 2
OUT_27_H_CS 4 X-LFWL
X-LFWL X-LFO X-LFO
SP-6111D SP-949F
WORK LAMPS #2
111C VT 1.0 949E BK 1.0
LMP-LF0
LEFT FRONT OPT WL OPTIONAL
IN_DIG_25_L
73
WORK LAMPS SWITCH #1 1 P N 2
WORK LIGHT
111B VT 1.0 949D BK 1.0
X-LF2 X-LF2
IN_DIG_26_L LMP-RF_WL
72
WORK LAMPS SWITCH #2 RIGHT FRONT WORK LIGHT
1 P N 2
OUT_28_H_CS 1
724 VT 1.0 2 2 724A VT 1.0 949B BK 1.0
RIGHT FRONT WORK LIGHT
SWITCH PAD
111G VT 1.0 X-RFWL X-RFWL 949J BK 1.0
CAN
1 2
C 71
IN_DIG_27_L SP-111G X-RFO X-RFO
SP-949J C
WORK LAMPS SWITCH #4 111E VT 1.0 949G BK 1.0
LMP-RFO
RIGHT FRONT OPT WL
X-X3
OPTIONAL
P N 2
1 WORK LIGHT
66 IN_DIG_28_L 111F VT 1.0 949H BK 1.0
WORK LAMPS SWITCH #5
X-RF2 X-RF2 SP-949A
X-X7
SH13: C-4 949 BK 2.0 6 6 949A BK 2.0
SP-953A
SH13: B-5 953 BK 2.0 7 7 953A BK 2.0
SH34: C-1 953B BK 0.8
SH34: A-1 953C BK 1.0
SH34: A-1 953D BK 1.0
LMP-LR_WL
LEFT REAR WORK LIGHT
SP-859A
19 P N
OUT_29_H_CS 1 2
859 VT 1.0 5 5 859A VT 1.0 859B VT 0.8 953E BK 1.0
REAR WORK LIGHTS
B X-LRWL X-LRWL
B
X-X4 X-CAB_R
LMP-RR_WL
RIGHT REAR WORK LIGHT
P N
859C VT 0.8 1 2 953F BK 1.0
X-RRWL X-RRWL
A A
6 5 4 3 2 1
SHT_31 1
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Wiring harnesses - Electrical schematic sheet 32 SH32 - CAB WIPER

/ WASHER
(ECU) (47554341)
Motor M-FW_M - FRONT WASHER X-FWW - FRONT WASHER
MOTOR (Motor) MOTOR [M-FW_M]
(84015523)
Motor M-RW_M - REAR WASHER X-RWW - REAR WASHER
MOTOR (Motor) MOTOR [M-RW_M]
(84015523)
Motor M-R_WPR_M - REAR WIPER X-RWM - REAR WIPER
MOTOR (Motor) MOTOR [M-R_WPR_M]
(87692862) X-RWM_G -
REAR WIPER MOTOR GRND
[SH13: C-2] (87693744)
Switch SW-WPR_SW - REAR WIPER X-SRWP - SWITCH REAR
SWITCH (Switch) WIPER [SW-WPR_SW]
(87716755)
Connector X-CAB_P2 X-CAB_P2 - CAB TO
PEDESTAL 2 [SH27: B-2]
(87705101)
TRANSMISSION [SH26:
A-2] (87696944)
Connector X-FWM X-FWM - FRONT WIPER
MOTOR (87692862)
Connector X-FWM_G X-FWM_G - FRONT WIPER
GROUND [SH14: D-5]
(87693744)
Connector X-FWW X-FWW - FRONT WASHER
MOTOR [M-FW_M]
(84015523)
Connector X-PED_2 X-PED_2 - PEDESTAL TO
CAB 2 (87705114)
Connector X-PG X-PG - PEDESTAL GROUND
[SH28: B-6] (87705607)
Connector X-RWM X-RWM - REAR WIPER
MOTOR [M-R_WPR_M]
(87692862)
Connector X-RWM_G X-RWM_G - REAR WIPER
MOTOR GRND [SH13: C-2]
(87693744)
Connector X-RWW X-RWW - REAR WASHER
MOTOR [M-RW_M]
(84015523)
Connector X-SRWP X-SRWP - SWITCH REAR
WIPER [SW-WPR_SW]
(87716755)
TO CAB (87696949)
(47554341)
(84538791)
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6 5 4 3 2 1
A-SFB
SMART FUSE BOX
OUT_01_WIPER 6 100 TN 2.0 F_WPR_M

FRONT WIPER MOTOR HIGH
FRONT WIPER MOTOR
X-X4
A 53b (HIGH)
D D
B 53 (LOW)
OUT_02_WIPER 10 101 TN 1.0
FRONT WIPER MOTOR LOW
D 31b
IN_DIG_02_L X-X6
58 FRONT WASHER SWITCH
M
CAN INPUT C PARK
IN_DIG_01_L 53a
59 102 TN 0.8
FRONT WIPER MOTOR PARK
31 (GND) A
X-X7 X-FWM
103 BK 2.0 SH14: D-5
IN_ANA_01
19 FRONT WIPER LOW SWITCH M-FW_M
FRONT WASHER MOTOR X-FWM_G
X-X7 X-TRANS
1 2
OUT_01_H_CS_M 6 6 A M B SH20: B-1
16 104A TN 0.8 391F BK 0.8
FRONT WASHER MOTOR
X-FWW X-FWW
M-RW_M
REAR WASHER MOTOR
1 2
OUT_03_H_CS_M 9 4 4 M SH20: B-1
106 OR 0.8 106A OR 0.8 A B 391E BK 0.8
REAR WASHER MOTOR
X-CAB_TR X-RWW X-RWW

OUT_03_WIPER 12 108 TN 1.0
REAR WIPER MOTOR LOW
X-X6
M-R_WPR_M
SH27: B-2 IN_DIG_03_L 57
981D VT 0.8 109 TN 0.8
C REAR WIPER MOTOR PARK
B 53 (MOTOR +)
REAR WIPER MOTOR
C
X-X7
D 31b
M
C PARK
53a
SH28: B-6 981B VT 0.8 X-PED_2
31 (GND) A
SP-981A X-RWM
955V BK 1.0 SH13: C-2
981C VT 0.8 981A VT 0.8 12 12
X-RWM_G
SW-WPR_SW
REAR WIPER SWITCH
P N
8 7 955D BK 0.8 SH28: D-1
IN1
SH28: D-1 955W BK 0.8 5
2A 55 IN_DIG_05_L
6 727A YE 0.8 9 9 727 YE 0.8 REAR WASHER SWITCH
IN2
SH28: D-1 955M BK 0.8 2
B 2B
3 728A YE 0.8 8 8 728 YE 0.8
56 IN_DIG_04_L
REAR WIPER SWITCH
B
P1 N1 X-X7
10 9 955G BK 0.8 SH28: D-1
X-SRWP X-SRWP
3 OUT_49_H_CS
283A VT 0.8 11 11 283 VT 0.8 WIPER INDICATOR
X-X4
X-CAB_P2
5
SH14: D-4 WIPER_GND
279 BK 2.0
WIPER GROUND
X-X6
A A
6 5 4 3 2 1
SHT_32 1
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Wiring harnesses - Electrical schematic sheet 33 SH33 - HEATING BLOWER HEATER, HVAC
ECU A-AC CONTROL PANEL - Connector X-07 X-07 - DENSO (87692855)
DENSO (ECU) Connector X-08 X-08 - DENSO
ECU A-DRIVER 24V - DENSO Connector X-10A X-10A - DENSO
(ECU) Connector X-10B X-10B - DENSO
ECU A-HVAC - DENSO (ECU) Connector X-11A X-11A - DENSO
ECU A-LIGHT HOLDER 2 - DENSO Connector X-11B X-11B - DENSO
(ECU) Connector X-12 X-12 - DENSO (41200689)
ECU A-LIGHT HOLDER1 - DENSO Connector X-ACT X-ACT - AC CLUTCH
(ECU) (87687239)
ECU A-SFB - SMART FUSE BOX X-X6 - SFB [A-SFB] Connector X-ACT_10 X-ACT_10 - AIR
(ECU) (47554341) COMPRESSOR CLUTCH
Sensor B-NTC SENSOR - DENSO PL10 (87693744)
(Sensor) Connector X-AIR X-AIR - HVAC CONSOLE
Ground GND-001 - (Ground) GND-001 [SH27: C-2] (84309048)
Motor M-BLOWER 24V - DENSO Connector X-CAB_E-2 X-CAB_E-2 - CAB TO ENG 2
(Motor) [SH9: C-2] (87703902)
Motor M-STEPPER MOTOR 24V - Connector X-ENG-2 X-ENG-2 - ENGINE TO CAB 2
DENSO (Motor) (87703931)
Resistor R-CERAMIC RESISTOR 24V Connector X-HVAC X-HVAC - INTRCECT TO
- DENSO (Resistor) HVAC SYSTEM BY HVAC
Switch SW-AC SWITCH - DENSO [SH33: D-4] (87696573)
(Switch) Connector X-HVAC2 X-HVAC2 - HVAC MECHINISM
Switch SW-LOW PRESSURE (87696550)
SWITCH N.C. - DENSO Connector X-J1333 X-J1333 - DENSO
(Switch) Connector X-J1338 X-J1338 - DENSO
Switch SW-POTENTIOMETER FOR Connector X-LC6 X-LC6 - LOADCENTER 6
MIX - DENSO (Switch) [SH16: A-3] (84380518)
Switch SW-PR_H2 - AC HIGH PRESS X-PRH2 - HIGH PRESSURE Connector X-PRH2 X-PRH2 - HIGH PRESSURE
SW (Switch) SWITCH 2 [SH33: C-6] SWITCH 2 [SH33: C-6]
(87688788) (87688788)
Switch SW-ROTARY FOR BLOWER Connector X-X5 X-X5 - SFB [SH3: D-3]
- DENSO (Switch) (47554342)
Connector X-01 X-01 - DENSO Connector X-X7 X-X7 - SFB [SH3: A-3]
Connector X-02 X-02 - DENSO (84538791)
Connector X-04 X-04 - DENSO Solenoid Y-ACT - AC COMPRESSOR
Connector X-05 X-05 - DENSO CLUTCH (Solenoid)
Connector X-06 X-06 - DENSO
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6 5 4 3 2 1
A-AC CONTROL PANEL
YERD
1 1 258A YE 0.8 1 1
WHBK
2 2 262C WH 0.8 2 2
BKPRP
260A PRP 0.8 3 3
3 3
4 4
TO BACK
LIGHTING SW-POTENTIOMETER FOR MIX
X-10B
SH27: C-2 285 VT 0.8

X-11A DENSO
D 285A VT 0.8 1
D
4 4 1
2 A-LIGHT HOLDER1
GND5490 SH12: D-2 256 BK 0.8 256A BK 0.8 5 5 256D BK 0.8 2
SP-256
ACC PWR SH9: B-1 876 OR 3.0 X-08

YEGN 10B-1
873D OR 0.8 6
6 873E YE 0.8 1
7 10B-2
258D YE 0.8 258C YE 0.8 7 261A GY 0.8 2
GYRD 10B-3 SW-AC SWITCH
SP-258 3
A-SFB A/C
10B-4
SMART FUSE BOX
1 SP-873 OPTION
36 OUT_48_H_CS_L
IN_ANA_12
260 VT 0.8
873 OR 0.8
261 WH 0.8
A/C ON INPUT HVAC MOD PWR
262 YE 0.8
X-X7 X-X5
X-11B
256C BK 0.8
256J BK 0.8
258 YE 0.8
256E BK 0.8 1 1
A-LIGHT HOLDER 2
285B VT 0.8 2 2
873A OR 0.8
873B OR 0.8
SW-PR_H2 SH13: B-6
AC HIGH PRESS SW 10A-5
X-ENG-2 903A BK 2.5 1
903 BK 2.5 8 8
9 9 264A GY 1.0 2
10A-1 1 5
264 GY 1.0
10A-2 2
B P 265 GN 2.0 1010 265A GN 2.0 3
C SH11: A-6 211B YE 1.0
OUT IN A
246C YE 1.0 L L 246 YE 0.8 266 YE 2.0 1111 266A YE 2.0 4
10A-3
10A-4
3
4
SW-ROTARY FOR BLOWER
C
X-HVAC
267 WH 2.5 1212 267A GY 2.5 5
X-PRH2 X-PRH2
AC CLTCH RLY X-CAB_E-2 X-10A
D D
A A
S S
H H
N
J J
G G
K K
B B
C C
E E
R R
X-AIR
F F
X-12
M
N
P
L
X-HVAC2
267B GY 2.5
A-HVAC
264B GY 1.0
X-05
SP-267 5 R-CERAMIC RESISTOR 24V

267C GY 2.5 4 4 R3
266B YE 2.0 3 3 R2
265B GN 2.0 2 2 R1
264C GY 1.0 1 1
SP-264B
-
1 2
SH11: A-2 187 YE 1.0 Y-ACT 267D GY 2.5 2 2
M M-BLOWER 24V
AC COMPRESSOR CLUTCH 876H OR 3.0 1 1
X-ACT 1
X-06 +
X-J1333
A
SH11: A-2 187A YE 1.0 262B PRP 0.35 2 2
261B WH 0.35 25 25
X-ACT_10
260B YE 0.35 20 20
B GND-001
258E GY 0.35 8 8
B
BODY GROUND 873C GN 0.35 1 1
256F BK 0.8 15 15
A-DRIVER 24V
258F RD 0.35 14 14
5 5
264D GY 0.35 16 16
17 17
3 3
317 YE 0.35 6 6
29 29
27 27
28 28
26 26
X-01
268 PRP 0.35
315 OR 0.35
314 GY 0.35
288 BL 0.35 6 6
286 RD 0.35 5 5
284 BL 0.35 4 4
M-STEPPER MOTOR 24V
282 WH 0.35 3 3
2 2
1 1
X-02
A A
1 1
NTC B-NTC SENSOR
2 2
X-04
B 2
246B WH 0.35 A 1
X-07
X-J1338
SW-LOW PRESSURE SWITCH N.C.
6 5 4 3 2 1
SHT_33 1
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Wiring harnesses - Electrical schematic sheet 34 SH34 - MIRRORS, HORN BEACON

ECU A-SFB - SMART FUSE BOX X-X6 - SFB [A-SFB] Connector X-CAB_P X-CAB_P - CAB TO
(ECU) (47554341) PEDESTAL [SH20: D-2]
Ground GND-017 - (Ground) GND-017 (87700155)
Ground GND-018 - (Ground) GND-018 Connector X-CAB_R X-CAB_R - CAB TO ROOF
Ground GND-019 - (Ground) GND-019 (87695891)
Ground GND-025 - (Ground) GND-025 Connector X-CG3 X-CG3 - CAB GROUND RH
Speaker H-HN - HORN (Speaker) X-HN2 - HORN_GRND HEADLINER [SH13: D-5]
[H-HN] (87697629) X-HN1 (84149207)
- HORN_PWR [H-HN] Connector X-FRNT X-FRNT - FRONT TO
(87697629) BOTTOM STD (87704426)
Relay K-LC3R4 - HORN RELAY X-LC3 - LOADCENTER 3 Connector X-HN1 X-HN1 - HORN_PWR [H-HN]
(Relay) [SH35: B-6] (84529039) (87697629)
Load L-MH_L - MIRROR HEATER X-MH_L - MIRROR HEATED Connector X-HN2 X-HN2 - HORN_GRND [H-HN]
LH (Load) LEFT [L-MH_L] (87695582) (87697629)
Lamp LMP-BEA_RT - ROTATING X-BEA - BEACON Connector X-LC3 X-LC3 - LOADCENTER 3
BEACON / LED STROBE [LMP-BEA_RT] (84015523) [SH35: B-6] (84529039)
LIGHT (Lamp) Connector X-MH_L X-MH_L - MIRROR HEATED
Lamp LMP-MH_R - MIRROR X-MH_R - MIRROR HEATED LEFT [L-MH_L] (87695582)
HEATER RH (Lamp) RIGHT [LMP-MH_R] Connector X-MH_R X-MH_R - MIRROR HEATED
(87695582) RIGHT [LMP-MH_R]
Switch SW-HN_RH_ARM - RH (87695582)
ARMREST HORN SWITCH Connector X-PED X-PED - PEDESTAL TO CAB
(Switch) (87700156)
Switch SW-HN_STLK - RH STALK X-STLK - STALK LEVER RH Connector X-ROOF X-ROOF - ROOF TO CAB
HORN SWITCH (Switch) [SW-HN_STLK] (84426133) (87700325)
Switch SW-MH_SW - MIRROR X-S_HMR - SWITCH HEATED Connector X-STLK X-STLK - STALK LEVER RH
HEATER SWITCH (Switch) MIRRORS [SH13: D-4] [SW-HN_STLK] (84426133)
(87716755) Connector X-S_HMR X-S_HMR - SWITCH HEATED
Connector X-A_RT X-A_RT - ARM REST RIGHT MIRRORS [SH13: D-4]
(87694112) (87716755)
Connector X-BEA X-BEA - BEACON Connector X-X3 X-X3 - SFB [SH3: A-1]
[LMP-BEA_RT] (84015523) (47554344)
Connector X-BTM X-BTM - BOTTOM TO CAB Connector X-X4 X-X4 - SFB (47554343)
STD (87704523) Connector X-X5 X-X5 - SFB [SH3: D-3]
Connector X-BTM_F X-BTM_F - BOTTOM TO (47554342)
FRONT STD (87696087) Connector X-X7 X-X7 - SFB [SH3: A-3]
Connector X-CAB_AR X-CAB_AR - CAB TO RH ARM (84538791)
REST (87694152)
[SH21: B-3] (87696945)
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A-SFB
SMART FUSE BOX H-HN
SW-HN_STLK SH28:C-2 X-FRNT
X-PED X-BTM HORN
RH STALK HORN SWITCH
SP-113
2 1 26 IN_DIG_08_L_WU 1
1 113B BR 0.8 4 4 113A BR 0.8 113 BR 0.8 21 21 112A YE 0.8 T T 112B YE 0.8 P
Horn Switch
X-HN1
X-X7
INTERNAL TO 1
X-CAB_P SH28: A-1
STALK X-STLK X-CAB_B 624B BK 0.8 N
D X-HN2
D
113C BR 0.8
X-BTM_F
55 W
SW-HN_RH_ARM
X-A_RT SH24:A-3
RH ARMREST HORN SWITCH
2 1
113D BR 0.8 5 5
112 YE 0.8
INTERNAL TO RH
113F BR 0.8
EH ARMREST X-CAB_AR
A-SFB
SMART FUSE BOX
K-LC3R4
HORN RELAY X-ROOF
87A R4_87A
R4_30 30
SH3: B-3 219D RD 0.8 87 R4_87
LMP-BEA_RT
R4_86 ROTATING BEACON / LED STROBE LIGHT
86 85 R4_85
SH3: A-3 219E RD 0.8 2
OUT_21_H_CS 3 1 P N
851 VT 0.8 3 3 851A VT 0.8 953B BK 0.8 SH31: B-2
Rotating Beacon
CAN INPUT W
X-LC3 X-X3 X-BEA 70 X-BEA
X-LC3
C C
A-SFB
SMART FUSE BOX
B B
OUT_01_MIRR_COM 17
SW-MH_SW
Mirror LH Common
BACKLIGHTING MIRROR HEATER SWITCH
8 P1 N1 7
SH27: A-2 981F VT 0.8 954B BK 0.8 SH13: C-4
IN_DIG_12_L
2 IN OUT 3 48 Mirror Heat SW
SH13: D-4 955K BK 0.8 116 YE 0.8 L-MH_L
10 P2 N2 9 X-X7 MIRROR HEATER LH
955J BK 0.8 SH13: D-3 SP-114A
6
OUT_01_H_CS P N SH31: B-2
114 TN 1.0 4 4 114A TN 1.0 114B TN 1.0 1 2 953C BK 1.0
X-S_HMR Mirror Heat Supply LOAD
X-S_HMR
X-MH_L X-MH_L
13
114C TN 1.0
OUT_46_H_CS_L OUT_02_MIRR_COM 8 X-CAB_R
115 WH 0.8
Optional Output 4 Mirror RH Common
X-X4
RH HVAC LMP-MH_R
CONSOLE MIRROR HEATER RH
A X-X5 1 P N
LOAD
2 953D BK 1.0 SH31: B-2 A
X-MH_R X-MH_R
6 5 4 3 2 1
SHT_34 1
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Wiring harnesses - Electrical schematic sheet 35 SH35 - CABIN RADIO

LOUDSPEAKER/12V CNVRTR
Speaker H-LSP1 - LOUDSPEAKER RT X-XLP1 - LOUDSPEAKER RT
(Speaker) [H-LSP1] (84147089)
Speaker H-LSP2 - LOUDSPEAKER LF X-XLP2 - LOUDSPEAKER LF
(Speaker) [H-LSP2] (84147089)
Speaker H-RADIO - 12V RADIO X-SPK - RADIO TO SPKRS
(Speaker) [H-RADIO] (87709371)
X-RAD - RADIO [H-RADIO]
(87709660)
Power outlet J-CNVRTR_24-12 - POWER X-CNV - 24 TO 12 POWER
CONVERTER (Power outlet) CONVERTER [SH35: B-4]
(87694112)
Power outlet J-PO1 - RH CONSOLE 12V X-X-PO1 - POWER OUTLET
POWER OUTLET (Power [J-PO1] (84398827)
outlet)
Lamp LMP-CIG_LTR - 24V CIGARX-CL - CIGAR LIGHTER
LIGHTER (Lamp) [LMP-CIG_LTR] (84015523)
Connector X-CL X-CL - CIGAR LIGHTER
[LMP-CIG_LTR] (84015523)
Connector X-CNV X-CNV - 24 TO 12 POWER
CONVERTER [SH35: B-4]
(87694112)
[SH35: B-6] (84529039)
Connector X-RAD X-RAD - RADIO [H-RADIO]
(87709660)
Connector X-SC X-SC - SEAT COMPRESSOR
[Y-SC] (87692855)
Connector X-SPK X-SPK - RADIO TO SPKRS
[H-RADIO] (87709371)
Connector X-X-PO1 X-X-PO1 - POWER OUTLET
[J-PO1] (84398827)
Connector X-XLP1 X-XLP1 - LOUDSPEAKER RT
[H-LSP1] (84147089)
Connector X-XLP2 X-XLP2 - LOUDSPEAKER LF
[H-LSP2] (84147089)
Solenoid Y-SC - SEAT COMPRESSOR X-SC - SEAT COMPRESSOR
(Solenoid) [Y-SC] (87692855)
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Y-SC
D SEAT COMPRESSOR D
SH9: B-2 742 OR 2.0 A SUPPLY GND B 955L BK 2.0 SH13: B-6
X-SC X-SC
LMP-CIG_LTR
24V CIGAR LIGHTER
P1 N 2
SH9: D-2 743 OR 2.0 1 LOAD 957 BK 2.0 SH14: C-3
X-CL X-CL
C P2
C
271 BK 0.8 SH13: B-2
SH8: C-2 753 OR 0.8
SH8: B-2 746 OR 3.0

X-RAD
6 4 7 8
87709660
H-RADIO
12V RADIO
SP-746
24V+ 1 1
24 V 746A OR 2.0
2 2 8 7 2 1
24V+ 746B OR 2.0 X-SPK
J-CNVRTR_24-12
POWER CONVERTER 3 87709371
GRND 3
B 12V MEMORY 4 4
277 BK 2.0 SH14: C-4 H-LSP1
LOUDSPEAKER RT
B
5
12V+ SW 5 748 OR 2.0 SH8: D-5
12 V 6 1
6 SH14: C-4 P
GRND (OPT) 276 BK 2.0 LP1-1 BL 1.0
X-CNV
2
LP1-2 BK 1.0 N
X-XLP1
H-LSP2
1
LP2-1 WH 1.0 P
2
LP2-2 BR 1.0 N
X-XLP2
J-PO1 LOUDSPEAKER LF
RH CONSOLE 12V POWER OUTLET
P1 N
SH8: D-1 750 OR 1.0 A LOAD C 275 BK 1.0 SH14: D-4
P2
X-X-PO1
A X-X-PO1
A
ON RH
CONSOLE
6 5 4 3 2 1
SHT_35 1
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Wiring harnesses - Electrical schematic sheet 36 SH36 - REAR DEFROST,

BACKUP ALARM
(ECU) (47554341)
Ground GND-069 - (Ground) GND-069
Speaker H-BU_ALRM - BACKUP X-BU2 - BACK UP ALARM
ALARM (Speaker) [H-BU_ALRM] (84426117)
X-BU1 - BACK UP ALARM
[H-BU_ALRM] (84426117)
Resistor R-WND_HTR - REAR X-RWHE1 - REAR WINDOW
WINDSHIELD HEATER HEATER [R-WND_HTR]
ELEMENT (Resistor) (87688695) X-RWHE2 - REAR
WINDOW HEATER [SH13:
C-3] (87688695)
Switch SW-BCK_U_SW - BACKUP X-S_BU - CANCEL BACKUP
ALRM CANCEL SW (Switch) ALARM [SW-BCK_U_SW]
(87716755)
Switch SW-R_DEF_SW - REAR X-S_RDF - SWITCH REAR
DEFROST SWITCH (Switch) DEFROST [SW-R_DEF_SW]
(87716755)
[H-BU_ALRM] (84426117)
[H-BU_ALRM] (84426117)
[SH7: B-5] (84807216)
Connector X-EHD_23 X-EHD_23 - ENG TO PL23
HOOD (87694154)
[SH18: C-6] (87696948)
Connector X-HD_23 X-HD_23 - HOOD PL23
(87694153)
Connector X-RWHE1 X-RWHE1 - REAR WINDOW
HEATER [R-WND_HTR]
(87688695)
Connector X-RWHE2 X-RWHE2 - REAR WINDOW
HEATER [SH13: C-3]
(87688695)
Connector X-S_BU X-S_BU - CANCEL BACKUP
ALARM [SW-BCK_U_SW]
(87716755)
Connector X-S_RDF X-S_RDF - SWITCH REAR
DEFROST [SW-R_DEF_SW]
(87716755)
(47554344)
(84538791)
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D D
A-SFB
SMART FUSE BOX
R-WND_HTR
REAR WINDSHIELD HEATER ELEMENT
1
SH13: C-3 272 BK 2.0 N
SW-R_DEF_SW X-RWHE2
REAR DEFROST SWITCH 7 1
OUT_43_H_CS_L SH8: A-5 SH8: A-2 P
120 YE 0.8 801 OR 2.0
Rear Defrost
P1 N1 X-RWHE1
SH27: A-2 981G VT 0.8 8 7 958 BK 0.8 SH13: B-3 TO RELAY
IN OUT 68
SH13: C-2 2 IN_DIG_30_L
955R BK 0.8 3 117 YE 0.8
Rear Defrost Switch
P2 N2
10 9 955A BK 0.8 SH13: D-2
X-S_RDF X-S_RDF
HVAC PANEL X-X3
7 OUT_10_H
122 YE 0.8
Rear Defrost Indicator
H-BU_ALRM
X-X7
BACKUP ALARM
X-ENG
21 1
OUT_45_H_CS_L
121 OR 0.8 7 7 121A OR 0.8 P
Backup Alarm X-BU2
C X-CAB_E X-EHD_23 1
C
244 BK 0.8 N
121B OR 0.8 1 1 121C OR 0.8 X-BU1
1.2 A
SW-BCK_U_SW
BACKUP ALRM CANCEL SW
SH30:B-3 X-HD_23
242F BK 0.8 SH29: B-1
P1 N1
SH27: B-2 981E VT 0.8 8 7 954T BK 0.8 SH13: A-3
SH15: B-2
OUT1 50 IN_DIG_10_L
3 119 YE 0.8
Backup Alarm Cancel
IN X-X7 X-X4
SH13: A-6 955S BK 0.8 2
OUT2
P2 N2
10 9 SH13: A-3
954G BK 0.8 PL23-26 ENGINE HARNESS
X-S_BU X-S_BU
6 OUT_44_H_CS_L
118 YE 0.8
BU CANCEL INDICATOR
X-X3
B B
NOTE HIDDEN
COLOR:
GREEN NA PL10-26 ENGINE HARNESS
A 3399FF NA PL10-26 HOOD HARNESS A

33CC00 EURO PL10-20 ENGINE HARNESS
BROWN EURO PL23-26 LIGHTHOOD HARNESS
006600
PL23-26 ENGINE HARNESS
3399FF PL23-26 NA HOOD HARNESS
6 5 4 3 2 1
SHT_36 1
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Wiring harnesses - Electrical schematic sheet 37 SH37 - HOOD LIFT

Relay K-LC6R1 - HOOD UP (Relay) X-LC6 - LOADCENTER 6
[SH16: A-3] (84380518)
Relay K-LC6R2 - HOOD DOWN
(Relay)
Motor M-HD_L_M - HOOD LIFT X-HDM - HOOD MOTOR
MOTOR (Motor) [M-HD_L_M] (87711966)
Switch SW-HD_L_SW - HOOD LIFT X-HD - HOOD LIFT SWITCH
SWITCH (Switch) [SH3: A-4] (84159859)
[SH7: B-5] (84807216)
[SH18: C-6] (87696948)
Connector X-HD X-HD - HOOD LIFT SWITCH
[SH3: A-4] (84159859)
Connector X-HDM X-HDM - HOOD MOTOR
[M-HD_L_M] (87711966)
[SH7: B-3] (87733581)
[SH16: A-3] (84380518)
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X-ENG
D D
SH7: B-3 205 RD 2.0 2 2
X-CAB_E
HOOD LIFT
209 WH 2.0
205A RD 2.0
K-LC6R1
HOOD UP
87A 41
38 30 208A BK 2.0
87 45
46 86 85 37
208B BK 1.0
M-HD_L_M
SP-250A HOOD LIFT MOTOR
205B RD 2.0 X-LC6 X-LC6
SW-HD_L_SW 1 2
A M B
C HOOD LIFT SWITCH
OUT1 3
C
206 WH 1.0 X-HDM X-HDM
2 IN
SH3: A-4 533 RD 1.0
OUT2 1
X-HD SP-208 208 BK 2.0 SH15: C-2

X-HD
210 GY 2.0
207 GY 1.0
205D RD 2.0
K-LC6R2
HOOD DOWN
87A 43
30
208C BK 2.0
40
87 47
48 86 85 39
208D BK 1.0
X-LC6 X-LC6
B B
A A
6 5 4 3 2 1
SHT_37 1
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Wiring harnesses - Electrical schematic sheet 38 SH38 - MISCELLANOUS,

TELEMATICS
ECU A-TELE - TELEMATIC X-X_TEL - TELEMATICS
MODULE (ECU) [SH38: C-6] (87700156)
Connector X-DIAG_T X-DIAG_T - TELEMATICS
DIAGNOSTIC [SH38: B-1]
(87694101)
[SH10: D-1] (87733595)
Connector X-X_TEL X-X_TEL - TELEMATICS
[SH38: C-6] (87700156)
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D D
A-TELE
TELEMATIC MODULE
NON-ISOLATED B+
RS232RX
GROUND
RS232TX
DIAGNOSTICS
CAN LO
CAN HI
IGN B+
TELEMATICS CONNECTOR
C C
12
3
7
12
3
1
7
4
X-X_TEL X-DIAG_T
SH24: C-2 CAN_HC YE 0.8 CAN_TH TN 0.8
912 BK 0.8 SH12: D-6

CAN_TL LB 0.8
SH24: D-2 CAN_LC GN 0.8
SH3: B-3 217A RD 0.8
SH10: C-3 168 OR 0.8 287 BK 0.8 SH12: C-3
B B
A A
6 5 4 3 2 1
SHT_38 1
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Wiring harnesses - Electrical schematic sheet 39 SH39 - MISCELLANOUS,

REAR CAMERA
ECU A-DISPLAY - (ECU)
ECU A-ORLACO CAMERA - REAR
VIEW CAMERA (ECU)
(ECU) (47554341)
[SH7: B-5] (84807216)
Connector X-CAM X-CAM - REAR CAMERA
(87700107)
Connector X-CAM2 X-CAM2 - CAMERA CHORD
(87700106)
[SH18: C-6] (87696948)
[SH7: B-3] (87733581)
(47554341)
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6 5 4 3 2 1
D D
A-DISPLAY
A-ORLACO CAMERA
REAR VIEW CAMERA
DSP
FROM CAN COMMUNICATION
SHEET
C C
GRILL
GROMMET
CAB
REAR CHASSIS VGA-CABLE HOOD
AND PWR & GRND
MONITOR1 0.0
B B
X-CAM
SH7: B-2 125 OR 0.8 1 1
SH13: D-5 955AD BK 0.8 2 2
124B VT 0.8 3 3
X-CAM2
DEUTSCH_DTM SERIES_6-WAY_RECEP HSG
REAR
CAMERA
TRIGGER
A-SFB
A SMART FUSE BOX X-ENG A
SP-124
OUT_18_H_CS
1
124 VT 0.8
NOT USED
124A VT 0.8 19 19
Reverse Lights
X-CAB_E
X-X6
6 5 4 3 2 1
SHT_39 1
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Wire connectors - Component diagram 00

X-001 - GRID HEATER CABLE GRND ON ENGINE (84398003) (Plug)
84398003
Pin From Wire Description Color-Size Frame
1 X-GH7 (Plug) pin 1 - GRID CABLE_07 GRID HEATER GROUND BK - 32.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
HEATER [R-RES-G_HTR] CABLE 1, GRID HEATER, FILTER HEATER
(87744835)
X-01 - DENSO (Receptacle)

1 X-HVAC2 (Plug) pin F - HVAC 873C 873C GN - 0.35 SHEET 33 SH33 - HEATING BLOWER
MECHINISM (87696550) HEATER, HVAC
2 X-HVAC2 (Plug) pin P - HVAC 262B 262B PRP - 0.35
MECHINISM (87696550)
3 X-04 (Receptacle) pin 1 - 315 315 OR - 0.35
DENSO
5 X-07 (Receptacle) pin B - 268 268 PRP - 0.35
DENSO (87692855)
6 X-02 (Receptacle) pin 1 - 317 317 YE - 0.35
DENSO
8 X-HVAC2 (Plug) pin L - HVAC 258E 258E GY - 0.35
14 X-HVAC2 (Plug) pin K - HVAC 258F DENSO RD - 0.35
15 X-HVAC2 (Plug) pin C - HVAC 256F 256F BK - 0.8
16 SP-264B-P-X 264D 264D GY - 0.35
17 X-04 (Receptacle) pin 2 - 314 314 GY - 0.35
DENSO
20 X-HVAC2 (Plug) pin M - HVAC 260B 260B YE - 0.35
25 X-HVAC2 (Plug) pin N - HVAC 261B 261B WH - 0.35
26 X-02 (Receptacle) pin 6 - 288 288 BL - 0.35
DENSO
DENSO
28 X-02 (Receptacle) pin 5 - 286 286 RD - 0.35
DENSO
29 X-02 (Receptacle) pin 3 - 282 282 WH - 0.35
DENSO

1 X-01 (Receptacle) pin 6 - 317 317 YE - 0.35 SHEET 33 SH33 - HEATING BLOWER
DENSO HEATER, HVAC
3 X-01 (Receptacle) pin 29 - 282 282 WH - 0.35
DENSO
DENSO
5 X-01 (Receptacle) pin 28 - 286 286 RD - 0.35
DENSO
DENSO

1 X-01 (Receptacle) pin 3 - 315 315 OR - 0.35 SHEET 33 SH33 - HEATING BLOWER
DENSO HEATER, HVAC
2 X-01 (Receptacle) pin 17 - 314 314 GY - 0.35
DENSO
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1 SP-264B-P-X 264C 264C GY - 1.0 SHEET 33 SH33 - HEATING BLOWER
2 X-HVAC2 (Plug) pin S - HVAC 265B 265B GN - 2.0 HEATER, HVAC
3 X-HVAC2 (Plug) pin J - HVAC 266B 266B YE - 2.0
4 SP-267-P-X 267C 267C GY - 2.5

1 X-HVAC2 (Plug) pin A - HVAC 876H 876H OR - 3.0 SHEET 33 SH33 - HEATING BLOWER
2 SP-267-P-X 267D 267D GY - 2.5
X-07 - DENSO (87692855) (Receptacle)
87692855
A X-HVAC2 (Plug) pin B - HVAC 246B 246B WH - 0.35 SHEET 33 SH33 - HEATING BLOWER
B X-01 (Receptacle) pin 5 - 268 268 PRP - 0.35
DENSO

1 X-12 (Receptacle) pin 6 - 873E HVAC PWR YE - 0.8 SHEET 33 SH33 - HEATING BLOWER
DENSO (41200689) HEATER, HVAC
2 X-12 (Receptacle) pin 7 - 261A 261A GY - 0.8
DENSO (41200689)
X-ACT - AC CLUTCH (87687239) (Plug)
87687239
X-ACT_10 - AIR COMPRESSOR CLUTCH PL10 (87693744) (Plug)
87693744
A X-LC6 pin 25 - LOADCENTER 187A AC COMPRESSOR YE - 1.0 SHEET 33 SH33 - HEATING BLOWER
6 [SH16: A-3] (84380518) HEATER, HVAC
A Y-ACT-P-IN WIRE6222 WIRE6222
X-AFS - AIR FILTER RSTCN SW [ SW-A_F_S] (84607243) (Receptacle)
84607243
1 SP-627-P-X 627B RELAY FILTER HEATING RD - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
HI SIDE 2, AT
2 X-ECU (Receptacle) pin 37 - 637 AIR FILTER SWITCH YE - 0.8
ECU CONNECTOR [A-ECU]
(84300197)
X-AFS2 - AIR FILTER SWITCH T2/3 [ SW-AFS2] (84607243) (Receptacle)
84607243
1 SP-669A-P-X 669C IGN PWR FOR AIR FLTR OR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
2 X-ENG (Plug) pin 18 - 319A AIR FILTER REST SW T2 YE - 0.8 / FAN CONTROL
ENGINE TO CAB [SH18: C-6]
(87696948)
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X-AIR - HVAC CONSOLE [ SH27: C-2] (84309048) (Receptacle)
84309048
1 X-HVAC (Receptacle) pin 262 TEMP SETTING YE - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
M - INTRCECT TO HVAC LIGHTS
SYSTEM BY HVAC [SH33:
D-4] (87696573)
2 X-HVAC (Receptacle) pin 261 TEMP SETTING WH - 0.8
N - INTRCECT TO HVAC
D-4] (87696573)
3 X-HVAC (Receptacle) pin 260 TEMP SETTING VT - 0.8
P - INTRCECT TO HVAC
D-4] (87696573)
4 X-X6 (Receptacle) pin 8 - SFB 285 SWITCH BACK LIGHTING VT - 0.8
[A-SFB] (47554341)
5 SP-256-P-X 256A CAB CLEAN GRND BK - 0.8
6 SP-873-P-X 873D HVAC POWER OR - 0.8
7 SP-258-P-X 258C AC ON SIGNAL YE - 0.8
8 CG1-P-1 CAB GROUND RH 903 HVAC GROUND BK - 2.5
HEADLINER
9 X-HVAC (Receptacle) pin 264 BLOWER SPEED GY - 1.0
R - INTRCECT TO HVAC
D-4] (87696573)
10 X-HVAC (Receptacle) pin 265 BLOWER SPEED GN - 2.0
S - INTRCECT TO HVAC
D-4] (87696573)
11 X-HVAC (Receptacle) pin 266 BLOWER SPEED YE - 2.0
J - INTRCECT TO HVAC
D-4] (87696573)
12 X-HVAC (Receptacle) pin 267 BLOWER SPEED WH - 2.5
H - INTRCECT TO HVAC
D-4] (87696573)
X-ALT - ALTERNATOR [ G-G1] (8602487) (Receptacle)
8602487 8
8602487
3 X-ENG (Plug) pin 26 - 228 ALTERNATOR VOLTAGE RD - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
ENGINE TO CAB [SH18: C-6] STARTER / KEY
(87696948)
4 X-ENG (Plug) pin 17 - 239 ALT LAMP SIGNAL YE - 0.8
(87696948)
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X-ALT_B - ALTERNATOR B+ (84399576) (Plug)
84399576 9
84399576
1 X-XM1C (Plug) pin 1 - 301 ALTERNATOR B+ RD - 13.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
STARTER (84401295) STARTER / KEY
X-AUX_1_LEFT - AUX 1 LEFT [ A-EH_VLV] (87695582) (Receptacle)
87695582 10
87695582
1 X-FRNT_EH (Receptacle) pin 351B AUX 1 LEFT WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
H - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-352B-P-X 352C AUX 1 LEFT ENABLE BR - 0.8
X-AUX_1_RIGHT - AUX 1 RIGHT [ A-EH_VLV] (87695582) (Receptacle)
87695582 11
87695582
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1 X-FRNT_EH (Receptacle) pin 355B AUX 1 RIGHT WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
K - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-352B-P-X 352D AUX 1 RIGHT ENABLE BR - 0.8
X-AUX_2_LEFT - AUX 2 LEFT [ A-EH_VLV] (87695582) (Receptacle)
87695582 12
87695582
1 X-FRNT_EH (Receptacle) pin 356B AUX 2 LEFT WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
L - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-357B-P-X 357C AUX 2 LEFT ENABLE BR - 0.8
X-AUX_2_RIGHT - AUX 2 RIGHT [ A-EH_VLV] (87695582) (Receptacle)
87695582 13
87695582
1 X-FRNT_EH (Receptacle) pin 360B AUX 2 RIGHT WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
N - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-357B-P-X 357D AUX 2 RIGHT ENABLE BR - 0.8
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X-A_RT - ARM REST RIGHT (87694112) (Receptacle)
87694112 14
87694112
5 SW-HN_RH_ARM-P-1 113D RH ARMREST HORN BR - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
SWITCH
X-A_RT3 - RIGHT ARM PILOT (87694152) (Plug)
87694152 15
87694152
1 X-A_RT_2B (Receptacle) pin 310A FORWARD REVERSE LB - 0.8 SHEET 23 SH23 - PILOT LOADER
11 - ARM REST RIGHT PILOT SIGNAL CONTROLS
2 (84281913)
2 SP-677H-P-X 677K 5V REF 3+ PK - 0.8
3 SP-967H-P-X 967K 5V REF3 GRND BL - 0.8
4 X-A_RT_2B (Receptacle) pin 311A FORWARD REVERSE WH - 0.8
12 - ARM REST RIGHT PILOT SIGNAL
2 (84281913)
5 SP-677H-P-X 677J 5V REF 3+ PK - 0.8
6 SP-967H-P-X 967J 5V REF3 GRND BL - 0.8
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X-A_RT_2A - ARM REST RIGHT PILOT 2 (84278761) (Plug)
84278761 16
84278761
X-A_RT_2B - ARM REST RIGHT PILOT 2 (84281913) (Receptacle)
84281913 17
84281913
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1 X-YPP (Plug) pin A - PILOT 344E PILOT ENABLE PILOT YE - 0.8 SHEET 23 SH23 - PILOT LOADER
PRESSURE SOLENOID CONTROLS
[Y-Y_PL] (87692855)
2 X-KDS (Plug) pin 2 - CAN 309B KICK DOWN SIGNAL YE - 0.8
(87311796)
2 X-P_JS (Plug) pin 6 - 309A KICK DOWN SIGNAL YE - 0.8
PILOT LOADER JOYSTICK
[SW-FNR] (87694152)
3 X-P_JS (Plug) pin 2 - 306A FOWARD SIGNAL WH - 0.8
[SW-FNR] (87694152)
4 X-P_JS (Plug) pin 3 - 307A NUETRAL SIGNAL YE - 0.8
[SW-FNR] (87694152)
5 X-P_JS (Plug) pin 4 - 308A REVERSE SIGNAL GY - 0.8
[SW-FNR] (87694152)
6 X-EM (Receptacle) pin 297A RTD DETENT WH - 0.8
3 - ELECTROMAGNETIC
DETENTS [Y-RTT DET]
(87694112)
7 X-EM (Receptacle) pin 298A HC DETENT WH - 0.8
2 - ELECTROMAGNETIC
DETENTS [Y-RTT DET]
(87694112)
8 X-EM (Receptacle) pin 299A RTT DETENT WH - 0.8
1 - ELECTROMAGNETIC
DETENTS [Y-RTT DET]
(87694112)
9 SP-677H-P-X 677H 5V REF 3+ PK - 0.8
10 SP-967H-P-X 967H 5V REF3 GRND BL - 0.8
11 X-A_RT3 (Plug) pin 1 - RIGHT 310A FORWARD REVERSE LB - 0.8
ARM PILOT (87694152) SIGNAL
12 X-A_RT3 (Plug) pin 4 - RIGHT 311A FORWARD REVERSE WH - 0.8
ARM PILOT (87694152) SIGNAL
X-A_RT_P - ARM REST RIGHT HAND PILOT (87694112) (Receptacle)
87694112 18
87694112
1 X-KDS (Plug) pin 4 - CAN 792H KICKDOWN SW PWR OR - 0.8 SHEET 23 SH23 - PILOT LOADER
(87311796) CONTROLS
1 X-P_JS (Plug) pin 1 - 792G IMP JOYSTICK IGN PWR OR - 0.8
[SW-FNR] (87694152)
2 SP-954U-P-X 954U CHASSIS GROUND BK - 1.0
5 X-HN (Plug) pin 2 - CAN 113E HORN BR - 0.8
[SW-HORN] (87311796)
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X-B4 - ALTERNATOR TO STARTER B+ (84401309) (Plug)
84401309 19
84401309
1 X-S244 (Plug) pin 1 - 20157 1990 AUX STEERING POWER RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
AUX STRG PWR RT ANGLE CABLE STARTER / KEY
CONN [SH21: D-3]
X-BAT-GND - BATTERY GROUND (84140737) (Plug)
84140737 20
84140737
1 X-563 (Plug) pin 1 - BATTERY CABLE-001 CABLE BATTERY BK - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
LUG [G-001] NEGATIVE STARTER / KEY
X-BEA - BEACON [ LMP-BEA_RT] (84015523) (Receptacle)
84015523 21
84015523
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1 X-ROOF (Receptacle) pin 3 - 851A ROTATING BEACON VT - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
ROOF TO CAB (87700325)
2 SP-953A-P-X 953B BEACON GND BK - 0.8
X-BOA - BOOM ANGLE SENSOR [ B-BM_ANG] (84403598) (Receptacle)
84403598 22
84403598
A SP-651D-P-X 651F 5V GND2 BL - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
B SP-471F-P-X 471G 5V REF2 PK - 0.8 CONTROL
C X-FRNT_EH (Receptacle) pin 647B BOOM ANGLE 1 YE - 0.8
S - FRONT TO BOTTOM EH
(87700170)
D X-FRNT_EH (Receptacle) pin 648B BOOM ANGLE 2 YE - 0.8
T - FRONT TO BOTTOM EH
(87700170)
E SP-570E-P-X 482X 5V GND1 BL - 0.8
F SP-486F-P-X 486K 5V REF1 PK - 0.8
X-BOOM_LOWER - BOOM LOWER SOLENOID [ A-EH_VLV] (87695582) (Receptacle)
87695582 23
87695582
1 X-FRNT_EH (Receptacle) pin 341B BOOM LOWER WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
D - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-339B-P-X 339D BOOM LOWER ENABLE BR - 0.8
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X-BOOM_RAISE - BOOM RAISE SOLENOID [ A-EH_VLV] (87695582) (Receptacle)
87695582 24
87695582
1 X-FRNT_EH (Receptacle) pin 340B BOOM RAISE WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
B - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-339B-P-X 339C BOOM RAISE ENABLE BR - 0.8
X-BPP - BRAKE PEDAL ANGLE [ B-BPP] (87710588) (Plug)
87710588 25
87710588
X-BTM - BOTTOM TO CAB STD (87704523) (Receptacle)
87704523 26
87704523
3 SP-651A-P-X 651A 5V GND2 BL - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
4 SP-471C-P-X 471C 5V REF2 PK - 0.8 CONTROL
5 X-BTM_F (Plug) pin P - 366A RIDE CONTROL SIG WH - 0.8
BOTTOM TO FRONT STD
(87696087)
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6 X-PBW (Receptacle) pin C - 640A BRAKE SUPPLY PRESS YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
BRAKE SUPPLY WARNING INSTRUMENTATION
PRES [B-PBW] (84078681)
7 X-PLB-PBD (Receptacle) pin 641A BRAKE PRESS SENSOR YE - 0.8
C - BRAKE PRES SENSR
[B-PBL/PEDAL/DECLTCH]
(84078681)
8 SP-486D-P-X 486D 5V REF1 PK - 0.8
9 X-BTM_F (Plug) pin S - 368A COUPLER VALVE RTRN BR - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
BOTTOM TO FRONT STD CONTROL
(87696087)
10 SP-482H-P-X 482H 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
11 X-BTS (Receptacle) pin 4 176A AUX STRG PRESS YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
- BOTTOM TO SEC STRG SIGNAL
[SH19: A-1] (87694112)
12 X-BTS (Receptacle) pin 1 441A SEC STRG SOL PWR OR - 0.8
- BOTTOM TO SEC STRG
[SH19: A-1] (87694112)
13 X-BTM_F (Plug) pin U - 291A ROLL BACK PRESSURE YE - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
BOTTOM TO FRONT STD SW CONTROL
(87696087)
14 X-BTM_F (Plug) pin R - 367A COUPLER VALVE SIG WH - 0.8
BOTTOM TO FRONT STD
(87696087)
15 X-BPP pin 3 - BRAKE PEDAL 402A BRAKE PEDAL ANGLE YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
ANGLE [B-BPP] (87710588) / FAN CONTROL
17 X-BTM_F (Plug) pin A - 687A FRONT AXLE TEMP YE - 0.8
BOTTOM TO FRONT STD
(87696087)
18 X-YPB (Receptacle) pin 1 388A PARK BRAKE SOL WH - 0.8
- VALVE PARKING BRAKE
[Y-Y_PB] (87695582)
19 X-YPB (Receptacle) pin 2 389A PARK BRAKE SOL BK - 0.8
- VALVE PARKING BRAKE
[Y-Y_PB] (87695582)
20 X-BTM_F (Plug) pin C - 132D LH HIGH BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
BOTTOM TO FRONT STD WARNING, BLINKERS, DRIVING
(87696087)
21 X-BTM_F (Plug) pin T - 112A HORN YE - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
BOTTOM TO FRONT STD
(87696087)
22 X-BTM_F (Plug) pin F - 133A LH LOW BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
BOTTOM TO FRONT STD WARNING, BLINKERS, DRIVING
(87696087)
23 X-BTM_F (Plug) pin H - 127B LH POSITION VT - 0.8
BOTTOM TO FRONT STD
(87696087)
24 X-BTM_F (Plug) pin J - 136B LH FRONT TURN VT - 0.8
BOTTOM TO FRONT STD
(87696087)
25 X-BTM_F (Plug) pin K - 137A RH HIGH BEAM LAMP VT - 0.8
BOTTOM TO FRONT STD
(87696087)
26 X-BTM_F (Plug) pin L - 138A RH LOW BEAM LAMP VT - 0.8
BOTTOM TO FRONT STD
(87696087)
27 X-BTM_F (Plug) pin M - 130E RH POSITION VT - 0.8
BOTTOM TO FRONT STD
(87696087)
28 X-BTM_F (Plug) pin N - 135D RH FRONT TURN VT - 0.8
BOTTOM TO FRONT STD
(87696087)
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X-BTM_EH - BOTTOM TO CAB EH (84281075) (Receptacle)
84281075 27
84281075
A X-BTM_FEH (Plug) pin A 344A PILOT ENABLE WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- BOTTOM TO FRONT EH CONTROL
(87700160)
B X-BTM_FEH (Plug) pin B 340A BOOM RAISE WH - 0.8
- BOTTOM TO FRONT EH
(87700160)
C X-BTM_FEH (Plug) pin C 339A BOOM ENABLE BR - 0.8
(87700160)
D X-BTM_FEH (Plug) pin D 341A BOOM LOWER WH - 0.8
(87700160)
E X-BTM_FEH (Plug) pin E 346A BUCKET ROLL WH - 0.8
(87700160)
F X-BTM_FEH (Plug) pin F 347A BUCKET ENABLE BR - 0.8
(87700160)
G X-BTM_FEH (Plug) pin G 350A BUCKET DUMP WH - 0.8
(87700160)
H X-BTM_FEH (Plug) pin H 351A AUX 1 LEFT WH - 0.8
(87700160)
J X-BTM_FEH (Plug) pin J 352A AUX 1 ENABLE BR - 0.8
(87700160)
K X-BTM_FEH (Plug) pin K 355A AUX 1 RIGHT WH - 0.8
(87700160)
L X-BTM_FEH (Plug) pin L 356A AUX 2 LEFT WH - 0.8
(87700160)
M X-BTM_FEH (Plug) pin M 357A AUX 2 ENABLE BR - 0.8
(87700160)
N X-BTM_FEH (Plug) pin N 360A AUX 2 RIGHT WH - 0.8
(87700160)
S X-BTM_FEH (Plug) pin S 647A BOOM ANGLE 1 YE - 0.8
(87700160)
T X-BTM_FEH (Plug) pin T 648A BOOM ANGLE 2 YE - 0.8
(87700160)
W X-BTM_FEH (Plug) pin W 653A BUCKET ANGLE 1 YE - 0.8
(87700160)
X X-BTM_FEH (Plug) pin X 654A BUCKET ANGLE 2 YE - 0.8
(87700160)
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X-BTM_F - BOTTOM TO FRONT STD (87696087) (Plug)
87696087 28
87696087
A X-BTM (Receptacle) pin 17 687A FRONT AXLE TEMP YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- BOTTOM TO CAB STD / FAN CONTROL
(87704523)
C X-BTM (Receptacle) pin 20 132D LH HIGH BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
- BOTTOM TO CAB STD WARNING, BLINKERS, DRIVING
(87704523)
F X-BTM (Receptacle) pin 22 133A LH LOW BEAM LAMP VT - 0.8
- BOTTOM TO CAB STD
(87704523)
H X-BTM (Receptacle) pin 23 127B LH POSITION VT - 0.8
- BOTTOM TO CAB STD
(87704523)
J X-BTM (Receptacle) pin 24 136B LH FRONT TURN VT - 0.8
- BOTTOM TO CAB STD
(87704523)
K X-BTM (Receptacle) pin 25 137A RH HIGH BEAM LAMP VT - 0.8
- BOTTOM TO CAB STD
(87704523)
L X-BTM (Receptacle) pin 26 138A RH LOW BEAM LAMP VT - 0.8
- BOTTOM TO CAB STD
(87704523)
M X-BTM (Receptacle) pin 27 130E RH POSITION VT - 0.8
- BOTTOM TO CAB STD
(87704523)
N X-BTM (Receptacle) pin 28 135D RH FRONT TURN VT - 0.8
- BOTTOM TO CAB STD
(87704523)
P X-BTM (Receptacle) pin 5 366A RIDE CONTROL SIG WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- BOTTOM TO CAB STD CONTROL
(87704523)
R X-BTM (Receptacle) pin 14 367A COUPLER VALVE SIG WH - 0.8
- BOTTOM TO CAB STD
(87704523)
S X-BTM (Receptacle) pin 9 368A COUPLER VALVE RTRN BR - 0.8
- BOTTOM TO CAB STD
(87704523)
T X-BTM (Receptacle) pin 21 112A HORN YE - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
- BOTTOM TO CAB STD
(87704523)
U X-BTM (Receptacle) pin 13 291A ROLL BACK PRESSURE YE - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- BOTTOM TO CAB STD SW CONTROL
(87704523)
V SP-651A-P-X 651C 5V GND2 BL - 0.8
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X-BTM_FEH - BOTTOM TO FRONT EH (87700160) (Plug)
87700160 29
87700160
A X-BTM_EH (Receptacle) pin 344A PILOT ENABLE WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
A - BOTTOM TO CAB EH CONTROL
(84281075)
B X-BTM_EH (Receptacle) pin 340A BOOM RAISE WH - 0.8
B - BOTTOM TO CAB EH
(84281075)
C X-BTM_EH (Receptacle) pin 339A BOOM ENABLE BR - 0.8
C - BOTTOM TO CAB EH
(84281075)
D X-BTM_EH (Receptacle) pin 341A BOOM LOWER WH - 0.8
D - BOTTOM TO CAB EH
(84281075)
E X-BTM_EH (Receptacle) pin 346A BUCKET ROLL WH - 0.8
E - BOTTOM TO CAB EH
(84281075)
F X-BTM_EH (Receptacle) pin 347A BUCKET ENABLE BR - 0.8
F - BOTTOM TO CAB EH
(84281075)
G X-BTM_EH (Receptacle) pin 350A BUCKET DUMP WH - 0.8
G - BOTTOM TO CAB EH
(84281075)
H X-BTM_EH (Receptacle) pin 351A AUX 1 LEFT WH - 0.8
H - BOTTOM TO CAB EH
(84281075)
J X-BTM_EH (Receptacle) pin 352A AUX 1 ENABLE BR - 0.8
J - BOTTOM TO CAB EH
(84281075)
K X-BTM_EH (Receptacle) pin 355A AUX 1 RIGHT WH - 0.8
K - BOTTOM TO CAB EH
(84281075)
L X-BTM_EH (Receptacle) pin 356A AUX 2 LEFT WH - 0.8
L - BOTTOM TO CAB EH
(84281075)
M X-BTM_EH (Receptacle) pin 357A AUX 2 ENABLE BR - 0.8
M - BOTTOM TO CAB EH
(84281075)
N X-BTM_EH (Receptacle) pin 360A AUX 2 RIGHT WH - 0.8
N - BOTTOM TO CAB EH
(84281075)
P SP-482H-P-X 482J 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
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Q SP-486D-P-X 486E 5V REF1 PK - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
S X-BTM_EH (Receptacle) pin 647A BOOM ANGLE 1 YE - 0.8 CONTROL
S - BOTTOM TO CAB EH
(84281075)
T X-BTM_EH (Receptacle) pin 648A BOOM ANGLE 2 YE - 0.8
T - BOTTOM TO CAB EH
(84281075)
V SP-471C-P-X 471D 5V REF2 PK - 0.8
W X-BTM_EH (Receptacle) pin 653A BUCKET ANGLE 1 YE - 0.8
W - BOTTOM TO CAB EH
(84281075)
X X-BTM_EH (Receptacle) pin 654A BUCKET ANGLE 2 YE - 0.8
X - BOTTOM TO CAB EH
(84281075)
X-BTS - BOTTOM TO SEC STRG [ SH19: A-1] (87694112) (Receptacle)
87694112 30
87694112
1 X-BTM (Receptacle) pin 12 441A SEC STRG SOL PWR OR - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
- BOTTOM TO CAB STD
(87704523)
2 SP-486D-P-X 486U 5V PWR REF 1 PK - 0.8
3 SP-482H-P-X 482F 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
4 X-BTM (Receptacle) pin 11 176A AUX STRG PRESS YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
- BOTTOM TO CAB STD SIGNAL
(87704523)
X-BU1 - BACK UP ALARM [ H-BU_ALRM] (84426117) (Plug)
84426117 31
84426117
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1 X-GND_ENG4 (Plug) pin 1 - 244 BACKUP ALARM GND BK - 0.8 SHEET 15 SH15 - POWER DISTRIBUTION 4
GROUND ENG BLOCK [SH29: ENGINE GROUND BLK
B-3] (84140737)
1 SP-242A-P-X 242F BACKUP ALARM GRND BK - 0.8
PL23 NA
X-BU2 - BACK UP ALARM [ H-BU_ALRM] (84426117) (Plug)
84426117 32
84426117
1 X-ENG (Plug) pin 7 - 121A BACKUP ALARM OR - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
ENGINE TO CAB [SH18: ALARM
C-6] (87696948)
1 X-HD_23 (Receptacle) pin 1 - 121C BACKUP ALARM PL23 OR - 0.8
HOOD PL23 (87694153)
X-BUA - BUCKET ANGLE SENSOR [ B-BKT_ANG] (84403598) (Receptacle)
84403598 33
84403598
A SP-651D-P-X 651E 5V GND2 BL - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
B SP-471F-P-X 471H 5V REF2 PK - 0.8 CONTROL
C X-FRNT_EH (Receptacle) pin 653B BUCKET ANGLE 1 YE - 0.8
W - FRONT TO BOTTOM EH
(87700170)
D X-FRNT_EH (Receptacle) pin 654B BUCKET ANGLE 2 YE - 0.8
X - FRONT TO BOTTOM EH
(87700170)
E SP-570E-P-X 482W 5V GND1 BL - 0.8
F SP-486F-P-X 486L 5V REF1 PK - 0.8
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X-BUCKET_DUMP - BUCKET DUMP SOLENOID [ A-EH_VLV] (87695582) (Receptacle)
87695582 34
87695582
1 X-FRNT_EH (Receptacle) pin 350B BUCKET DUMP WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
G - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-347B-P-X 347D BUCKET DUMP ENABLE BR - 0.8
X-BUCKET_ROLL - BUCKET ROLL SOLENOID [ A-EH_VLV] (87695582) (Receptacle)
87695582 35
87695582
1 X-FRNT_EH (Receptacle) pin 346B BUCKET ROLL WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
E - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-347B-P-X 347C BUCKET ROLL ENABLE BR - 0.8
X-CAB_AR - CAB TO RH ARM REST (87694152) (Plug)
87694152 36
87694152
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1 X-LC5 (Receptacle) pin 6A - 792 IMP JOYSTICK PWR OR - 0.8 SHEET 24 SH24 - CAN STRUCTURE
LOADCENTER 5 [SH10: D-1]
(87733595)
2 X-CG4 (Receptacle) pin K - 954K RH ARMREST JOYSTICK BK - 1.0
CAB GROUND [SH24: B-6] GND
(84149207)
3 SP-B_HJ-P-X CANB_HI CAN WH - 0.8
4 SP-B_LJ-P-X CANB_LI CAN BL - 0.8
5 SP-113-P-X 113C RH ARMREST HORN BR - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
SWITCH
X-CAB_B - CAB TO BOTTOM [ SH21: B-3] (87696945) (Plug)
87696945 37
87696945
3 SP-651-P-X 651J 5V GND2 BL - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
4 SP-471-P-X 471A 5V REF2 PK - 0.8 CONTROL
5 X-UCM3B (Receptacle) pin 6 366 RIDE CONTROL SIG WH - 0.8
- UCM [A-UCM] (84130760)
6 X-UCM1A (Receptacle) pin 640 BRAKE SUPPLY PRESS YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
10 - UCM (82016219) INSTRUMENTATION
7 X-UCM1B (Receptacle) pin 20 641 BRAKE PRESSURE YE - 0.8
- UCM [SH22: A-6] (87410946)
8 SP-486-P-X 486A 5V PWR REF 1 PK - 0.8
9 X-UCM3B (Receptacle) pin 4 368 COUPLER VALVE RTRN BR - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- UCM [A-UCM] (84130760) CONTROL
10 SP-482-P-X 482C 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
11 X-UCM1A (Receptacle) pin 8 176 AUX STRG PRESS YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
- UCM (82016219) SIGNAL
12 X-LC3 (Receptacle) pin 441 SEC STRG SOL PWR OR - 0.8 SHEET 08 SH08 - POWER DISTRIBUTION
R2_87 - LOADCENTER 3 (FUSE BLOCK LC3)
[SH35: B-6] (84529039)
13 X-UCM4B (Receptacle) pin 291 ROLL BACK PRESSURE YE - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
24 - UCM [A-UCM] (82028495) SW CONTROL
14 X-UCM3B (Receptacle) pin 7 367 COUPLER VALVE SIG WH - 0.8
- UCM [A-UCM] (84130760)
15 X-UCM1A (Receptacle) pin 402 BRAKE PEDAL ANGLE YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
16 - UCM (82016219) / FAN CONTROL
16 X-UCM1A (Receptacle) pin 5 3686 PARK BRAKE PRESS YE - 0.8
- UCM (82016219)
17 X-UCM4A (Receptacle) pin 687 FRONT AXLE TEMP YE - 0.8
17 - UCM (82028493)
18 X-UCM3B (Receptacle) pin 388 PARK BRAKE SOL WH - 0.8
27 - UCM [A-UCM] (84130760)
19 X-UCM1A (Receptacle) pin 389 PARK BRAKE SOL WH - 0.8
22 - UCM (82016219)
20 SP-132-P-X 132A LH HIGH BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
WARNING, BLINKERS, DRIVING
21 X-LC3 (Receptacle) pin 112 HORN YE - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
R4_87 - LOADCENTER 3
[SH35: B-6] (84529039)
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22 X-X5 (Receptacle) pin 21 - 133 LH LOW BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
SFB [SH3: D-3] (47554342) WARNING, BLINKERS, DRIVING
23 SP-127-P-X 127A LH POSITION VT - 0.8
24 X-X4 (Receptacle) pin 12 - 136 LH FRONT TURN VT - 0.8
SFB (47554343)
25 X-X4 (Receptacle) pin 10 - 137 RH HIGH BEAM LAMP VT - 0.8
SFB (47554343)
26 X-X5 (Receptacle) pin 13 - 138 RH LOW BEAM LAMP VT - 0.8
SFB [SH3: D-3] (47554342)
27 SP-130-P-X 130D RH POSITION VT - 0.8
28 X-X5 (Receptacle) pin 15 - 135 RH FRONT TURN VT - 0.8
SFB [SH3: D-3] (47554342)
X-CAB_E - CAB TO ENGINE [ SH7: B-5] (84807216) (Receptacle)
84807216 38
84807216
1 X-LC5 (Receptacle) pin 9A - 850 IGN PWR FOR REAR OR - 2.0 SHEET 11 SH11 - PWR DISTR ENG
LOADCENTER 5 [SH10: D-1] COMPARTMENT (FUSE BLOCK LC6)
(87733595)
2 X-LC2 (Receptacle) pin 9A - 205 HOOD LIFT RD - 2.0 SHEET 37 SH37 - HOOD LIFT
LOADCENTER 2 [SH7: B-3]
(87733581)
3 X-SP_PK_CLN (Receptacle) 857 CLEAN GROUND BK - 2.0 SHEET 12 SH12 - POWER DISTRIBUTION 1
pin X - SPLICE PACK CLEAN CLEAN GROUND BLK
GRND [SH25: C-1] (87352746)
4 X-LC2 (Receptacle) pin 9B - 216E HOOD LIFT NON-DISC RD - 2.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
LOADCENTER 2 [SH7: B-3] PWR STARTER / KEY
(87733581)
5 X-UCM4A (Receptacle) pin 433 COOLANT TEMP YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
6 X-X4 (Receptacle) pin 9 - SFB 131 RH REAR TURN LAMP VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
(47554343)
7 X-X4 (Receptacle) pin 21 - 121 BACKUP ALARM OR - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
SFB (47554343) ALARM
8 X-UCM4A (Receptacle) pin 633 FUEL LEVEL YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
9 SP-482-P-X 482G 5V GRND1 BL - 0.8
10 X-X6 (Receptacle) pin 2 - SFB 126 LH BRAKE LAMP VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
[A-SFB] (47554341)
11 SP-130-P-X 130A RH TAIL LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
12 SP-127-P-X 127D LH TAIL LAMP VT - 0.8 WARNING, BLINKERS, DRIVING
13 SP-LA-P-X CAN_LA CAN GN - 0.8 SHEET 24 SH24 - CAN STRUCTURE
14 SP-HA-P-X CAN_HA CAN YE - 0.8
15 X-UCM3A (Receptacle) pin 5 663 OK TO START YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- UCM (84130757) / FAN CONTROL
16 X-UCM4B (Receptacle) pin 400 FAN SPEED SENSOR YE - 0.8
30 - UCM [A-UCM] (82028495) SGNL
17 X-X7 (Receptacle) pin 67 - 239A ALT LAMP SIGNAL YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
SFB [SH3: A-3] (84538791) STARTER / KEY
18 X-UCM2A (Receptacle) pin 319 AIR FILTER REST SW T2 YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
17 - UCM (82028493) / FAN CONTROL
19 SP-124-P-X 124A REVERSE LIGHTS VT - 0.8 SHEET 39 SH39 - MISCELLANOUS, REAR
CAMERA
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20 X-DIA (Plug) pin E - 303 ISO K LINE WH - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
DIAGNOSTIC PORT [A-DIA] 1, GRID HEATER, FILTER HEATER
(87736919)
21 X-X3 (Receptacle) pin 12 - 129 LH BRAKE LAMP VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
SFB [SH3: A-1] (47554344)
22 X-X5 (Receptacle) pin 18 - 128 LH REAR TURN LAMP VT - 0.8
SFB [SH3: D-3] (47554342)
25 X-X3 (Receptacle) pin 17 - 280 LICENSE PLATE LIGHT VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
SFB [SH3: A-1] (47554344) LIGHTS
26 X-X5 (Receptacle) pin 4 - SFB 228A ALTERNATOR VOLTAGE RD - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
[SH3: D-3] (47554342) STARTER / KEY
28 SP-677-P-X 677L FSS PWR PK - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
/ FAN CONTROL
X-CAB_E-2 - CAB TO ENG 2 [ SH9: C-2] (87703902) (Plug)
87703902 39
87703902
A X-THRTL (Receptacle) pin 409 THROTTLE PEDAL YE - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
A - THROTTLE CONTROL POSITION 1, GRID HEATER, FILTER HEATER
[B-ACCEL] (84403598)
B X-THRTL (Receptacle) pin 471B 5V REF2 PK - 0.8
C - THROTTLE CONTROL
[B-ACCEL] (84403598)
C X-THRTL (Receptacle) pin 651H 5V GND2 BL - 0.8
B - THROTTLE CONTROL
[B-ACCEL] (84403598)
D X-THRTL (Receptacle) pin 408 THROTTLE IDLE SW WH - 0.8
D - THROTTLE CONTROL
[B-ACCEL] (84403598)
E X-THRTL (Receptacle) pin 643C THROTTLE GRND BK - 0.8
F - THROTTLE CONTROL
[B-ACCEL] (84403598)
F X-X4 (Receptacle) pin 17 - 250 ISOLATOR SET YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
SFB (47554343) STARTER / KEY
G X-X7 (Receptacle) pin 8 - SFB 237 ISOLATOR RESET YE - 0.8
[SH3: A-3] (84538791)
H X-X_TEL (Receptacle) pin 12 217A TELE NON- RD - 0.8
- TELEMATICS [SH38: C-6] DISCONNECTED PWR
(87700156)
J SP-219A-P-X 219A NON ISOLATED PWR RD - 0.8
K X-LC4 (Receptacle) pin 3A - 875 AC CLUTCH PWR OR - 1.0 SHEET 11 SH11 - PWR DISTR ENG
LOADCENTER 4 [SH35: C-6] COMPARTMENT (FUSE BLOCK LC6)
(87733595)
L X-HVAC (Receptacle) pin 246 SIG_HVAC_A/C HIGH YE - 0.8 SHEET 33 SH33 - HEATING BLOWER
B - INTRCECT TO HVAC PRESSURE SW HEATER, HVAC
D-4] (87696573)
M X-UCM2A (Receptacle) pin 582 HEAT LOAD VALVE BR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
22 - UCM (82028493) SIGNAL / FAN CONTROL
N X-UCM2A (Receptacle) pin 692 FAN REVERSER SGNL BR - 0.8
21 - UCM (82028493)
P X-UCM2A (Receptacle) pin 392 FAN CONTROL SGNL YE - 0.8
25 - UCM (82028493)
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X-CAB_EH - CAB TO BOTTOM EH (87700159) (Plug)
87700159 40
87700159
A X-UCM3B (Receptacle) pin 344 PILOT ENABLE WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
18 - UCM [A-UCM] (84130760) CONTROL
B X-UCM4A (Receptacle) pin 7 340 BOOM RAISE WH - 0.8
- UCM (82028493)
C X-UCM1B (Receptacle) pin 2 339 BOOM ENABLE BR - 0.8
- UCM [SH22: A-6] (87410946)
D X-UCM4A (Receptacle) pin 6 341 BOOM LOWER WH - 0.8
- UCM (82028493)
E X-UCM3B (Receptacle) pin 346 BUCKET ROLL WH - 0.8
17 - UCM [A-UCM] (84130760)
F X-UCM1B (Receptacle) pin 30 347 BUCKET ENABLE BR - 0.8
- UCM [SH22: A-6] (87410946)
G X-UCM3B (Receptacle) pin 350 BUCKET DUMP WH - 0.8
25 - UCM [A-UCM] (84130760)
H X-UCM3B (Receptacle) pin 351 AUX 1 LEFT WH - 0.8
32 - UCM [A-UCM] (84130760)
J X-UCM1B (Receptacle) pin 10 352 AUX 1 ENABLE BR - 0.8
- UCM [SH22: A-6] (87410946)
K X-UCM3B (Receptacle) pin 355 AUX 1 RIGHT WH - 0.8
33 - UCM [A-UCM] (84130760)
L X-UCM4A (Receptacle) pin 356 AUX 2 LEFT WH - 0.8
19 - UCM (82028493)
M X-UCM1A (Receptacle) pin 357 AUX 2 ENABLE BR - 0.8
21 - UCM (82016219)
N X-UCM4A (Receptacle) pin 360 AUX 2 RIGHT WH - 0.8
13 - UCM (82028493)
S X-UCM1B (Receptacle) pin 19 647 BOOM ANGLE 1 YE - 0.8
- UCM [SH22: A-6] (87410946)
T X-UCM1B (Receptacle) pin 22 648 BOOM ANGLE 2 YE - 0.8
- UCM [SH22: A-6] (87410946)
W X-UCM1B (Receptacle) pin 21 653 BUCKET ANGLE 1 YE - 0.8
- UCM [SH22: A-6] (87410946)
X X-UCM1B (Receptacle) pin 23 654 BUCKET ANGLE 2 YE - 0.8
- UCM [SH22: A-6] (87410946)
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X-CAB_JSS - CAB TO JSS FRAME HARNESS [ SH24: A-6] (87694112) (Receptacle)
87694112 41
87694112
1 SP-799-P-X 799A JSS PILOT DUMP OR - 0.8 SHEET 10 SH10 - IGNITION PWR DISTR
(FUSE BLOCK LC5)
2 X-UCM3A (Receptacle) pin 676 JSS PILOT PRESS SIG YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
12 - UCM (84130757)
3 SP-677-P-X 677 5V REF3 OUT PK - 0.8
5 X-CG4 (Receptacle) pin B - 955X JSS GROUND BK - 0.8
CAB GROUND [SH24: B-6]
(84149207)
6 X-UCM3B (Receptacle) pin 273 JSS CUTOFF SIG B YE - 0.8
15 - UCM [A-UCM] (84130760)
X-CAB_L - CAB TO JSS L ARMREST (87700156) (Receptacle)
87700156 42
87700156
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1 SP-471-P-X 471J 5V REF2 PK - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
2 X-UCM2A (Receptacle) pin 670 JSS JOYSTICK 1 YE - 0.8
18 - UCM (82028493)
3 SP-651-P-X 651L 5V GND2 BL - 0.8
4 X-UCM2B (Receptacle) pin 675 LH ARMREST POSITION GY - 0.8
12 - UCM [A-UCM] (82028495) UP
5 X-UCM2A (Receptacle) pin 630 JSS JOYSTICK 2 YE - 0.8
12 - UCM (82028493)
6 SP-967-P-X 967C 5 V REF GRND3 BL - 0.8
7 SP-677-P-X 677C 5V REF3 OUT PK - 0.8
8 X-UCM2B (Receptacle) pin 673 LH ARMREST POSITION TN - 0.8
20 - UCM [A-UCM] (82028495) DWN
9 X-UCM3B (Receptacle) pin 678 JSS ACTIVATION WH - 0.8
16 - UCM [A-UCM] (84130760)
10 SP-799-P-X 799B JSS IGNITION POWER OR - 0.8
11 X-CG4 (Receptacle) pin J - 954J LH JSS GND BK - 0.8
(84149207)
12 X-UCM3B (Receptacle) pin 682 JSS ACTIVATION NC YE - 0.8
23 - UCM [A-UCM] (84130760)
X-CAB_L2 - CAB TO LEFT JSS (87696138) (Receptacle)
87696138 43
87696138
1 X-UCM4B (Receptacle) pin 691 JSS INDICATOR WH - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
16 - UCM [A-UCM] (82028495)
2 SP-981-P-X 981J BACKLIGHTING VT - 0.8
X-CAB_P - CAB TO PEDESTAL [ SH20: D-2] (87700155) (Plug)
87700155 44
87700155
2 X-X5 (Receptacle) pin 16 - 189 RH TURN INDICATOR VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
SFB [SH3: D-3] (47554342) WARNING, BLINKERS, DRIVING
3 SP-132-P-X 132C LH HIGH BEAM LAMP VT - 0.8
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4 SP-113-P-X 113A RH STALK HORN BR - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
SWITCH
5 X-UCM4B (Receptacle) pin 9 134 WARNING INDICATOR YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- UCM [A-UCM] (82028495) LED / FAN CONTROL
6 X-X7 (Receptacle) pin 28 - 141 HAZARD SWITCH YE - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
SFB [SH3: A-3] (84538791) WARNING, BLINKERS, DRIVING
7 X-CG4 (Receptacle) pin D - 954D PEDESTAL GND BK - 1.0
(84149207)
8 X-X3 (Receptacle) pin 16 - 269A HAZARD INDICATOR BK - 0.8
SFB [SH3: A-1] (47554344) LIGHT
9 SP-19H-P-X 19J IGN PWR OR - 0.8 SHEET 24 SH24 - CAN STRUCTURE
10 SP-HL-P-X CAN_HN CAN YE - 0.8
11 SP-LL-P-X CAN_LN CAN GN - 0.8
X-CAB_P2 - CAB TO PEDESTAL 2 [ SH27: B-2] (87705101) (Receptacle)
87705101 45
87705101
1 X-UCM2A (Receptacle) pin 679 STALK FNR R YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
11 - UCM (82028493) / FAN CONTROL
2 X-UCM2A (Receptacle) pin 680 STALK FNR N YE - 0.8
16 - UCM (82028493)
3 X-UCM2A (Receptacle) pin 686 STALK FNR F YE - 0.8
10 - UCM (82028493)
5 X-UCM2B (Receptacle) pin 407 GEAR SELECT 3_4 YE - 0.8
21 - UCM [A-UCM] (82028495)
6 SP-19C-P-X 19D IGN PWR OR - 0.8
8 X-X7 (Receptacle) pin 56 - 728 REAR WASHER SWITCH YE - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
SFB [SH3: A-3] (84538791)
9 X-X7 (Receptacle) pin 55 - 727 REAR WIPER SWITCH YE - 0.8
SFB [SH3: A-3] (84538791)
11 X-X4 (Receptacle) pin 3 - SFB 283 REAR WIPER INDICATOR VT - 0.8
(47554343)
12 SP-981-P-X 981D SWITCH BACK LIGHTING VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
LIGHTS
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X-CAB_R - CAB TO ROOF (87695891) (Plug)
87695891 46
87695891
1 X-X3 (Receptacle) pin 2 - SFB 111 LEFT FRONT WORK VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
[SH3: A-1] (47554344) LIGHT LIGHTS CAB ROOF, FRONT AND REAR
2 X-X3 (Receptacle) pin 1 - SFB 724 RIGHT FRONT WORK VT - 1.0
[SH3: A-1] (47554344) LIGHT
3 X-X3 (Receptacle) pin 3 - SFB 851 ROTATING BEACON VT - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
[SH3: A-1] (47554344)
4 X-X5 (Receptacle) pin 6 - SFB 114 MIRROR HEAT SUPPLY TN - 1.0
[SH3: D-3] (47554342)
5 X-X4 (Receptacle) pin 19 - 859 REAR WORK LIGHTS VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
SFB (47554343) LIGHTS CAB ROOF, FRONT AND REAR
7 CG1-P-1 CAB GROUND RH 953 ROOF GND BK - 2.0
HEADLINER
X-CAB_TR - CAB TO TRANSMISSION [ SH26: A-2] (87696944) (Receptacle)
87696944 47
87696944
1 X-UCM1A (Receptacle) pin 443 BRAKE ACCUMULATOR YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
15 - UCM (82016219) PRSR INSTRUMENTATION
2 SP-702A-P-X 702E SPEED SENSOR GRND BL - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
3 SP-482-P-X 482B 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
4 X-X6 (Receptacle) pin 9 - SFB 106 REAR WASHER MOTOR OR - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
[A-SFB] (47554341)
5 X-TECM (Receptacle) pin 842 VALVE BODY TEMP SIG YE - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
39 - TRANS CONTROLLER
[SH25: C-6] (84550089)
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7 X-TECM (Receptacle) pin 699 ENG SPEED SENSOR YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
[SH25: C-6] (84550089)
8 X-TECM (Receptacle) pin 700 TURBINE SPEED YE - 0.8
41 - TRANS CONTROLLER SENSOR
[SH25: C-6] (84550089)
9 X-TECM (Receptacle) pin 701 INTERMEDIATE SPEED YE - 0.8
[SH25: C-6] (84550089)
10 X-TECM (Receptacle) pin 578A OUTPUT SPEED YE - 0.8
[SH25: C-6] (84550089)
11 SP-702A-P-X 702A SPEED SENSOR GRND BL - 0.8
12 X-TECM (Receptacle) pin 697 TRANS SIGNL RETURN BL - 0.8
[SH25: C-6] (84550089)
13 X-TECM (Receptacle) pin 425 GEAR OIL TEMP YE - 0.8
[SH25: C-6] (84550089)
14 SP-702A-P-X 702F SPEED SENSOR GRND BL - 0.8
15 X-TECM (Receptacle) pin 419 TRANS LOCKUP BR - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
50 - TRANS CONTROLLER SOLENOID
[SH25: C-6] (84550089)
16 X-TECM (Receptacle) pin 834 K4 CLUTCH TN - 0.8
[SH25: C-6] (84550089)
17 X-TECM (Receptacle) pin 836 KR CLUTCH TN - 0.8
[SH25: C-6] (84550089)
[SH25: C-6] (84550089)
[SH25: C-6] (84550089)
20 X-TECM (Receptacle) pin 839 KV CLUTCH TN - 0.8
[SH25: C-6] (84550089)
22 SP-841-P-X 841A TRANS OUTPUT SW WH - 0.8
PWR VPS1
23 X-UCM3A (Receptacle) pin 636 HYD FILTER YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
24 X-UCM1A (Receptacle) pin 638 RED BRAKE SW SIG YE - 0.8
17 - UCM (82016219)
25 SP-420C-P-X 420C TECM POWER WH - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
26 SP-486-P-X 486B 5V PWR REF 1 PK - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
27 X-UCM3B (Receptacle) pin 1 390 DIFF LOCK SIGNAL WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- UCM [A-UCM] (84130760) / FAN CONTROL
28 X-TECM (Receptacle) pin 703 OUTPUT SPEED BL - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
[SH25: C-6] (84550089)
29 SP-19C-P-X 19G OUTPUT SP SENS IGN OR - 0.8 SHEET 10 SH10 - IGNITION PWR DISTR
PWR (FUSE BLOCK LC5)
30 X-UCM4A (Receptacle) pin 634 HYD OIL TEMP SIG YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
31 X-TECM (Receptacle) pin 423 FILTER MAINTENANCE WH - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
17 - TRANS CONTROLLER SIGNAL
[SH25: C-6] (84550089)
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X-CAM - REAR CAMERA (87700107) (Receptacle)
87700107 48
87700107
1 X-LC2 (Receptacle) pin 11A 125 REVERSE CAMERA OR - 0.8 SHEET 39 SH39 - MISCELLANOUS, REAR
- LOADCENTER 2 [SH7: B-3] POWER CAMERA
(87733581)
2 X-CG3 (Receptacle) pin 955AD CAMERA MONITOR BK - 0.8
D - CAB GROUND RH GROUND
(84149207)
3 SP-124-P-X 124B REVERSE SIGNAL VT - 0.8
X-CAM2 - CAMERA CHORD (87700106) (Plug)
87700106 49
87700106
X-CAN - CAN (87696093) (Receptacle)
87696093 50
87696093
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1 X-ECU (Receptacle) pin 71 - 671 CAN HI PROTO ONLY YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
ECU CONNECTOR [A-ECU] 3, AT
(84300197)
2 X-ECU (Receptacle) pin 95 - 695 CAN LO PROTO ONLY GN - 0.8
(84300197)
X-CG3 - CAB GROUND RH HEADLINER [ SH13: D-5] (84149207) (Receptacle)
84149207 51
84149207
A X-S_RDF (Receptacle) pin 9 955A REAR DEFROST SWITCH BK - 0.8 SHEET 13 SH13 - POWER DISTRIBUTION 2
- SWITCH REAR DEFROST IND GND CAB GROUND BLK
[SW-R_DEF_SW] (87716755)
B X-S_HMR (Receptacle) pin 9 955J MIRROR HEATER BK - 0.8
- SWITCH HEATED MIRRORS INDICATOR GND
[SH13: D-4] (87716755)
C X-S_HMR (Receptacle) pin 2 955K MIRROR HEATER SW BK - 0.8
- SWITCH HEATED MIRRORS GND
[SH13: D-4] (87716755)
D X-CAM (Receptacle) pin 2 - 955AD CAMERA MONITOR BK - 0.8
REAR CAMERA (87700107) GROUND
F X-S_RDF (Receptacle) pin 2 955R REAR DEFROST SWITCH BK - 0.8
- SWITCH REAR DEFROST GND
[SW-R_DEF_SW] (87716755)
H X-DM_G (Receptacle) pin 955N MAP LIGHT GND BK - 0.8
1 - DOME LIGHT GROUND
[LMP-DM] (87688695)
J X-DS (Receptacle) pin 2 - 955P LH DOOR AJAR SW GND BK - 0.8
DOOR SWITCH [SH27: C-6]
(87382906)
K X-MAP (Receptacle) pin C 955Q MAP LIGHT GND BK - 0.8
- MAP LIGHT [SH13: C-6]
(84058093)
L X-RWM_G (Plug) pin A - 955V REAR WIPER MOTOR BK - 1.0
REAR WIPER MOTOR GRND GND
[SH13: C-2] (87693744)
M X-S_HMR (Receptacle) pin 7 954B CAB GRND BK - 0.8
- SWITCH HEATED MIRRORS
[SH13: D-4] (87716755)
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X-CG4 - CAB GROUND [ SH24: B-6] (84149207) (Receptacle)
84149207 52
84149207
A X-LC4 (Receptacle) pin 85 - 954A ACCESSORY RELAY BK - 0.8 SHEET 13 SH13 - POWER DISTRIBUTION 2
LOADCENTER 4 [SH35: C-6] COIL GND CAB GROUND BLK
(87733595)
B X-CAB_JSS (Receptacle) 955X JSS GROUND BK - 0.8
pin 5 - CAB TO JSS FRAME
HARNESS [SH24: A-6]
(87694112)
C X-SC (Plug) pin B - SEAT 955L SEAT COMPRESSOR BK - 2.0
COMPRESSOR [Y-SC] GND
(87692855)
D X-CAB_P (Plug) pin 7 - CAB 954D PEDESTAL GND BK - 1.0
TO PEDESTAL [SH20: D-2]
(87700155)
E X-DSP (Receptacle) pin X - 954E DISPLAY GND BK - 0.8
DISPLAY [A-DSP] (82016219)
F X-LC3 (Receptacle) pin 954F SPARE RELAY COIL GND BK - 0.8
[SH35: B-6] (84529039)
G SP-954L-P-X 954L CAB GROUND BK - 0.8
H X-LC5 (Receptacle) pin 85 - 954H IGNITION RELAY COIL BK - 0.8
LOADCENTER 5 [SH10: D-1] GND
(87733595)
J X-CAB_L (Receptacle) pin 11 954J LH JSS GND BK - 0.8
- CAB TO JSS L ARMREST
(87700156)
K X-CAB_AR (Plug) pin 2 - CAB 954K RH ARMREST JOYSTICK BK - 1.0
TO RH ARM REST (87694152) GND
M SP-954S-P-X 954S GROUND BK - 0.8
X-CL - CIGAR LIGHTER [ LMP-CIG_LTR] (84015523) (Receptacle)
84015523 53
84015523
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1 X-LC4 (Receptacle) pin 1A - 743 24V CIGAR LIGHTER OR - 2.0 SHEET 35 SH35 - CABIN RADIO
LOADCENTER 4 [SH35: C-6] LOUDSPEAKER/12V CNVRTR
(87733595)
X-CNV - 24 TO 12 POWER CONVERTER [ SH35: B-4] (87694112) (Receptacle)
87694112 54
87694112
1 SP-746-P-X 746A POWER CONVERTER OR - 2.0 SHEET 35 SH35 - CABIN RADIO
ACC POWER LOUDSPEAKER/12V CNVRTR
2 SP-746-P-X 746B POWER CONVERTER OR - 2.0
ACC POWER
3 CG2-P-1 CAB GROUND 277 CAB GROUND BK - 2.0
BLOCK
5 X-LC3 (Receptacle) pin F3_11 748 12V ACC POWER OR - 2.0 SHEET 08 SH08 - POWER DISTRIBUTION
- LOADCENTER 3 [SH35: B-6] (FUSE BLOCK LC3)
(84529039)
6 CG2-P-1 CAB GROUND 276 CAB GROUND BK - 2.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
BLOCK PWR DISTR
X-COV1 - CUT OFF VALVE SOL [ Y-C0V_1] (87695582) (Receptacle)
87695582 55
87695582
1 SP-854A-P-X 854 JSS COV WH - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
2 SP-955Y-P-X 955AB JSS GROUND BK - 0.8
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X-COV2 - CUT OFF VALVE SOL [ Y-COV_2] (87695582) (Receptacle)
87695582 56
87695582
1 SP-854A-P-X 854B JSS COV WH - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
2 SP-955Y-P-X 955AC JSS GROUND BK - 0.8
X-CP - CAB POWER (84401295) (Plug)
84401295 57
84401295
1 JC4-P-1 CAB POWER FROM 240 CAB POWER RD - 19.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
REAR STUD STARTER / KEY
X-CPWR - CAB POWER (84401295) (Plug)
84401295 58
84401295
1 X-JC1 (Plug) pin 1 - 235 B+ TO REAR JUNCTION RD - 19.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
JUNCTION STUD OF B+ BLOCK STARTER / KEY
IN REAR (84399576)
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X-CTS - DOC UPSTREAM TEMP [ B-C_TS] (84532147) (Receptacle)
84532147 59
84532147
1 X-SCR2 (Plug) pin 8 - INLINE 616A DOC UPSTREAM TEMP YE - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
FROM SCR SENSORS 2, AT
HARNESS (87695724)
1 X-ECU (Receptacle) pin 16 - 616B TEMP SENSOR DOC UP YE - 0.8
(84300197)
2 SP-610-P-X 610F TEMP SENSOR GRND BK - 0.8
2 X-SCR2 (Plug) pin 7 - INLINE 610E TEMP SENSOR GROUND BK - 0.8
FROM SCR SENSORS
HARNESS (87695724)
X-D(B) - MASTER DISCONNECT BATTERY (84140737) (Plug)
84140737 60
84140737
1 X-566 (Plug) pin 1 - BATTERY CABLE-003 BATTERY POWER RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
POSITIVE [G-002] STARTER / KEY
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X-D(S) - MASTER DISCONNECT SWITCHED [ K-ISOLATOR] (84163398) (Plug)
84163398 61
84163398
1 X-XM1B (Plug) pin 1 - CABLE-004 BATTERY CABLE RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
STARTER LUG FROM STARTER / KEY
ISOLATOR (84596842)
X-DC2 - NON-DISC POWER STUD [ K-ISOLATOR] (84140737) (Plug)
84140737 62
84140737
1 SP-216A-P-X 216A NON-DISCONNECT PWR RD - 3.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
STARTER / KEY
X-DEF1 - INLINE TO DEF QUALITY SENSOR (87694153) (Receptacle)
87694153 63
87694153
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1 SP-201-P-X 201A SCR SENSORS CLEAN BK - 1.0 SHEET 18 SH18 - ENGINE CONTROL UNIT
GROUND 3, AT
1 SP-201D-P-X 201J SCR SENSORS CLEAN BK - 1.0
GROUND
2 SP-CAN_L1-P-X CANC_LA CAN GN - 0.8
3 SP-CAN_H1-P-X CANC_HA CAN YE - 0.8
4 SP-200-P-X 200A SCR SENSOR POWER OR - 1.0
4 SP-200D-P-X 200H SCR SENSOR POWER OR - 1.0
X-DEF2 - INLINE FROM DEF QUALITY SENSOR (87694154) (Plug)
87694154 64
87694154
1 X-DEFQ pin 6 - DEF QUALITY 201C SCR SENSORS CLEAN BK - 1.0 SHEET 18 SH18 - ENGINE CONTROL UNIT
SENSOR (UQS) [B-DEF_Q] GROUND 3, AT
(84149219)
2 X-DEFQ pin 5 - DEF QUALITY CANC_LZ CAN GN - 0.8
(84149219)
3 X-DEFQ pin 4 - DEF QUALITY CANC_HZ CAN YE - 0.8
(84149219)
4 X-DEFQ pin 3 - DEF QUALITY 200C SCR SENSOR POWER OR - 1.0
(84149219)
X-DEFQ - DEF QUALITY SENSOR (UQS) [ B-DEF_Q] (84149219) (Receptacle)
84149219 65
84149219
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X-DIA - DIAGNOSTIC PORT [ A-DIA] (87736919) (Plug)
87736919 66
87736919
A X-SP_PK_CLN (Receptacle) 945 CAB CLEAN GROUND BK - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
pin X - SPLICE PACK CLEAN DIAG 1, GRID HEATER, FILTER HEATER
GRND [SH25: C-1] (87352746)
B X-LC2 (Receptacle) pin 8A - 798 DIAGNOSTIC B+ RD - 0.8
(87733581)
C SP-HH-P-X CAN_HI CAN YE - 0.8
D SP-LH-P-X CAN_LI CAN GN - 0.8
E X-CAB_E (Receptacle) pin 20 303 ISO K LINE WH - 0.8
- CAB TO ENGINE [SH7: B-5]
(84807216)
H SP-B_HE-P-X CANB_HD CAN WH - 0.8
J SP-B_LE-P-X CANB_LD CAN BL - 0.8
X-DIAG_T - TELEMATICS DIAGNOSTIC [ SH38: B-1] (87694101) (Receptacle)
87694101 67
87694101
2 X-X_TEL (Receptacle) pin 7 CAN_TH CAN TN - 0.8 SHEET 38 SH38 - MISCELLANOUS,
- TELEMATICS [SH38: C-6] TELEMATICS
(87700156)
3 X-X_TEL (Receptacle) pin 6 CAN_TL CAN LB - 0.8
- TELEMATICS [SH38: C-6]
(87700156)
4 X-SP_PK_CLN (Receptacle) 912 CAB GROUND CLN BK - 0.8 SHEET 12 SH12 - POWER DISTRIBUTION 1
pin X - SPLICE PACK CLEAN CLEAN GROUND BLK
GRND [SH25: C-1] (87352746)
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X-DM_G - DOME LIGHT GROUND [ LMP-DM] (87688695) (Receptacle)
87688695 68
87688695
1 X-CG3 (Receptacle) pin 955N MAP LIGHT GND BK - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
H - CAB GROUND RH LIGHTS
(84149207)
X-DM_P - DOME LIGHT POSITIVE [ LMP-DM] (84015523) (Receptacle)
84015523 69
84015523
1 X-X6 (Receptacle) pin 17 - 148 EGRESS/DOME LAMP B+ VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
SFB [A-SFB] (47554341) LIGHTS
2 X-X5 (Receptacle) pin 12 - 149 DOME LAMP SW OR - 0.8
SFB [SH3: D-3] (47554342)
X-DS - DOOR SWITCH [ SH27: C-6] (87382906) (Receptacle)
87382906 70
87382906
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1 X-X7 (Receptacle) pin 80 - 151 LH DOOR AJAR SW YE - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
SFB [SH3: A-3] (84538791) LIGHTS
2 X-CG3 (Receptacle) pin 955P LH DOOR AJAR SW GND BK - 0.8 SHEET 13 SH13 - POWER DISTRIBUTION 2
J - CAB GROUND RH CAB GROUND BLK
(84149207)
X-DSP - DISPLAY [ A-DSP] (82016219) (Receptacle)
82016219 71
82016219
X-DSR - UREA DOSING VALVE [ Y-DSV] (87709798) (Receptacle)
87709798 72
87709798
1 X-ECU (Receptacle) pin 96 - 696B DOSING VALVE TN - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
(84300197)
1 X-SCR2 (Plug) pin 5 - INLINE 696A DOSING VALVE TN - 0.8
FROM SCR SENSORS
HARNESS (87695724)
2 X-ECU (Receptacle) pin 23 - 623B DOSING VALVE WH - 0.8
(84300197)
2 X-SCR2 (Plug) pin 6 - INLINE 623A UREA DOSING VALVE 2 WH - 0.8
FROM SCR SENSORS
HARNESS (87695724)
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X-DTLTS - DEF LEVEL / TEMP [ B-U_LVL] (84062580) (Plug)
84062580 73
84062580
X-DTS - SCR DOWNSTREAM TEMP [ B-D_TS] (84532147) (Receptacle)
84532147 74
84532147
1 X-ECU (Receptacle) pin 9 - 609B TEMP SENSOR SCR UP YE - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
(84300197)
1 X-SCR2 (Plug) pin 10 - INLINE 609A SCR DOWNSTREAM YE - 0.8
FROM SCR SENSORS TEMP
HARNESS (87695724)
2 SP-610-P-X 610G TEMP SENSOR GROUND BK - 0.8
2 X-SCR2 (Plug) pin 9 - INLINE 610C TEMP SENSOR GROUND BK - 0.8
FROM SCR SENSORS
HARNESS (87695724)
X-ECU - ECU CONNECTOR [ A-ECU] (84300197) (Receptacle)
84300197 75
84300197
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1 SP-233-P-X 233A EDC FUSED POWER RD - 1.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
3 SP-603-P-X 603A CLEAN GROUND BK - 1.0 1, GRID HEATER, FILTER HEATER
5 SP-603-P-X 603B CLEAN GROUND BK - 1.0
7 X-PUMP pin 3 - DENOX 607 DENOX CONTROL UNIT YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
CONTROL UNIT [A-PMP] 3 3, AT
(47421681)
8 X-LEV1 pin 3 - INLINE TO DEF 608 SCR LEVEL AND TEMP YE - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
LEVEL & TEMP (84062580) 2, AT
9 X-DTS (Receptacle) pin 1 - 609B TEMP SENSOR SCR UP YE - 0.8
SCR DOWNSTREAM TEMP
[B-D_TS] (84532147)
9 X-SCR1 (Receptacle) pin 10 609 SCR DOWNSTREAM YE - 0.8
- INLINE TO SCR SENSORS TEMP
HARNESS (87695592)
10 SP-610-P-X 610 TEMP SENSOR GROUND BK - 0.8
13 X-WIF (Receptacle) pin 1 613 WATER IN FUEL YE - 0.8
- WATER IN FUEL [B-WIF]
(87709663)
15 X-HTS (Receptacle) pin 2 615 HUMIDITY TEMP YE - 0.8
- HUMIDITY AND TEMP SENSOR
SENSOR [B-HT] (87709809)
16 X-SCR1 (Receptacle) pin 8 616 DOC UPSTREAM TEMP YE - 0.8
- INLINE TO SCR SENSORS
HARNESS (87695592)
16 X-CTS (Receptacle) pin 1 616B TEMP SENSOR DOC UP YE - 0.8
- DOC UPSTREAM TEMP
[B-C_TS] (84532147)
19 X-LC6 pin 36 - LOADCENTER 619 START CONTROL RELAY YE - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
6 [SH16: A-3] (84380518) 1, GRID HEATER, FILTER HEATER
20 X-LC6 pin 34 - LOADCENTER 620 ENG AUX WH - 0.8
6 [SH16: A-3] (84380518)
23 X-DSR (Receptacle) pin 623B DOSING VALVE WH - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
2 - UREA DOSING VALVE 2, AT
[Y-DSV] (87709798)
23 X-SCR1 (Receptacle) pin 6 623 UREA DOSING VALVE 2 WH - 0.8
HARNESS (87695592)
25 SP-233-P-X 233B EDC FUSED POWER RD - 1.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
26 SP-233-P-X 233C EDC FUSED POWER RD - 1.0 1, GRID HEATER, FILTER HEATER
27 SP-627-P-X 627 RELAY FILTER HEATING RD - 0.8
HI SIDE
28 SP-603-P-X 603C CLEAN GROUND BK - 1.0
31 X-LEV1 pin 1 - INLINE TO DEF 631 SENSOR TANK LEVEL YE - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
LEVEL & TEMP (84062580) AND TEMP 2, AT
32 X-UTS (Receptacle) pin 632 SCR UPSTREAM TEMP YE - 0.8
1 - UPSTREAM OF SCR
TEMP SENSOR [B-U_TS]
(84532147)
37 X-AFS (Receptacle) pin 2 637 AIR FILTER SWITCH YE - 0.8
- AIR FILTER RSTCN SW
[SW-A_F_S] (84607243)
39 SP-639-P-X 639 SENSOR TANK LEVEL BL - 0.8
AND TEMP
40 X-HTS (Receptacle) pin 4 642 HUMIDITY TEMP YE - 0.8
- HUMIDITY AND TEMP SENSOR
SENSOR [B-HT] (87709809)
43 SP-643-P-X 643 HUMIDITY TEMP BK - 0.8
SENSOR
45 X-LC6 pin 29 - LOADCENTER 645 ENG AUX BK - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
6 [SH16: A-3] (84380518) 1, GRID HEATER, FILTER HEATER
46 X-ENG (Plug) pin 14 - CAN_H CAN YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
ENGINE TO CAB [SH18: C-6] 3, AT
(87696948)
47 X-ENG (Plug) pin 13 - CAN_L CAN GN - 0.8
(87696948)
49 SP-233-P-X 233D EDC FUSED POWER RD - 1.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
1, GRID HEATER, FILTER HEATER
50 SP-650-P-X 650 DENOX CONTROL UNIT OR - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
9 3, AT
52 SP-603-P-X 603D CLEAN GROUND BK - 1.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
60 X-ENG-2 (Receptacle) pin D - 408A THROTTLE PEDAL WH - 0.8 1, GRID HEATER, FILTER HEATER
ENGINE TO CAB 2 (87703931)
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61 X-LC7 pin 9 - LOAD CENTER 661 RELAY FILTER HEATING BK - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
7 (84563565) LOW SIDE STARTER / KEY
63 SP-663A-P-X 663B OK TO START YE - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
66 X-ENG-2 (Receptacle) pin B - 471K THROTTLE PEDAL PK - 0.8 1, GRID HEATER, FILTER HEATER
68 X-PUMP pin 2 - DENOX 668 DENOX CONTROL UNIT PK - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
(47421681)
69 X-SW_DISC (Receptacle) pin 669 ECU IGN PWR OR - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
3 - DISCONNECT SWITCH 1, GRID HEATER, FILTER HEATER
[SH37: C-4] (87694112)
71 X-CAN (Receptacle) pin 1 - 671 CAN HI PROTO ONLY YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
CAN (87696093) 3, AT
72 X-THV pin 3 - SCR 672 SCR TANK HEATING BL - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
TANK HEATING VALVE VALVE 2, AT
[Y-TNK_HTR] (84146685)
73 SP-233-P-X 233E EDC FUSED POWER RD - 1.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
74 X-GHC pin 1 - GRID HEATER 674 GRID HEATER RELAY HI WH - 0.8 1, GRID HEATER, FILTER HEATER
75 SP-603-P-X 603E CLEAN GROUND BK - 1.0
79 X-ENG-2 (Receptacle) pin A - 409A THROTTLE PEDAL YE - 0.8
80 X-ENG-2 (Receptacle) pin C - 651K THROTTLE PEDAL BL - 0.8
83 X-GHC pin 2 - GRID HEATER 683 GRID HEATER RELAY LO BL - 0.8
84 X-PUMP pin 10 - DENOX 684 DENOX CONTROL UNIT YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
(47421681)
85 X-PUMP pin 12 - DENOX 685 DENOX CONTROL UNIT GY - 0.8
CONTROL UNIT [A-PMP] 12
(47421681)
88 X-LC6 pin 31 - LOADCENTER 688 START CONTROL RELAY BL - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
6 [SH16: A-3] (84380518) LOW SIDE 1, GRID HEATER, FILTER HEATER
89 X-PUMP pin 8 - DENOX 689 DENOX CONTROL UNIT GY - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
(47421681)
90 X-HTS (Receptacle) pin 1 690 HUMIDITY TEMP OR - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
- HUMIDITY AND TEMP SENSOR 2, AT
SENSOR [B-HT] (87709809)
95 X-CAN (Receptacle) pin 2 - 695 CAN LO PROTO ONLY GN - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
CAN (87696093) 3, AT
96 X-DSR (Receptacle) pin 696B DOSING VALVE TN - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
[Y-DSV] (87709798)
96 X-SCR1 (Receptacle) pin 5 696 UREA DOSING VALVE 1 TN - 0.8
HARNESS (87695592)
X-EDC7 - ENGINE CONTROLLER T2/3 [ SH18: C-5] (84160698) (Plug)
84160698 76
84160698
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2 SP-233-P-X 233F EDC FUSED POWER RD - 1.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
3 SP-233-P-X 233G EDC FUSED POWER RD - 1.0 1, GRID HEATER, FILTER HEATER
5 SP-603-P-X 603F CLEAN GROUND BK - 1.0
6 SP-603-P-X 603G CLEAN GROUND BK - 1.0
8 SP-233-P-X 233H EDC FUSED POWER RD - 1.0
9 SP-233-P-X 233J EDC FUSED POWER RD - 1.0
10 SP-603-P-X 603H CLEAN GROUND BK - 1.0
11 SP-603-P-X 603J CLEAN GROUND BK - 1.0
12 X-GHC pin 1 - GRID HEATER 674A T2 GRID HTR HI WH - 0.8
13 SP-627-P-X 627E T2 EDC 7 PWR RD - 0.8
13 X-LC6 pin 34 - LOADCENTER 627F FUEL FILTER HTR T2 RD - 0.8
6 [SH16: A-3] (84380518)
17 X-LC6 pin 31 - LOADCENTER 688A START CONTROL RELAY BL - 0.8
6 [SH16: A-3] (84380518) LOW SIDE
29 SP-643F-P-X 643F EDC GRND BK - 0.8
32 X-LC6 pin 7 - LOADCENTER 21E T2 OK TO START FROM YE - 0.8
6 [SH16: A-3] (84380518) UCM
34 X-ENG (Plug) pin 13 - CAN_L7 CAN GN - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
ENGINE TO CAB [SH18: C-6] 3, AT
(87696948)
35 X-ENG (Plug) pin 14 - CAN_H7 CAN YE - 0.8
(87696948)
36 X-LC7 pin 9 - LOAD CENTER 661A FUEL FILTER HEATER BK - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
7 (84563565) 1, GRID HEATER, FILTER HEATER
37 X-LC6 pin 36 - LOADCENTER 619A START CONTROL RELAY YE - 0.8
6 [SH16: A-3] (84380518)
40 SP-669A-P-X 669B ECU IGN PWR OR - 0.8
42 X-WIF (Receptacle) pin 1 613A WATER IN FUEL SIGNAL YE - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
- WATER IN FUEL [B-WIF] T2 2, AT
(87709663)
48 X-ENG-2 (Receptacle) pin D - 408B THROTTLE PEDAL WH - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
ENGINE TO CAB 2 (87703931) 1, GRID HEATER, FILTER HEATER
51 X-LC6 pin 29 - LOADCENTER 645A T2 EVGT LSD BK - 0.8
6 [SH16: A-3] (84380518)
52 SP-2LC-P-X CAN2_LB CAN GN - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
53 SP-2HC-P-X CAN2_HB CAN YE - 0.8 3, AT
75 X-GHC pin 2 - GRID HEATER 683B T2 GRID HTR LOW BL - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
CONTROL [K-GH] (82012083) 1, GRID HEATER, FILTER HEATER
77 X-ENG-2 (Receptacle) pin B - 471P THROTTLE PEDAL PK - 0.8
78 X-ENG-2 (Receptacle) pin C - 651P THROTTLE PEDAL BL - 0.8
79 X-ENG-2 (Receptacle) pin A - 409B THROTTLE PEDAL YE - 0.8
89 X-ENG (Plug) pin 20 - 303A ISO K WH - 0.8
(87696948)
X-EHD_23 - ENG TO PL23 HOOD (87694154) (Plug)
87694154 77
87694154
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1 X-ENG (Plug) pin 7 - 121B BACKUP ALARM PL23 OR - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
ENGINE TO CAB [SH18: ALARM
C-6] (87696948)
X-EM - ELECTROMAGNETIC DETENTS [ Y-RTT DET] (87694112) (Receptacle)
87694112 78
87694112
1 X-A_RT_2B (Receptacle) pin 299A RTT DETENT WH - 0.8 SHEET 23 SH23 - PILOT LOADER
8 - ARM REST RIGHT PILOT CONTROLS
2 (84281913)
2 X-A_RT_2B (Receptacle) pin 298A HC DETENT WH - 0.8
7 - ARM REST RIGHT PILOT
2 (84281913)
3 X-A_RT_2B (Receptacle) pin 297A RTD DETENT WH - 0.8
2 (84281913)
4 SP-954U-P-X 954V CHASSIS GROUND BK - 0.8
5 SP-954U-P-X 954W CHASSIS GROUND BK - 0.8
6 SP-954U-P-X 954X CHASSIS GROUND BK - 0.8
X-ENG - ENGINE TO CAB [ SH18: C-6] (87696948) (Plug)
87696948 79
87696948
1 SP-850A-P-X 850A IGN PWR FOR REAR OR - 2.0 SHEET 11 SH11 - PWR DISTR ENG
2 SP-250A-P-X 205A HOOD LIFT RD - 2.0 SHEET 37 SH37 - HOOD LIFT
3 X-GND_CENG1 (Plug) pin 857A CAB CLEAN GRND BK - 2.0 SHEET 12 SH12 - POWER DISTRIBUTION 1
1 - GROUND CLEAN ENG CLEAN GROUND BLK
BLOCK (84140737)
4 SP-216A-P-X 216D HOOD LIFT NON-DISC RD - 2.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
PWR STARTER / KEY
5 X-RECT (Receptacle) pin 1 433A COOLANT TEMP YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
- ENGINE COOLANT TEMP INSTRUMENTATION
[B-RECTD] (84607243)
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6 X-RH-TAIL (Receptacle) 131F TURN RH EURO VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
pin 4 - RH REAR TAIL
[LMP-R-NA-TAIL] (87694101)
6 X-ENG_H (Plug) pin 4 131A RH REAR TURN LAMP VT - 0.8
- ENGINE TO HOOD NA
(87700321)
7 X-BU2 (Plug) pin 1 - BACK 121A BACKUP ALARM OR - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
UP ALARM [H-BU_ALRM] ALARM
(84426117)
7 X-EHD_23 (Plug) pin 1 - ENG 121B BACKUP ALARM PL23 OR - 0.8
TO PL23 HOOD (87694154)
8 X-FL pin 2 - FUEL LEVEL 633A FUEL LEVEL YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
[B-RFLG] (82012083) INSTRUMENTATION
9 SP-482R-P-X 482R 5V GRND REF1 BL - 0.8
10 X-ENG_H (Plug) pin 2 126A LH BRAKE LAMP NA VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
- ENGINE TO HOOD
(87700321)
10 X-LH-TAIL (Receptacle) pin 126E STOP LH EURO VT - 0.8
2 - LH REAR TAIL LIGHT NA
[L-NA-TAIL] (87694101)
11 X-ENG_H (Plug) pin 5 130B RH TAIL LAMP NA VT - 0.8
- ENGINE TO HOOD
(87700321)
11 X-RH-TAIL (Receptacle) 130J TAIL RH EURO VT - 0.8
[LMP-R-NA-TAIL] (87694101)
12 X-LH-TAIL (Receptacle) pin 127J TAIL EURO VT - 0.8
[L-NA-TAIL] (87694101)
12 X-ENG_H (Plug) pin 6 127E LH TAIL LAMP NA VT - 0.8
- ENGINE TO HOOD
(87700321)
13 X-ECU (Receptacle) pin 47 - CAN_L CAN GN - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
(84300197)
13 X-EDC7 (Plug) pin 34 - CAN_L7 CAN GN - 0.8
ENGINE CONTROLLER T2/3
[SH18: C-5] (84160698)
14 X-ECU (Receptacle) pin 46 - CAN_H CAN YE - 0.8
(84300197)
14 X-EDC7 (Plug) pin 35 - CAN_H7 CAN YE - 0.8
[SH18: C-5] (84160698)
15 SP-663A-P-X 663A OK TO START YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
16 X-FAN (Receptacle) pin 400A FAN SPEED YE - 0.8 / FAN CONTROL
4 - FAN SPEED SENSOR
JUMPER [SH11: C-1]
(87694112)
17 X-ALT (Receptacle) pin 239 ALT LAMP SIGNAL YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
4 - ALTERNATOR [G-G1] STARTER / KEY
(8602487)
18 X-AFS2 (Receptacle) pin 2 319A AIR FILTER REST SW T2 YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- AIR FILTER SWITCH T2/3 / FAN CONTROL
[SW-AFS2] (84607243)
20 X-EDC7 (Plug) pin 89 - 303A ISO K WH - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
ENGINE CONTROLLER T2/3 1, GRID HEATER, FILTER HEATER
[SH18: C-5] (84160698)
21 X-ENG_H (Plug) pin 7 129A RH BRAKE LAMP NA VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
- ENGINE TO HOOD
(87700321)
21 X-RH-TAIL (Receptacle) 129E STOP RH EURO VT - 0.8
[LMP-R-NA-TAIL] (87694101)
22 X-ENG_H (Plug) pin 3 128A LH REAR TURN LAMP NA VT - 0.8
- ENGINE TO HOOD
(87700321)
22 X-LH-TAIL (Receptacle) pin 128E LH TURN EURO VT - 0.8
[L-NA-TAIL] (87694101)
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25 X-E_HD (Receptacle) pin A 280C LICENSE PLATE LIGHT VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
- ENGINE TO HOOD EURO EURO LIGHTS
[SH29: B-1] (87692858)
25 X-ENG_H (Plug) pin 8 280A LICENSE PLATE LIGHT VT - 0.8
- ENGINE TO HOOD
(87700321)
26 X-ALT (Receptacle) pin 228 ALTERNATOR VOLTAGE RD - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
3 - ALTERNATOR [G-G1] STARTER / KEY
(8602487)
28 X-FAN (Receptacle) pin 677M 5V REF PWR1 PK - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
3 - FAN SPEED SENSOR / FAN CONTROL
JUMPER [SH11: C-1]
(87694112)
X-ENG-2 - ENGINE TO CAB 2 (87703931) (Receptacle)
87703931 80
87703931
A X-ECU (Receptacle) pin 79 - 409A THROTTLE PEDAL YE - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
ECU CONNECTOR [A-ECU] 1, GRID HEATER, FILTER HEATER
(84300197)
A X-EDC7 (Plug) pin 79 - 409B THROTTLE PEDAL YE - 0.8
[SH18: C-5] (84160698)
B X-ECU (Receptacle) pin 66 - 471K THROTTLE PEDAL PK - 0.8
(84300197)
B X-EDC7 (Plug) pin 77 - 471P THROTTLE PEDAL PK - 0.8
[SH18: C-5] (84160698)
C X-ECU (Receptacle) pin 80 - 651K THROTTLE PEDAL BL - 0.8
(84300197)
C X-EDC7 (Plug) pin 78 - 651P THROTTLE PEDAL BL - 0.8
[SH18: C-5] (84160698)
D X-EDC7 (Plug) pin 48 - 408B THROTTLE PEDAL WH - 0.8
[SH18: C-5] (84160698)
D X-ECU (Receptacle) pin 60 - 408A THROTTLE PEDAL WH - 0.8
(84300197)
E SP-643-P-X 643D THROTTLE PEDAL BK - 0.8
E SP-643F-P-X 643E EDC7 GRND BK - 0.8
F X-ISO pin 2 - ISOLATOR 250A ISOLATOR SET YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
[K-ISOLATOR] (87687242) STARTER / KEY
G X-ISO pin 1 - ISOLATOR 237A ISOLATOR RESET YE - 0.8
[K-ISOLATOR] (87687242)
H X-LC6 pin 24 - LOADCENTER 217 TELEMATICS/SFB PWR RD - 0.8
6 [SH16: A-3] (84380518)
J X-SW_DISC (Receptacle) pin 219 NON ISOLATED PWR RD - 0.8
4 - DISCONNECT SWITCH
[SH37: C-4] (87694112)
K X-LC6 pin 18 - LOADCENTER 875A AC CLUTCH ACC PWR OR - 1.0 SHEET 11 SH11 - PWR DISTR ENG
6 [SH16: A-3] (84380518) COMPARTMENT (FUSE BLOCK LC6)
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L X-PRH2 (Plug) pin A - HIGH 246C AC HIGH PRESS YE - 1.0 SHEET 33 SH33 - HEATING BLOWER
PRESSURE SWITCH 2 [SH33: HEATER, HVAC
C-6] (87688788)
M X-FAN (Receptacle) pin 582A HEAT LOAD VALVE BR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
1 - FAN SPEED SENSOR / FAN CONTROL
JUMPER [SH11: C-1]
(87694112)
N X-YFR (Receptacle) pin 2 - 692A FAN REVERSER SGNL BR - 0.8
FAN REVESER SOLENOID
[Y-Y_FR] (87695582)
P X-YFN (Receptacle) pin A - 392A FAN CONTROL SGNL YE - 0.8
SOLENOID FAN CONTROL
[Y-Y_FC] (87693821)
X-ENG_H - ENGINE TO HOOD (87700321) (Plug)
87700321 81
87700321
1 X-GND_ENG4 (Plug) pin 1 - 242 TAIL LIGHT GROUND BK - 1.0 SHEET 29 SH29 - LIGHTING REAR TAILS
GROUND ENG BLOCK [SH29:
B-3] (84140737)
2 X-ENG (Plug) pin 10 - 126A LH BRAKE LAMP NA VT - 0.8
(87696948)
3 X-ENG (Plug) pin 22 - 128A LH REAR TURN LAMP NA VT - 0.8
(87696948)
4 X-ENG (Plug) pin 6 - 131A RH REAR TURN LAMP VT - 0.8
ENGINE TO CAB [SH18: NA
C-6] (87696948)
5 X-ENG (Plug) pin 11 - 130B RH TAIL LAMP NA VT - 0.8
(87696948)
6 X-ENG (Plug) pin 12 - 127E LH TAIL LAMP NA VT - 0.8
(87696948)
7 X-ENG (Plug) pin 21 - 129A RH BRAKE LAMP NA VT - 0.8
(87696948)
8 X-ENG (Plug) pin 25 - 280A LICENSE PLATE LIGHT VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
ENGINE TO CAB [SH18: C-6] LIGHTS
(87696948)
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X-ESS - SPEED SENSOR ENGINE [ B-ES_S] (84364854) (Receptacle)
84364854 82
84364854
1 X-TRANS (Plug) pin 7 - 699A ENG SPEED SENSOR YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
TRANSMISSION TO CAB
(87696949)
2 X-TRANS (Plug) pin 2 - 702D SPEED SENSOR GRND BL - 0.8
TRANSMISSION TO CAB
(87696949)
X-E_HD - ENGINE TO HOOD EURO [ SH29: B-1] (87692858) (Receptacle)
87692858 83
87692858
A X-ENG (Plug) pin 25 - 280C LICENSE PLATE LIGHT VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
ENGINE TO CAB [SH18: C-6] EURO LIGHTS
(87696948)
A X-HD_N (Receptacle) pin 8 - 280T TRKY LICENSE PLT VT - 0.8
HOOD TO ENG (87700325) LIGHT
C SP-242A-P-X 242T TRKY LICENSE PLT BK - 0.8
LIGHT
C SP-243-P-X 243C LPL GRND EURO BK - 0.8
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X-FAN - FAN SPEED SENSOR JUMPER [ SH11: C-1] (87694112) (Receptacle)
87694112 84
87694112
1 X-ENG-2 (Receptacle) pin 582A HEAT LOAD VALVE BR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
M - ENGINE TO CAB 2 / FAN CONTROL
(87703931)
2 SP-852-P-X 852C HEAT LOAD IGN PWR OR - 0.8 SHEET 11 SH11 - PWR DISTR ENG
3 X-ENG (Plug) pin 28 - 677M 5V REF PWR1 PK - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
ENGINE TO CAB [SH18: C-6] / FAN CONTROL
(87696948)
4 X-ENG (Plug) pin 16 - 400A FAN SPEED YE - 0.8
(87696948)
5 SP-482R-P-X 482N 5V GRND REF1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
X-FAN2 - FAN SPEED SENSOR JUMPER (87694152) (Plug)
87694152 85
87694152
1 X-YLV (Receptacle) pin 2 - 582B HEAT LOAD VALVE BR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
HEAT LOAD VALVE [Y-YLV] SIGNAL / FAN CONTROL
(87695582)
2 X-YLV (Receptacle) pin 1 - 852A HEAT LOAD VALVE OR - 0.8
HEAT LOAD VALVE [Y-YLV]
(87695582)
3 X-FSS pin 3 - FAN SPEED 677N 5V REF PWR1 PK - 0.8
SENSOR [B-FSS] (47696743)
4 X-FSS pin 2 - FAN SPEED 400B FAN SPEED SENSOR YE - 0.8
SENSOR [B-FSS] (47696743) SGNL
5 X-FSS pin 1 - FAN SPEED 482V 5V GRND REF1 BL - 0.8
SENSOR [B-FSS] (47696743)
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X-FAX - FRONT AXLE TEMP SENSOR [ SH20: A-6] (87711966) (Receptacle)
87711966 86
87711966
1 X-FRNT (Receptacle) pin A 687B FRONT AXLE TEMP YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- FRONT TO BOTTOM STD / FAN CONTROL
(87704426)
2 SP-651D-P-X 651G 5V REF2 BL - 0.8
2 X-FRNT (Receptacle) pin V 651N TEMP SENS PILOT BL - 0.8
- FRONT TO BOTTOM STD
(87704426)
X-FFH - FILTER HEATER [ Y-F_F_H] (87679438) (Receptacle)
87679438 87
87679438
A SP-421-P-X 421A FUEL FILTER HEATER OR - 2.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
B X-GND_ENG1 (Plug) pin 1 - 196 FUEL FILTER HEATER BK - 2.0 1, GRID HEATER, FILTER HEATER
GROUND ENG BLOCK [SH16: GND
A-1] (84140737)
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X-FL - FUEL LEVEL [ B-RFLG] (82012083) (Plug)
82012083 88
82012083
X-FM - PRESSURE SWITCH OIL FILTER [ B-FM] (82012083) (Plug)
82012083 89
82012083
X-FRNT - FRONT TO BOTTOM STD (87704426) (Receptacle)
87704426 90
87704426
A X-FAX (Receptacle) pin 1 - 687B FRONT AXLE TEMP YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
FRONT AXLE TEMP SENSOR / FAN CONTROL
[SH20: A-6] (87711966)
B X-PXF (Plug) pin A - RETURN 294B RTD SIG YE - 0.8 SHEET 23 SH23 - PILOT LOADER
TO DIG PROX [B-PXF] CONTROLS
(87692858)
B X-PXT (Plug) pin A - RTD XT 294C RTD XT SIGNAL YE - 0.8
[B-PXT] (87644909)
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C X-LLF pin 3 - FRONT COMBO 132E LH HIGH BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
LAMP LEFT [LMP-LF_LT] WARNING, BLINKERS, DRIVING
(87694109)
F X-LLF pin 2 - FRONT COMBO 133B LH LOW BEAM LAMP VT - 0.8
(87694109)
H X-LLF pin 4 - FRONT COMBO 127C LH POSITION VT - 0.8
(87694109)
J X-LLF pin 5 - FRONT COMBO 136C LH FRONT TURN VT - 0.8
(87694109)
K X-LRF pin 3 - FRONT COMBO 137B RH HIGH BEAM LAMP VT - 0.8
LAMP RT [LMP-RF_LT]
(87694109)
L X-LRF pin 2 - FRONT COMBO 138B RH LOW BEAM LAMP VT - 0.8
LAMP RT [LMP-RF_LT]
(87694109)
M X-LRF pin 4 - FRONT COMBO 130F RH POSITION VT - 0.8
LAMP RT [LMP-RF_LT]
(87694109)
N X-LRF pin 5 - FRONT COMBO 135E RH FRONT TURN VT - 0.8
LAMP RT [LMP-RF_LT]
(87694109)
P X-YRC (Receptacle) pin 1 - 366B RIDE CONTROL SOL WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
RIDE CONTROL SOLENOID PWR CONTROL
[Y-YRC] (84607243)
R X-YPE (Receptacle) pin 1 - 367B COUPLER SOL PWR WH - 0.8
COUPLER VALVE [Y-YPE]
(87695582)
S X-YPE (Receptacle) pin 2 - 368B COUPLER SOL RETURN BR - 0.8
COUPLER VALVE [Y-YPE]
(87695582)
T X-HN1 (Plug) pin 1 - 112B HORN YE - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
HORN_PWR [H-HN]
(87697629)
U X-PRB (Plug) pin A - ROLL 291B ROLL BACK PRESSURE YE - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
BACK PRESSURE SWITCH SW CONTROL
[SW-PRB] (87692877)
V SP-651D-P-X 651D 5V GND2 BL - 0.8
V X-FAX (Receptacle) pin 2 - 651N TEMP SENS PILOT BL - 0.8
FRONT AXLE TEMP SENSOR
[SH20: A-6] (87711966)
W SP-792D-P-X 792D PILOT TARGETS OR - 0.8 SHEET 23 SH23 - PILOT LOADER
X X-PXH (Plug) pin A - HEIGHT 295B HT CNTRL SIGNAL YE - 0.8 CONTROLS
CNTRL PROX [B-PXH]
(87644909)
X-FRNT_EH - FRONT TO BOTTOM EH (87700170) (Receptacle)
87700170 91
87700170
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A X-PILOT_ENABLE 344B PILOT ENABLE WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
(Receptacle) pin 1 - PILOT CONTROL
ENABLE SOLENOID [SH28:
A-1] (87695582)
B X-BOOM_RAISE 340B BOOM RAISE WH - 0.8
(Receptacle) pin 1 -
BOOM RAISE SOLENOID
[A-EH_VLV] (87695582)
C SP-339B-P-X 339B BOOM ENABLE BR - 0.8
D X-BOOM_LOWER 341B BOOM LOWER WH - 0.8
BOOM LOWER SOLENOID
[A-EH_VLV] (87695582)
E X-BUCKET_ROLL 346B BUCKET ROLL WH - 0.8
(Receptacle) pin 1 - BUCKET
ROLL SOLENOID [A-EH_VLV]
(87695582)
F SP-347B-P-X 347B BUCKET ENABLE BR - 0.8
G X-BUCKET_DUMP 350B BUCKET DUMP WH - 0.8
BUCKET DUMP SOLENOID
[A-EH_VLV] (87695582)
H X-AUX_1_LEFT (Receptacle) 351B AUX 1 LEFT WH - 0.8
pin 1 - AUX 1 LEFT
[A-EH_VLV] (87695582)
J SP-352B-P-X 352B AUX 1 ENABLE BR - 0.8
K X-AUX_1_RIGHT 355B AUX 1 RIGHT WH - 0.8
(Receptacle) pin 1 - AUX
1 RIGHT [A-EH_VLV]
(87695582)
L X-AUX_2_LEFT (Receptacle) 356B AUX 2 LEFT WH - 0.8
pin 1 - AUX 2 LEFT
[A-EH_VLV] (87695582)
M SP-357B-P-X 357B AUX 2 ENABLE BR - 0.8
N X-AUX_2_RIGHT 360B AUX 2 RIGHT WH - 0.8
(Receptacle) pin 1 - AUX
2 RIGHT [A-EH_VLV]
(87695582)
P SP-570E-P-X 482U 5V GND1 BL - 0.8
Q SP-486F-P-X 486H 5V REF1 PK - 0.8
S X-BOA (Receptacle) pin C 647B BOOM ANGLE 1 YE - 0.8
- BOOM ANGLE SENSOR
[B-BM_ANG] (84403598)
T X-BOA (Receptacle) pin D 648B BOOM ANGLE 2 YE - 0.8
- BOOM ANGLE SENSOR
[B-BM_ANG] (84403598)
V SP-471F-P-X 471F 5V REF2 PK - 0.8
W X-BUA (Receptacle) pin C - 653B BUCKET ANGLE 1 YE - 0.8
BUCKET ANGLE SENSOR
[B-BKT_ANG] (84403598)
X X-BUA (Receptacle) pin D - 654B BUCKET ANGLE 2 YE - 0.8
BUCKET ANGLE SENSOR
[B-BKT_ANG] (84403598)
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X-FSS - FAN SPEED SENSOR [ B-FSS] (47696743) (Receptacle)
47696743 92
47696743
X-FWM - FRONT WIPER MOTOR (87692862) (Plug)
87692862 93
87692862
A X-X4 (Receptacle) pin 6 - SFB 100 FRONT WIPER MOTOR TN - 2.0 SHEET 32 SH32 - CAB WIPER / WASHER
(47554343) HIGH
D X-X7 (Receptacle) pin 59 - 102 FRONT WIPER MOTOR TN - 0.8
SFB [SH3: A-3] (84538791) PARK
X-FWM_G - FRONT WIPER GROUND [ SH14: D-5] (87693744) (Plug)
87693744 94
87693744
A CG2-P-1 CAB GROUND 103 FRONT WIPER MOTOR BK - 2.0 SHEET 32 SH32 - CAB WIPER / WASHER
BLOCK GND
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X-FWW - FRONT WASHER MOTOR [ M-FW_M] (84015523) (Receptacle)
84015523 95
84015523
1 X-TRANS (Plug) pin 6 - 104A FRONT WASHER MOTOR TN - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
TRANSMISSION TO CAB
(87696949)
2 SP-391A-P-X 391F FRONT WASHER MOTOR BK - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
GND / FAN CONTROL
X-GH1 - GRID HEATER (84140737) (Plug)
84140737 96
84140737
1 X-GH2 (Plug) pin 1 - GRID CABLE 06 GRID HEATER CABLE RD - 32.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
HEATER [F-GH] (84140737) STARTER / KEY
X-GH2 - GRID HEATER [ F-GH] (84140737) (Plug)
84140737 97
84140737
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1 X-GH1 (Plug) pin 1 - GRID CABLE 06 GRID HEATER CABLE RD - 32.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
HEATER (84140737) STARTER / KEY
X-GH3 - GRID HEATER RING TERMINAL [ F-GH] (84140737) (Plug)
84140737 98
84140737
1 GH4-P-1 RELAY GRID CABLE 05 GRID HEATER POWER RD - 32.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
HEATER (K1-7:87) CABLE STARTER / KEY
X-GH6 - GRID HEATER [ R-RES-G_HTR] (87744835) (Plug)
87744835 99
87744835
1 GH5-P-1 GRID HEATER FUSE CABLE_06 GRID HEATER POWER RD - 32.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
CABLE 1, GRID HEATER, FILTER HEATER
X-GH7 - GRID HEATER [ R-RES-G_HTR] (87744835) (Plug)
87744835 100
87744835
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1 X-001 (Plug) pin 1 - GRID CABLE_07 GRID HEATER GROUND BK - 32.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
HEATER CABLE GRND ON CABLE 1, GRID HEATER, FILTER HEATER
ENGINE (84398003)
X-GHC - GRID HEATER CONTROL [ K-GH] (82012083) (Plug)
82012083 101
82012083
X-GND_CENG1 - GROUND CLEAN ENG BLOCK (84140737) (Plug)
84140737 102
84140737
1 X-ENG (Plug) pin 3 - 857A CAB CLEAN GRND BK - 2.0 SHEET 12 SH12 - POWER DISTRIBUTION 1
ENGINE TO CAB [SH18: CLEAN GROUND BLK
C-6] (87696948)
1 X-TURBO_2 (Receptacle) 203A EVGT CLN GRND BK - 1.0
pin 5 - ENGINE HARNESS
INTERFACE T2 [SH18: B-5]
(87694583)
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X-GND_CENG2 - GROUND CLEAN ENG BLOCK [ SH12: A-4] (84140737) (Plug)
84140737 103
84140737
1 X-LC6 pin 17 - LOADCENTER 254 AC CLUTCH RELAY BK - 0.8 SHEET 11 SH11 - PWR DISTR ENG
6 [SH16: A-3] (84380518) GRND COMPARTMENT (FUSE BLOCK LC6)
1 SP-603-P-X 603 CLEAN GROUND BK - 5.0
1 SP-201D-P-X 201K SCR SENSOR GROUND BK - 3.0
1 SP-201-P-X 201 SCR SENSORS CLEAN BK - 3.0
GROUND
X-GND_ENG1 - GROUND ENG BLOCK [ SH16: A-1] (84140737) (Plug)
84140737 104
84140737
1 X-LC7 pin 1 - LOAD CENTER 197 ENG GROUND BK - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
7 (84563565) STARTER / KEY
1 X-WSH (Receptacle) pin 195 FUEL FILTER HTR GRND BK - 2.0
A - WATER SEPERATOR
HEATER [Y-W_S_H]
(87679438)
1 X-LC6 pin 3 - LOADCENTER 198 CHASSIS GRND T2 BK - 0.8
6 [SH16: A-3] (84380518)
1 X-FFH (Receptacle) pin B - 196 FUEL FILTER HEATER BK - 2.0
FILTER HEATER [Y-F_F_H] GND
(87679438)
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X-GND_ENG3 - GROUND ENG BLOCK [ SH15: C-3] (84140737) (Plug)
84140737 105
84140737
1 SP-208-P-X 208 HOOD LIFT GROUND BK - 2.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
1 X-GRD_WIF (Plug) pin 1 281 WIF GROUND BK - 1.0 PWR DISTR
- WATER IN FUEL GRND
(84426120)
X-GND_ENG4 - GROUND ENG BLOCK [ SH29: B-3] (84140737) (Plug)
84140737 106
84140737
1 X-ISO pin 3 - ISOLATOR 251 ISOLATOR GRND BK - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
[K-ISOLATOR] (87687242) STARTER / KEY
1 X-ENG_H (Plug) pin 1 242 TAIL LIGHT GROUND BK - 1.0
- ENGINE TO HOOD
(87700321)
1 SP-243-P-X 243 TAIL LIGHTS GRND BK - 0.8
EURO
1 X-BU1 (Plug) pin 1 - BACK 244 BACKUP ALARM GND BK - 0.8
UP ALARM [H-BU_ALRM]
(84426117)
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X-GND_FRNT - CHASSIS GROUND (84140737) (Plug)
84140737 107
84140737
1 X-GND_RR (Plug) pin 061 CHASSIS GROUND BK - 5.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
1 - CHASSIS GROUND PWR DISTR
(84140737)
X-GND_GRL - GROUND GRILL TERMINAL (84140737) (Plug)
84140737 108
84140737
1 GND_RR5-P-1 CHASSIS 313 HOOD GRILL GROUND BK - 2.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
GROUND PWR DISTR
X-GND_PED - GROUND PEDESTAL RING [ SH14: B-6] (84140737) (Plug)
84140737 109
84140737
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1 X-PG (Receptacle) pin H - 955U PEDESTAL GND BK - 1.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
PEDESTAL GROUND [SH28: PWR DISTR
B-6] (87705607)
X-GND_RR - CHASSIS GROUND (84140737) (Plug)
84140737 110
84140737
1 X-GND_FRNT (Plug) pin 061 CHASSIS GROUND BK - 5.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
1 - CHASSIS GROUND PWR DISTR
(84140737)
X-GND_RR2 - CHASSIS GROUND [ SH28: B-2] (84426126) (Plug)
84426126 111
84426126
1 SP-624D-P-X 624D FRONT CHASSIS GND BK - 2.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
PWR DISTR
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X-GND_RR3 - SEC STRG CHASSIS GRND [ SH14: B-4] (84426126) (Plug)
84426126 112
84426126
X-GND_RR4 - (84140737) (Plug)
84140737 113
84140737
1 SP-391A-P-X 391A DIFF LOCK BK - 1.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
PWR DISTR
X-GRD_WIF - WATER IN FUEL GRND (84426120) (Plug)
84426120 114
84426120
1 X-GND_ENG3 (Plug) pin 1 - 281 WIF GROUND BK - 1.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
GROUND ENG BLOCK [SH15: PWR DISTR
C-3] (84140737)
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X-HD - HOOD LIFT SWITCH [ SH3: A-4] (84159859) (Receptacle)
84159859 115
84159859
1 X-LC6 pin 48 - LOADCENTER 207 HOOD DOWN GY - 1.0 SHEET 37 SH37 - HOOD LIFT
6 [SH16: A-3] (84380518)
2 X-SW_DISC (Receptacle) pin 533 HOOD LIFT SIGNAL RD - 1.0
5 - DISCONNECT SWITCH
[SH37: C-4] (87694112)
3 X-LC6 pin 46 - LOADCENTER 206 HOOD UP WH - 1.0
6 [SH16: A-3] (84380518)
X-HDM - HOOD MOTOR [ M-HD_L_M] (87711966) (Receptacle)
87711966 116
87711966
1 X-LC6 pin 38 - LOADCENTER 209 HOOD UP WH - 2.0 SHEET 37 SH37 - HOOD LIFT
6 [SH16: A-3] (84380518)
2 X-LC6 pin 40 - LOADCENTER 210 HOOD DOWN GY - 2.0
6 [SH16: A-3] (84380518)
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X-HD_23 - HOOD PL23 (87694153) (Receptacle)
87694153 117
87694153
1 X-BU2 (Plug) pin 1 - BACK 121C BACKUP ALARM PL23 OR - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
UP ALARM [H-BU_ALRM] ALARM
(84426117)
2 SP-124H-P-X 124H REVERSE LIGHTS PL23 VT - 0.8 SHEET 30 SH30 - OLD EURO LIGHTING
X-HD_E - HOOD EURO TO EURO ENG HARN (87644909) (Plug)
87644909 118
87644909
A X-LPL (Plug) pin A - LICENSE 280D LICENSE PLATE LIGHT VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
PLATE LIGHT [LMP-LPL] EURO LIGHTS
(87692855)
C X-LPL (Plug) pin B - LICENSE 243D LPL GRND EURO BK - 0.8
PLATE LIGHT [LMP-LPL]
(87692855)
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X-HD_N - HOOD TO ENG (87700325) (Receptacle)
87700325 119
87700325
1 SP-242H-P-X 242H HOOD GRND PL23 BK - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
1 SP-242A-P-X 242A TAIL LIGHTS GRND NA BK - 1.0
2 X-LH-TAIL (Receptacle) pin 126B LH BRAKE LAMP NA VT - 0.8
[L-NA-TAIL] (87694101)
2 X-LH-REAR-TAIL-EURO 126D STOP PL23 EURO VT - 0.8
LH REAR TAIL LIGHT
(87694112)
3 X-LH-TAIL (Receptacle) pin 128B LH REAR TURN LAMP NA VT - 0.8
[L-NA-TAIL] (87694101)
3 X-LH-REAR-TAIL-EURO 128D TURN PL23 EURO VT - 0.8
LH REAR TAIL LIGHT
(87694112)
4 X-RH-REAR-TAIL-EURO 131E TAIL EURO VT - 0.8
RH-REAR-TAIL-EURO
[LMP-R-EURO-TAIL]
(87694112)
4 X-RH-TAIL (Receptacle) 131B RH REAR TURN LAMP VT - 0.8
pin 4 - RH REAR TAIL NA
[LMP-R-NA-TAIL] (87694101)
5 X-RH-REAR-TAIL-EURO 130H TA VT - 0.8
RH-REAR-TAIL-EURO
[LMP-R-EURO-TAIL]
(87694112)
5 X-RH-TAIL (Receptacle) 130C RH TAIL LAMP NA VT - 0.8
[LMP-R-NA-TAIL] (87694101)
6 X-LH-REAR-TAIL-EURO 127H TAIL PL23 EURO VT - 0.8
LH REAR TAIL LIGHT
(87694112)
6 X-LH-TAIL (Receptacle) pin 127F LH TAIL LAMP NA VT - 0.8
[L-NA-TAIL] (87694101)
7 X-RH-TAIL (Receptacle) 129B RH BRAKE LAMP NA VT - 0.8
[LMP-R-NA-TAIL] (87694101)
7 X-RH-REAR-TAIL-EURO 129D STOP PL23 EURO VT - 0.8
RH-REAR-TAIL-EURO
[LMP-R-EURO-TAIL]
(87694112)
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8 X-E_HD (Receptacle) pin A 280T TRKY LICENSE PLT VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
- ENGINE TO HOOD EURO LIGHT LIGHTS
[SH29: B-1] (87692858)
8 X-LPL (Plug) pin A - LICENSE 280B LICENSE PLATE LIGHT VT - 0.8
PLATE LIGHT [LMP-LPL]
(87692855)
X-HN - CAN [ SW-HORN] (87311796) (Plug)
87311796 120
87311796
2 X-A_RT_P (Receptacle) pin 113E HORN BR - 0.8 SHEET 23 SH23 - PILOT LOADER
5 - ARM REST RIGHT HAND CONTROLS
PILOT (87694112)
X-HN1 - HORN_PWR [ H-HN] (87697629) (Plug)
87697629 121
87697629
1 X-FRNT (Receptacle) pin T 112B HORN YE - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
(87704426)
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X-HN2 - HORN_GRND [ H-HN] (87697629) (Plug)
87697629 122
87697629
1 SP-624D-P-X 624B HORN GND BK - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
X-HOT - HYD OIL TEMP [ B-HOT] (84607243) (Receptacle)
84607243 123
84607243
1 X-TRANS (Plug) pin 30 - 634A HYD OIL TEMP SIG YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
TRANSMISSION TO CAB INSTRUMENTATION
(87696949)
2 SP-482A-P-X 482S HOT GRND BL - 0.8
X-HTS - HUMIDITY AND TEMP SENSOR [ B-HT] (87709809) (Receptacle)
87709809 124
87709809
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1 X-ECU (Receptacle) pin 90 - 690 HUMIDITY TEMP OR - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
ECU CONNECTOR [A-ECU] SENSOR 2, AT
(84300197)
2 X-ECU (Receptacle) pin 15 - 615 HUMIDITY TEMP YE - 0.8
ECU CONNECTOR [A-ECU] SENSOR
(84300197)
3 SP-643-P-X 643A HUMIDITY TEMP BK - 0.8
SENSOR
4 X-ECU (Receptacle) pin 40 - 642 HUMIDITY TEMP YE - 0.8
ECU CONNECTOR [A-ECU] SENSOR
(84300197)
X-HVAC - INTRCECT TO HVAC SYSTEM BY HVAC [ SH33: D-4] (87696573) (Receptacle)
87696573 125
87696573
A X-LC4 (Receptacle) pin 6A - 876 HVAC ACCESSORY OR - 3.0 SHEET 09 SH09 - ACCESSORY PWR DIST
LOADCENTER 4 [SH35: C-6] POWER (FUSE BLOCK LC4)
(87733595)
B X-CAB_E-2 (Plug) pin L - 246 SIG_HVAC_A/C HIGH YE - 0.8 SHEET 33 SH33 - HEATING BLOWER
CAB TO ENG 2 [SH9: C-2] PRESSURE SW HEATER, HVAC
(87703902)
C SP-256-P-X 256C CAB CLEAN GRND BK - 0.8
D SP-256-P-X 256J CAB CLEAN GRND BK - 0.8
E SP-873-P-X 873A HVAC POWER OR - 0.8
F SP-873-P-X 873B HVAC POWER OR - 0.8
H X-AIR (Receptacle) pin 12 - 267 BLOWER SPEED WH - 2.5
HVAC CONSOLE [SH27: C-2]
(84309048)
J X-AIR (Receptacle) pin 11 - 266 BLOWER SPEED YE - 2.0
(84309048)
L SP-258-P-X 258 HVAC ON SIGNAL YE - 0.8
M X-AIR (Receptacle) pin 1 - 262 TEMP SETTING YE - 0.8
(84309048)
N X-AIR (Receptacle) pin 2 - 261 TEMP SETTING WH - 0.8
(84309048)
P X-AIR (Receptacle) pin 3 - 260 TEMP SETTING VT - 0.8
(84309048)
R X-AIR (Receptacle) pin 9 - 264 BLOWER SPEED GY - 1.0
(84309048)
S X-AIR (Receptacle) pin 10 - 265 BLOWER SPEED GN - 2.0
(84309048)
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X-HVAC2 - HVAC MECHINISM (87696550) (Plug)
87696550 126
87696550
A X-06 (Receptacle) pin 1 - 876H 876H OR - 3.0 SHEET 33 SH33 - HEATING BLOWER
DENSO HEATER, HVAC
B X-07 (Receptacle) pin A - 246B 246B WH - 0.35
DENSO (87692855)
C X-01 (Receptacle) pin 15 - 256F 256F BK - 0.8
DENSO
F X-01 (Receptacle) pin 1 - 873C 873C GN - 0.35
DENSO
H SP-267-P-X 267B 267B GY - 2.5
J X-05 (Receptacle) pin 3 - 266B 266B YE - 2.0
DENSO
K X-01 (Receptacle) pin 14 - 258F DENSO RD - 0.35
DENSO
L X-01 (Receptacle) pin 8 - 258E 258E GY - 0.35
DENSO
M X-01 (Receptacle) pin 20 - 260B 260B YE - 0.35
DENSO
N X-01 (Receptacle) pin 25 - 261B 261B WH - 0.35
DENSO
P X-01 (Receptacle) pin 2 - 262B 262B PRP - 0.35
DENSO
R SP-264B-P-X 264B 264B GY - 1.0
S X-05 (Receptacle) pin 2 - 265B 265B GN - 2.0
DENSO
X-ISO - ISOLATOR [ K-ISOLATOR] (87687242) (Plug)
87687242 127
87687242
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X-ISS - SPEED SENSOR MIDDLE WHEEL CHAIN [ B-IS_S] (84364854) (Receptacle)
84364854 128
84364854
1 X-TRANS (Plug) pin 9 - 701A INTERMEDIATE SPEED YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
TRANSMISSION TO CAB SENSOR
(87696949)
2 X-TRANS (Plug) pin 11 - 702B SPEED SENSOR GRND BL - 0.8
TRANSMISSION TO CAB
(87696949)
X-JC1 - JUNCTION STUD OF B+ IN REAR (84399576) (Plug)
84399576 129
84399576
1 X-CPWR (Plug) pin 1 - CAB 235 B+ TO REAR JUNCTION RD - 19.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
POWER (84401295) BLOCK STARTER / KEY
X-JC2 - JUNCTION STUD OF B+ IN REAR [ SH3: C-4] (84186853) (Plug)
84186853 130
84186853
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1 X-LC6 pin 3 - LOADCENTER 212 B+ RD - 3.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
6 [SH16: A-3] (84380518) STARTER / KEY
1 X-LC6 pin 30 - LOADCENTER 212A EVGT POWER RD - 3.0
6 [SH16: A-3] (84380518)
1 X-LC6 pin 9 - LOADCENTER 416 B+ RD - 5.0
6 [SH16: A-3] (84380518)
X-JC3 - JUNCTION STUD OF B+ IN REAR (84253168) (Plug)
84253168 131
84253168
1 X-LC7 pin 3 - LOAD CENTER 229 B+ RD - 5.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
7 (84563565) STARTER / KEY
X-JS+ - JUMP START STUD POS [ J-JS+] (Plug)

PIN1 X-P5320 (Plug) pin PIN1 - CABLE09 JUMP START RD - 32.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
JUMP START [G-002] STARTER / KEY
X-JS- - JUMP START STUD NEG [ J-JS-] (Plug)

PIN1 X-P5321 (Plug) pin PIN1 - CABLE08 JUMP START MINUS BK - 32.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
JUMP START [G-001] STARTER / KEY
X-JSS_CAN - CAN (87695580) (Receptacle)
87695580 132
87695580
A SP-B_HM-P-X CANB_HO CAN WH - 0.8 SHEET 24 SH24 - CAN STRUCTURE
B SP-B_LM-P-X CANB_LO CAN BL - 0.8
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X-JSS_COM - JSS FRAME TO CAB CAN (87695723) (Plug)
87695723 133
87695723
A SP-B_HP-P-X CANB_HP CAN WH - 0.8 SHEET 24 SH24 - CAN STRUCTURE
B SP-B_LP-P-X CANB_LP CAN BL - 0.8
X-JSS_CO_1 - CUT OFF SENSOR [ K-JSS_CO_1] (87694153) (Receptacle)
87694153 134
87694153
1 SP-677A-P-X 677G 5V REF3 OUT PK - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
2 SP-967A-P-X 967G 5 V REF GRND3 BL - 0.8
4 X-JSS_FR (Plug) pin 2 - JSS 676A JSS PILOT PRESS SIG YE - 0.8
FRAME HARNESS TO CAB
(87694152)
X-JSS_CO_2 - CUT OFF SENSOR [ B-JSS_CO_2] (87694153) (Receptacle)
87694153 135
87694153
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1 SP-677A-P-X 677F 5V REF3 OUT PK - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
2 SP-967A-P-X 967F 5 V REF GRND3 BL - 0.8
4 X-JSS_FR (Plug) pin 6 - JSS 273A JSS CUTOFF SIG B YE - 0.8
FRAME HARNESS TO CAB
(87694152)
X-JSS_FR - JSS FRAME HARNESS TO CAB (87694152) (Plug)
87694152 136
87694152
1 SP-799C-P-X 799C JSS IGN PWR OR - 0.8 SHEET 24 SH24 - CAN STRUCTURE
2 X-JSS_CO_1 (Receptacle) 676A JSS PILOT PRESS SIG YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
pin 4 - CUT OFF SENSOR
[K-JSS_CO_1] (87694153)
3 SP-677A-P-X 677A 5V REF3 OUT PK - 0.8
4 SP-967A-P-X 967A 5 V REF GRND3 BL - 0.8
5 SP-955Y-P-X 955Y JSS GROUND BK - 0.8
6 X-JSS_CO_2 (Receptacle) 273A JSS CUTOFF SIG B YE - 0.8
pin 4 - CUT OFF SENSOR
[B-JSS_CO_2] (87694153)
X-JSS_JOY - JSS LEFT HAND JOYSTICK [ B-JSS] (87700107) (Receptacle)
87700107 137
87700107
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1 X-LFT_A (Plug) pin 7 - 677D 5V REF3 OUT PK - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
JSS TO CAB L ARMREST
(87700155)
2 X-LFT_A (Plug) pin 2 - 670A JSS JOYSTICK 1 YE - 0.8
(87700155)
3 X-LFT_A (Plug) pin 6 - 967D 5 V REF GRND3 BL - 0.8
(87700155)
4 X-LFT_A (Plug) pin 1 - 471L 5V REF2 PK - 0.8
(87700155)
5 X-LFT_A (Plug) pin 5 - 630A JSS JOYSTICK 2 YE - 0.8
(87700155)
6 X-LFT_A (Plug) pin 3 - 651M 5V GND2 BL - 0.8
(87700155)
X-JSV - JOYSTICK STEERING VALVE [ SH21: B-2] (87695592) (Receptacle)
87695592 138
87695592
4 SP-B_HV-P-X CANB_HW CAN WH - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
5 SP-B_LV-P-X CANB_LW CAN BL - 0.8
6 SP-854A-P-X 854A TO JSS CUTOFF VALVES WH - 0.8
7 SP-955Y-P-X 955AA JSS GROUND BK - 0.8
8 SP-799C-P-X 799E JSS IGN PWR OR - 0.8
9 SP-B_LS-P-X CANB_LT CAN BL - 0.8
10 SP-B_HS-P-X CANB_HT CAN WH - 0.8
X-KDD - KICK DOWN SW (84146428) (Receptacle)
84146428 139
84146428
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X-KDS - CAN (87311796) (Plug)
87311796 140
87311796
2 X-A_RT_2B (Receptacle) pin 309B KICK DOWN SIGNAL YE - 0.8 SHEET 23 SH23 - PILOT LOADER
2 (84281913)
4 X-A_RT_P (Receptacle) pin 792H KICKDOWN SW PWR OR - 0.8
1 - ARM REST RIGHT HAND
PILOT (87694112)
X-KEY - KEY SWITCH [ SW-KEY] (87699176) (Receptacle)
87699176 141
87699176
A SP-219A-P-X 219B NON-ISOLATED PWR RD - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
B X-X7 (Receptacle) pin 30 - 220 SIG_IGNITION YE - 0.8 STARTER / KEY
SFB [SH3: A-3] (84538791) SWITCH_START
C X-X7 (Receptacle) pin 32 - 225 SIG_IGNITION YE - 0.8
SFB [SH3: A-3] (84538791) SWITCH_ACC
D X-X7 (Receptacle) pin 31 - 221 SIG_IGNITION YE - 0.8
SFB [SH3: A-3] (84538791) SWITCH_RUN
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X-LC1 - LOADCENTER 1 [ SH10: A-6] (47728326) (Receptacle)
47728326 142
47728326
X-LC2 - LOADCENTER 2 [ SH7: B-3] (87733581) (Receptacle)
87733581 143
87733581
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1A F-2F1-P-2 WIRE6246 WIRE6246 SHEET 07 SH07 - BATTERY PWR DISTR
1A X-UCM1A (Receptacle) pin 465 CAB ISOLATED B+ RD - 1.0 (FUSE BLOCK LC2)
20 - UCM (82016219)
2A F-2F2-P-2 WIRE6247 WIRE6247
2A SP-448-P-X 448 CAB ISOLATED B+ RD - 3.0
6A SP-165-P-X 165 TECM_RH STALK B+ RD - 1.0
7A X-DSP (Receptacle) pin X - 805 DISPLAY B+ RD - 0.8
DISPLAY [A-DSP] (82016219)
8A X-DIA (Plug) pin B - 798 DIAGNOSTIC B+ RD - 0.8
DIAGNOSTIC PORT [A-DIA]
(87736919)
9A X-CAB_E (Receptacle) pin 2 205 HOOD LIFT RD - 2.0
(84807216)
11A F-2F11-P-2 WIRE6229 WIRE6229
11A X-CAM (Receptacle) pin 1 - 125 REVERSE CAMERA OR - 0.8
REAR CAMERA (87700107) POWER
12A F-2F12-P-2 WIRE6224 WIRE6224
13A F-2F13-P-2 WIRE6228 WIRE6228
1B X-P1196 (Plug) pin 1 - B+ 526 CAB ISOLATED B+ RD - 1.0
POWER STUD (84140737)
1B F-2F1-P-1 WIRE6245 WIRE6245
7B X-P1002 (Plug) pin 1 - B+ 532 CAB ISOLATED POWER RD - 3.0
7B SP-2F7-P-X WIRE6232 WIRE6232
9B X-CAB_E (Receptacle) pin 4 216E HOOD LIFT NON-DISC RD - 2.0
- CAB TO ENGINE [SH7: B-5] PWR
(84807216)
12B SP-878-P-X 878C IGN PWR OR - 3.0
12B SP-F12-P-X WIRE6223 WIRE6223
X-LC3 - LOADCENTER 3 [ SH35: B-6] (84529039) (Receptacle)
84529039 144
84529039
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F6_6 X-P1009 (Plug) pin 1 - B+ 541 CAB ISOLATED POWER RD - 2.0 SHEET 08 SH08 - POWER DISTRIBUTION
POWER STUD (84140737) (FUSE BLOCK LC3)
F6_6 SP-F6_6-P-X WIRE6256 WIRE6256
F8_4 F-3F8-P-2 WIRE6263 WIRE6263
F8_4 X-LC3 (Receptacle) pin 191 SWBAT_ISOLA- RD - 3.0
R1_30 - LOADCENTER 3 TOR_SPARE SUPPLY
[SH35: B-6] (84529039)
F8_8 F-3F8-P-1 WIRE6262 WIRE6262
F8_8 X-P1009 (Plug) pin 1 - B+ 917 CAB ISOLATED POWER RD - 3.0
F1_13 F-3F1-P-2 WIRE6261 WIRE6261
F1_13 X-X-PO1 (Receptacle) pin A 750 RH CONSOLE 12V PWR OR - 1.0
- POWER OUTLET [J-PO1] OUTLET
(84398827)
F3_11 X-CNV (Receptacle) pin 5 - 24 748 12V ACC POWER OR - 2.0
TO 12 POWER CONVERTER
[SH35: B-4] (87694112)
F3_11 SP-F3_11-P-X WIRE6250 WIRE6250
F3_15 F-3F3-P-2 WIRE6260 WIRE6260
F3_15 X-RAD (Receptacle) pin 7 - 753 12V FUSED ACC PWR OR - 0.8
RADIO [H-RADIO] (87709660)
R1_30 X-LC3 (Receptacle) pin F8_4 191 SWBAT_ISOLA- RD - 3.0
- LOADCENTER 3 [SH35: B-6] TOR_SPARE SUPPLY
(84529039)
R1_30 K-3R1-P-30 WIRE6264 WIRE6264
R1_85 X-LC3 (Receptacle) pin WIRE6266 WIRE6266
[SH35: B-6] (84529039)
R1_85 X-CG4 (Receptacle) pin F - 954F SPARE RELAY COIL GND BK - 0.8
(84149207)
R1_85 X-LC3 (Receptacle) pin WIRE6266 WIRE6266
[SH35: B-6] (84529039)
R1_86 K-3R1-P-86 WIRE6275 WIRE6275
R1_86 X-X3 (Receptacle) pin 15 - 192 SIG_DC_CONVERTER OR - 0.8
SFB [SH3: A-1] (47554344)
R1_87 K-3R1-P-87 WIRE6265 WIRE6265
R1_87 SP-746-P-X 746 POWER CONVERTER OR - 3.0
ACC POWER
R2_30 K-3R2-P-30 WIRE6274 WIRE6274
R2_30 X-LC5 (Receptacle) pin 5A - 182 SEC STRG IGN PWR OR - 0.8
LOADCENTER 5 [SH10: D-1]
(87733595)
R2_85 K-3R2-P-85 WIRE6268 WIRE6268
R2_85 SP-954S-P-X 954R SEC STRG SIG GRND BK - 0.8
R2_86 K-3R2-P-86 WIRE6273 WIRE6273
R2_87 K-3R2-P-87 WIRE6267 WIRE6267
R2_87 X-CAB_B (Plug) pin 12 - CAB 441 SEC STRG SOL PWR OR - 0.8
TO BOTTOM [SH21: B-3]
(87696945)
R3_30 K-3R3-P-30 WIRE6272 WIRE6272
R3_30 X-LC4 (Receptacle) pin 8A - 877 REAR DEFROST OR - 2.0
LOADCENTER 4 [SH35: C-6] ACCESSORY POWER
(87733595)
R3_85 K-3R3-P-85 WIRE6270 WIRE6270
R3_85 SP-954S-P-X 954M REAR DEFROST RELAY BK - 0.8
GND
R3_86 K-3R3-P-86 WIRE6271 WIRE6271
R3_86 X-X3 (Receptacle) pin 7 - SFB 120 REAR DEFROST YE - 0.8
[SH3: A-1] (47554344)
R3_87 K-3R3-P-87 WIRE6269 WIRE6269
R3_87 X-RWHE1 (Receptacle) pin 801 REAR DEFROST PWR OR - 2.0
1 - REAR WINDOW HEATER
[R-WND_HTR] (87688695)
R4_30 SP-219A-P-X 219D NON-ISOLATED PWR RD - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
STARTER / KEY
R4_85 SP-113-P-X 113F HORN SIGNAL BR - 0.8 SHEET 13 SH13 - POWER DISTRIBUTION 2
R4_86 SP-219A-P-X 219E NON-ISOLATED PWR RD - 0.8 CAB GROUND BLK
R4_87 X-CAB_B (Plug) pin 21 - CAB 112 HORN YE - 0.8
(87696945)
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X-LC4 - LOADCENTER 4 [ SH35: C-6] (87733595) (Receptacle)
87733595 145
87733595
30 K-4KR1-P-30 WIRE6289 WIRE6289 SHEET 09 SH09 - ACCESSORY PWR DIST
85 K-4KR1-P-85 WIRE6292 WIRE6292 (FUSE BLOCK LC4)
85 X-CG4 (Receptacle) pin A - 954A ACCESSORY RELAY BK - 0.8
CAB GROUND [SH24: B-6] COIL GND
(84149207)
86 K-4KR1-P-86 WIRE6290 WIRE6290
86 X-X3 (Receptacle) pin 11 - 226 ACCESSORY POWER YE - 0.8
SFB [SH3: A-1] (47554344)
87 X-LC4 (Receptacle) pin 2B - 919 ACCESSORY POWER OR - 3.0
LOADCENTER 4 [SH35: C-6]
(87733595)
(87733595)
87 K-4KR1-P-87 WIRE6291 WIRE6291
(87733595)
1A X-CL (Receptacle) pin 743 24V CIGAR LIGHTER OR - 2.0
1 - CIGAR LIGHTER
[LMP-CIG_LTR] (84015523)
3A X-CAB_E-2 (Plug) pin K - 875 AC CLUTCH PWR OR - 1.0
CAB TO ENG 2 [SH9: C-2]
(87703902)
6A X-HVAC (Receptacle) pin 876 HVAC ACCESSORY OR - 3.0
A - INTRCECT TO HVAC POWER
D-4] (87696573)
7A X-SC (Plug) pin A - SEAT 742 12V FUSED ACC PWR OR - 2.0
COMPRESSOR [Y-SC] FOR SEAT COMP
(87692855)
8A X-LC3 (Receptacle) pin 877 REAR DEFROST OR - 2.0 SHEET 08 SH08 - POWER DISTRIBUTION
R3_30 - LOADCENTER 3 ACCESSORY POWER (FUSE BLOCK LC3)
[SH35: B-6] (84529039)
2B SP-6201-P-X WIRE6276 WIRE6276 SHEET 09 SH09 - ACCESSORY PWR DIST
2B X-LC4 (Receptacle) pin 87 - 919 ACCESSORY POWER OR - 3.0 (FUSE BLOCK LC4)
(87733595)
6B X-LC4 (Receptacle) pin 87 - 920 ACCESSORY POWER OR - 3.0
(87733595)
8B X-LC4 (Receptacle) pin 87 - 874 ACCESSORY POWER OR - 3.0
(87733595)
8B SP-4F8-P-X WIRE6283 WIRE6283
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X-LC5 - LOADCENTER 5 [ SH10: D-1] (87733595) (Receptacle)
87733595 146
87733595
30 X-LC1 pin B1 - LOADCENTER 173 ISOLATED_SFB_IGNI- RD - 5.0 SHEET 10 SH10 - IGNITION PWR DISTR
1 [SH10: A-6] (47728326) TION SUPPLY (FUSE BLOCK LC5)
30 K-5KR1-P-30 WIRE6302 WIRE6302
85 X-CG4 (Receptacle) pin H - 954H IGNITION RELAY COIL BK - 0.8
(84149207)
85 K-5KR1-P-85 WIRE6296 WIRE6296
86 X-X3 (Receptacle) pin 8 - SFB 222 SIG_IGNITION YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
[SH3: A-1] (47554344) RELAY_COIL STARTER / KEY
86 K-5KR1-P-86 WIRE6308 WIRE6308
87 K-5KR1-P-87 WIRE6307 WIRE6307 SHEET 10 SH10 - IGNITION PWR DISTR
87 SP-878-P-X 878 IGNITION POWER OR - 5.0 (FUSE BLOCK LC5)
1A X-DSP (Receptacle) pin X - 806 DISPLAY WAKE-UP OR - 0.8
DISPLAY [A-DSP] (82016219) IGNITION POWER
2A SP-466-P-X 466 IGNITION POWR FOR OR - 0.8
UCM
3A SP-19C-P-X 19C IGN PWR OR - 2.0
4A X-X_TEL (Receptacle) pin 2 168 TELEMATICS IGN OR - 0.8
- TELEMATICS [SH38: C-6] POWER
(87700156)
5A X-LC3 (Receptacle) pin 182 SEC STRG IGN PWR OR - 0.8
[SH35: B-6] (84529039)
6A X-CAB_AR (Plug) pin 1 - CAB 792 IMP JOYSTICK PWR OR - 0.8
TO RH ARM REST (87694152)
7A X-SW_PD (Receptacle) pin 807 KEYPAD IGN POWER OR - 0.8
1 - SWITCH PAD [SW-PD]
(87694153)
8A SP-799-P-X 799 JSS IGNITION POWER OR - 0.8
9A X-CAB_E (Receptacle) pin 1 850 IGN PWR FOR REAR OR - 2.0
(84807216)
10A F-5F10-P-2 WIRE6309 WIRE6309
10A SP-19H-P-X 19H STALK/DIFF FUSED PWR OR - 0.8
3B SP-878-P-X 878A IGNITION POWER OR - 3.0
9B SP-878-P-X 878B IGN PWR OR - 3.0
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X-LC6 - LOADCENTER 6 [ SH16: A-3] (84380518) (Receptacle)
84380518 147
84380518
X-LC7 - LOAD CENTER 7 (84563565) (Receptacle)
84563565 148
84563565
X-LEV1 - INLINE TO DEF LEVEL & TEMP (84062580) (Plug)
84062580 149
84062580
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X-LEV2 - INLINE TO DEF LEVEL & TEMP (87680689) (Receptacle)
87680689 150
87680689
X-LF2 - WORK LIGHT OPT [ LMP-LF0] (87695582) (Receptacle)
87695582 151
87695582
1 SP-6111D-P-X 111B WORK LIGHT JUMPER VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
2 SP-949F-P-X 949D WORK LIGHT BK - 1.0 LIGHTS CAB ROOF, FRONT AND REAR
X-LFO - WORK LIGHT OPTION (87695584) (Plug)
87695584 152
87695584
1 SP-6111D-P-X 111C WORK LIGHT JUMPER VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
2 SP-949F-P-X 949E WORK LIGHT JUMPER BK - 1.0 LIGHTS CAB ROOF, FRONT AND REAR
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X-LFT_2 - LEFT JS TO CAB (87700105) (Plug)
87700105 153
87700105
1 X-SW_JSS (Receptacle) pin 691A JSS INDICATOR WH - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
10 - JOYSTICK STEERING
SWITCH [SW-SW_JSS]
(87716755)
2 X-SW_JSS (Receptacle) pin 981K BACKLIGHTING VT - 0.8
SWITCH [SW-SW_JSS]
(87716755)
X-LFT_A - JSS TO CAB L ARMREST (87700155) (Plug)
87700155 154
87700155
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1 X-JSS_JOY (Receptacle) 471L 5V REF2 PK - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
pin 4 - JSS LEFT HAND
JOYSTICK [B-JSS]
(87700107)
2 X-JSS_JOY (Receptacle) 670A JSS JOYSTICK 1 YE - 0.8
JOYSTICK [B-JSS]
(87700107)
3 X-JSS_JOY (Receptacle) 651M 5V GND2 BL - 0.8
JOYSTICK [B-JSS]
(87700107)
4 X-LH_ARM_UP (Receptacle) 675A LH ARMREST POSITION GY - 0.8
pin 3 - LH JSS ARM REST UP
DOWN [SW-ARM_POS_UP]
(84000405)
5 X-JSS_JOY (Receptacle) 630A JSS JOYSTICK 2 YE - 0.8
JOYSTICK [B-JSS]
(87700107)
6 X-JSS_JOY (Receptacle) 967D 5 V REF GRND3 BL - 0.8
JOYSTICK [B-JSS]
(87700107)
7 X-JSS_JOY (Receptacle) 677D 5V REF3 OUT PK - 0.8
JOYSTICK [B-JSS]
(87700107)
8 X-LH_ARM_DWN 673A LH ARMREST POSITION TN - 0.8
(Receptacle) pin 3 - LH DWN
JSS ARM REST DOWN
[SW-ARM_POS_DWN]
(84000405)
9 X-SW_JSS (Receptacle) pin 678A JSS ACTIVATION WH - 0.8
SWITCH [SW-SW_JSS]
(87716755)
10 SP-799A-P-X 799G JSS IGNITION POWER OR - 0.8
11 SP-954-P-X 954 LH JSS GND BK - 0.8
12 X-SW_JSS (Receptacle) pin 682A JSS ACTIVATION NC YE - 0.8
SWITCH [SW-SW_JSS]
(87716755)
X-LFWL - LEFT FRONT WORK LIGHT [ LMP-LF_WL] (87695582) (Receptacle)
87695582 155
87695582
1 X-ROOF (Receptacle) pin 1 - 111A LEFT FRONT WORK VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
ROOF TO CAB (87700325) LIGHT LIGHTS CAB ROOF, FRONT AND REAR
1 SP-6111D-P-X 111D WORK LIGHT JUMPER VT - 1.0
2 SP-949A-P-X 949C LEFT FRONT WORK BK - 1.0
LIGHT GND
2 SP-949F-P-X 949F WORK LIGHT JUMPER BK - 1.0
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X-LH-REAR-TAIL-EURO - LH REAR TAIL LIGHT EURO [ LMP-L-EURO-TAIL] (87694112) (Receptacle)
87694112 156
87694112
1 X-HD_N (Receptacle) pin 2 - 126D STOP PL23 EURO VT - 0.8 SHEET 30 SH30 - OLD EURO LIGHTING
HOOD TO ENG (87700325)
2 X-HD_N (Receptacle) pin 3 - 128D TURN PL23 EURO VT - 0.8
3 X-HD_N (Receptacle) pin 6 - 127H TAIL PL23 EURO VT - 0.8
4 SP-124H-P-X 124K REVERSE LIGHTS PL23 VT - 0.8
5 SP-242H-P-X 242L GRND BK - 0.8
X-LH-TAIL - LH REAR TAIL LIGHT NA [ L-NA-TAIL] (87694101) (Receptacle)
87694101 157
87694101
1 SP-243-P-X 243A TAIL LIGHTS GRND BK - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
EURO
1 SP-242A-P-X 242C TAIL LIGHTS GRND NA BK - 1.0
2 X-ENG (Plug) pin 10 - 126E STOP LH EURO VT - 0.8
(87696948)
2 X-HD_N (Receptacle) pin 2 - 126B LH BRAKE LAMP NA VT - 0.8
3 X-HD_N (Receptacle) pin 6 - 127F LH TAIL LAMP NA VT - 0.8
3 X-ENG (Plug) pin 12 - 127J TAIL EURO VT - 0.8
(87696948)
4 X-ENG (Plug) pin 22 - 128E LH TURN EURO VT - 0.8
(87696948)
4 X-HD_N (Receptacle) pin 3 - 128B LH REAR TURN LAMP NA VT - 0.8
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X-LH_ARM_DWN - LH JSS ARM REST DOWN [ SW-ARM_POS_DWN] (84000405) (Receptacle)
84000405 158
84000405
1 SP-799A-P-X 799J JSS IGNITION POWER OR - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
3 X-LFT_A (Plug) pin 8 - 673A LH ARMREST POSITION TN - 0.8
JSS TO CAB L ARMREST DWN
(87700155)
X-LH_ARM_UP - LH JSS ARM REST DOWN [ SW-ARM_POS_UP] (84000405) (Receptacle)
84000405 159
84000405
1 SP-799A-P-X 799K JSS IGNITION POWER OR - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
3 X-LFT_A (Plug) pin 4 - 675A LH ARMREST POSITION GY - 0.8
JSS TO CAB L ARMREST UP
(87700155)
X-LLF - FRONT COMBO LAMP LEFT [ LMP-LF_LT] (87694109) (Plug)
87694109 160
87694109
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X-LPL - LICENSE PLATE LIGHT [ LMP-LPL] (87692855) (Plug)
87692855 161
87692855
A X-HD_E (Plug) pin A - HOOD 280D LICENSE PLATE LIGHT VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
EURO TO EURO ENG HARN EURO LIGHTS
(87644909)
A X-HD_N (Receptacle) pin 8 - 280B LICENSE PLATE LIGHT VT - 0.8
B X-HD_E (Plug) pin C - HOOD 243D LPL GRND EURO BK - 0.8
EURO TO EURO ENG HARN
(87644909)
B SP-242A-P-X 242D LICENSE PLAT LIGHT BK - 0.8
GRND
X-LRF - FRONT COMBO LAMP RT [ LMP-RF_LT] (87694109) (Plug)
87694109 162
87694109
X-LRWL - LEFT REAR WORK LIGHT [ LMP-LR_WL] (87695582) (Receptacle)
87695582 163
87695582
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1 SP-859A-P-X 859B LEFT REAR WORK LIGHT VT - 0.8 SHEET 31 SH31 - LIGHTING WORKING
2 SP-953A-P-X 953E LEFT REAR WORK LIGHT BK - 1.0 LIGHTS CAB ROOF, FRONT AND REAR
GND
X-MAP - MAP LIGHT [ SH13: C-6] (84058093) (Receptacle)
84058093 164
84058093
A X-X3 (Receptacle) pin 18 - 147 MAP LAMP VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
SFB [SH3: A-1] (47554344) LIGHTS
C X-CG3 (Receptacle) pin 955Q MAP LIGHT GND BK - 0.8 SHEET 13 SH13 - POWER DISTRIBUTION 2
K - CAB GROUND RH CAB GROUND BLK
(84149207)
X-MH_L - MIRROR HEATED LEFT [ L-MH_L] (87695582) (Receptacle)
87695582 165
87695582
1 SP-114A-P-X 114B MIRROR HEAT SUPPLY TN - 1.0 SHEET 34 SH34 - MIRRORS, HORN BEACON
LH
2 SP-953A-P-X 953C MIRROR HEAT GND LH BK - 1.0 SHEET 31 SH31 - LIGHTING WORKING
LIGHTS CAB ROOF, FRONT AND REAR
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X-MH_R - MIRROR HEATED RIGHT [ LMP-MH_R] (87695582) (Receptacle)
87695582 166
87695582
1 SP-114A-P-X 114C MIRROR HEAT SUPPLY TN - 1.0 SHEET 34 SH34 - MIRRORS, HORN BEACON
RH
2 SP-953A-P-X 953D MIRROR HEAT GND RH BK - 1.0
X-NH3 - NH3 SENSOR [ B-NH3] (84146686) (Receptacle)
84146686 167
84146686
X-NOXD - SCR DOWNSTREAM NOX SENSOR [ B-NOX_DU] (84190317) (Receptacle)
84190317 168
84190317
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1 SP-200D-P-X 200F SCR SENSOR POWER OR - 1.0 SHEET 18 SH18 - ENGINE CONTROL UNIT
2 SP-201D-P-X 201F SCR SENSORS CLEAN BK - 1.0 3, AT
GROUND
3 SP-CANC_LE-P-X CANC_LF CAN GN - 0.8
4 SP-CANC_HE-P-X CANC_HF CAN YE - 0.8
5 SP-201D-P-X 201G SCR SENSORS CLEAN BK - 0.8
GROUND
X-NOXS - DOC UPSTREAM NOX SENSOR [ B-NOX_SD] (84190317) (Receptacle)
84190317 169
84190317
1 SP-200D-P-X 200G SCR SENSOR POWER OR - 1.0 SHEET 18 SH18 - ENGINE CONTROL UNIT
2 SP-201D-P-X 201H SCR SENSORS CLEAN BK - 1.0 3, AT
GROUND
3 SP-CANC_LG-P-X CANC_LJ CAN GN - 0.8
4 SP-CANC_HG-P-X CANC_HJ CAN YE - 0.8
X-OSS - SPEED SENSOR GEAR TRANS [ B-OSS] (84062580) (Plug)
84062580 170
84062580
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X-PBBS - PARK BRAKE PRES SENSR [ B-PBBS] (Plug)
X-PBW - BRAKE SUPPLY WARNING PRES [ B-PBW] (84078681) (Receptacle)
84078681 171
84078681
A SP-482H-P-X 482K 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
B SP-486D-P-X 486F 5V REF1 PK - 0.8 INSTRUMENTATION
C X-BTM (Receptacle) pin 6 640A BRAKE SUPPLY PRESS YE - 0.8
- BOTTOM TO CAB STD
(87704523)
X-PED - PEDESTAL TO CAB (87700156) (Receptacle)
87700156 172
87700156
1 X-TT (Receptacle) pin 2 188A LH TURN INDICATOR VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
- TELL TALE INDICATOR WARNING, BLINKERS, DRIVING
[LMP-TTI] (87715979)
2 X-TT (Receptacle) pin 5 189A RIGHT TURN TELL TALE VT - 0.8
- TELL TALE INDICATOR
[LMP-TTI] (87715979)
3 X-TT (Receptacle) pin 3 132G LH HIGH BEAM LAMP VT - 0.8
- TELL TALE INDICATOR
[LMP-TTI] (87715979)
4 X-STLK (Receptacle) pin 113B RH STALK HORN BR - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
1 - STALK LEVER RH SWITCH
[SW-HN_STLK] (84426133)
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5 X-TT (Receptacle) pin 4 134A WARNING INDICATOR YE - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
- TELL TALE INDICATOR LED WARNING, BLINKERS, DRIVING
[LMP-TTI] (87715979)
6 X-S_HZD (Receptacle) 141A HAZARD SWTICH YE - 0.8
pin 3 - SWITCH HAZARD
[SW-HZD_SW] (87716755)
7 X-PG (Receptacle) pin J - 955B PEDESTAL GND BK - 1.0
PEDESTAL GROUND [SH28:
B-6] (87705607)
8 X-S_HZD (Receptacle) pin 269 HAZARD INDICATOR BK - 0.8
10 - SWITCH HAZARD
[SW-HZD_SW] (87716755)
9 X-STLK (Receptacle) pin 19K IGN PWR OR - 0.8 SHEET 24 SH24 - CAN STRUCTURE
3 - STALK LEVER RH
[SW-HN_STLK] (84426133)
10 SP-HP-P-X CAN_HP CAN YE - 0.8
11 SP-LP-P-X CAN_LP CAN GN - 0.8
X-PED_2 - PEDESTAL TO CAB 2 (87705114) (Plug)
87705114 173
87705114
1 X-TS1 (Plug) pin C - 679A STALK FNR R YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
TRANS SHIFTER1 [A-PFNR] / FAN CONTROL
(87692817)
2 X-TS1 (Plug) pin D - 680A STALK FNR N YE - 0.8
TRANS SHIFTER1 [A-PFNR]
(87692817)
3 X-TS1 (Plug) pin B - 683A STALK FNR F YE - 0.8
(87692817)
4 X-TS2 pin C - TRANS 406A GEAR SELECT 1_4 YE - 0.8
SHIFTER 2 [A-PFNR]
(47702209)
5 X-TS2 pin B - TRANS 407A GEAR SELECT 3_4 YE - 0.8
SHIFTER 2 [A-PFNR]
(47702209)
6 X-TS1 (Plug) pin A - 4029 DW3 IGN PWR OR - 0.8
(87692817)
8 X-SRWP (Receptacle) pin 728A REAR WASHER SWITCH YE - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
3 - SWITCH REAR WIPER
[SW-WPR_SW] (87716755)
9 X-SRWP (Receptacle) pin 727A REAR WIPER SWITCH YE - 0.8
[SW-WPR_SW] (87716755)
11 X-SRWP (Receptacle) pin 283A REAR WIPER INDICATOR VT - 0.8
[SW-WPR_SW] (87716755)
12 SP-981A-P-X 981A SWITCH BACK LIGHTING VT - 0.8
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X-PG - PEDESTAL GROUND [ SH28: B-6] (87705607) (Receptacle)
87705607 174
87705607
A X-TT (Receptacle) pin 1 955T TELL TALE INDICATOR BK - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
- TELL TALE INDICATOR GND WARNING, BLINKERS, DRIVING
[LMP-TTI] (87715979)
B X-S_HZD (Receptacle) 955H HAZARD SW GND BK - 0.8
[SW-HZD_SW] (87716755)
C X-SRWP (Receptacle) pin 955G REAR WIPER SW GND BK - 0.8
[SW-WPR_SW] (87716755)
D X-STLK (Receptacle) pin 955F LH TURN SW GND BK - 0.8
7 - STALK LEVER RH
[SW-HN_STLK] (84426133)
E X-S_HZD (Receptacle) 955E HAZARD SW INDICATOR BK - 0.8
pin 7 - SWITCH HAZARD GND
[SW-HZD_SW] (87716755)
F X-SRWP (Receptacle) pin 955D REAR WIPER SW BK - 0.8
7 - SWITCH REAR WIPER INDICATOR GND
[SW-WPR_SW] (87716755)
G X-SRWP (Receptacle) pin 955W PEDESTAL GROUND BK - 0.8
[SW-WPR_SW] (87716755)
H X-GND_PED (Plug) pin 1 - 955U PEDESTAL GND BK - 1.0
GROUND PEDESTAL RING
[SH14: B-6] (84140737)
J X-PED (Receptacle) pin 955B PEDESTAL GND BK - 1.0
7 - PEDESTAL TO CAB
(87700156)
K X-S_HZD (Receptacle) 955C PED GROUND BK - 0.8
[SW-HZD_SW] (87716755)
L X-SRWP (Receptacle) pin 955M GROUND BK - 0.8
[SW-WPR_SW] (87716755)
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X-PHF - HYDRAULIC FILTER SENSOR [ SW-PHF] (84352277) (Plug)
84352277 175
84352277
1 X-TRANS (Plug) pin 23 - 636A HYD FILTER SIGNAL YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
TRANSMISSION TO CAB INSTRUMENTATION
(87696949)
X-PILOT_ENABLE - PILOT ENABLE SOLENOID [ SH28: A-1] (87695582) (Receptacle)
87695582 176
87695582
1 X-FRNT_EH (Receptacle) pin 344B PILOT ENABLE WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
A - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-624D-P-X 624E PILOT ENABLE GRND BK - 0.8
X-PLB-PBD - BRAKE PRES SENSR [ B-PBL/PEDAL/DECLTCH] (84078681) (Receptacle)
84078681 177
84078681
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A SP-482H-P-X 482L 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
B SP-486D-P-X 486G 5V REF1 PK - 0.8 INSTRUMENTATION
C X-BTM (Receptacle) pin 7 641A BRAKE PRESS SENSOR YE - 0.8
- BOTTOM TO CAB STD
(87704523)
X-PRB - ROLL BACK PRESSURE SWITCH [ SW-PRB] (87692877) (Plug)
87692877 178
87692877
A X-FRNT (Receptacle) pin U 291B ROLL BACK PRESSURE YE - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- FRONT TO BOTTOM STD SW CONTROL
(87704426)
B SP-624D-P-X 624F PRB GRND BK - 0.8
X-PRB1 - REDUNDANT BRAKE SW 1 [ B-PRB1] (84078681) (Receptacle)
84078681 179
84078681
A SP-482A-P-X 482D 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
B SP-486N-P-X 486R 5V PWR REF 1 PK - 0.8 INSTRUMENTATION
C X-TRANS (Plug) pin 1 - 443A RED BRAKE SW SIG YE - 0.8
TRANSMISSION TO CAB
(87696949)
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X-PRB2 - REDUNDANT BRAKE SW 2 [ B-PRB2] (84078681) (Receptacle)
84078681 180
84078681
A SP-482A-P-X 482E 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
B SP-486N-P-X 486S 5V PWR REF 1 PK - 0.8 INSTRUMENTATION
C X-TRANS (Plug) pin 24 - 638B RED BRAKE SW SIG YE - 0.8
TRANSMISSION TO CAB
(87696949)
X-PRH2 - HIGH PRESSURE SWITCH 2 [ SH33: C-6] (87688788) (Plug)
87688788 181
87688788
A X-ENG-2 (Receptacle) pin L - 246C AC HIGH PRESS YE - 1.0 SHEET 33 SH33 - HEATING BLOWER
ENGINE TO CAB 2 (87703931) HEATER, HVAC
B X-LC6 pin 26 - LOADCENTER 211B A/C SIGNAL YE - 1.0 SHEET 11 SH11 - PWR DISTR ENG
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X-PSS - STEERING PRESSURE SENSOR [ B-PSS] (84078681) (Receptacle)
84078681 182
84078681
A X-SST (Plug) pin 3 - SEC 482P 5V GRND1 BL - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
STRG TO TRANS (87694152)
B X-SST (Plug) pin 2 - SEC 486W 5V PWR REF 1 PK - 0.8
STRG TO TRANS (87694152)
C X-SST (Plug) pin 4 - SEC 176B AUX STRG PRESS YE - 0.8
STRG TO TRANS (87694152) SIGNAL
X-PUMP - DENOX CONTROL UNIT [ A-PMP] (47421681) (Receptacle)
47421681 183
47421681
X-PXF - RETURN TO DIG PROX [ B-PXF] (87692858) (Plug)
87692858 184
87692858
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A X-FRNT (Receptacle) pin B 294B RTD SIG YE - 0.8 SHEET 23 SH23 - PILOT LOADER
- FRONT TO BOTTOM STD CONTROLS
(87704426)
B SP-293-P-X 293A RTD GRND BK - 0.8
C SP-792D-P-X 792E RTD IGN PWR OR - 0.8
X-PXH - HEIGHT CNTRL PROX [ B-PXH] (87644909) (Plug)
87644909 185
87644909
A X-FRNT (Receptacle) pin X 295B HT CNTRL SIGNAL YE - 0.8 SHEET 23 SH23 - PILOT LOADER
(87704426)
B SP-293-P-X 293B HT CNTRL GRND BK - 0.8
C SP-792D-P-X 792F HT_CNTRL IGN PWR OR - 0.8
X-PXT - RTD XT [ B-PXT] (87644909) (Plug)
87644909 186
87644909
A X-FRNT (Receptacle) pin B 294C RTD XT SIGNAL YE - 0.8 SHEET 23 SH23 - PILOT LOADER
(87704426)
B SP-293-P-X 293C RTD XT GRND BK - 0.8
C SP-792D-P-X 792K RTD XT PWR OR - 0.8
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X-P_JS - PILOT LOADER JOYSTICK [ SW-FNR] (87694152) (Plug)
87694152 187
87694152
1 X-A_RT_P (Receptacle) pin 792G IMP JOYSTICK IGN PWR OR - 0.8 SHEET 23 SH23 - PILOT LOADER
1 - ARM REST RIGHT HAND CONTROLS
PILOT (87694112)
2 X-A_RT_2B (Receptacle) pin 306A FOWARD SIGNAL WH - 0.8
2 (84281913)
3 X-A_RT_2B (Receptacle) pin 307A NUETRAL SIGNAL YE - 0.8
2 (84281913)
4 X-A_RT_2B (Receptacle) pin 308A REVERSE SIGNAL GY - 0.8
2 (84281913)
6 X-A_RT_2B (Receptacle) pin 309A KICK DOWN SIGNAL YE - 0.8
2 (84281913)
X-RAD - RADIO [ H-RADIO] (87709660) (Receptacle)
87709660 188
87709660
7 X-LC3 (Receptacle) pin 753 12V FUSED ACC PWR OR - 0.8 SHEET 35 SH35 - CABIN RADIO
F3_15 - LOADCENTER 3 LOUDSPEAKER/12V CNVRTR
[SH35: B-6] (84529039)
8 CG1-P-1 CAB GROUND RH 271 RADIO GRND BK - 0.8
HEADLINER
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X-RECT - ENGINE COOLANT TEMP [ B-RECTD] (84607243) (Receptacle)
84607243 189
84607243
1 X-ENG (Plug) pin 5 - 433A COOLANT TEMP YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
ENGINE TO CAB [SH18: INSTRUMENTATION
C-6] (87696948)
2 SP-482R-P-X 482T COOLANT TEMP GRND BL - 0.8
X-RF2 - WORK LIGHT OPTION [ LMP-RFO] (87695582) (Receptacle)
87695582 190
87695582
1 SP-111G-P-X 111F WORK LIGHT JUMPER VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
2 SP-949J-P-X 949H WORK LIGHT JUMPER BK - 1.0 LIGHTS CAB ROOF, FRONT AND REAR
X-RFO - WORK LIGHT OPTION (87695584) (Plug)
87695584 191
87695584
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1 SP-111G-P-X 111E WORK LIGHT JUMPER VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
2 SP-949J-P-X 949G WORK LIGHT JUMPER BK - 1.0 LIGHTS CAB ROOF, FRONT AND REAR
X-RFWL - RIGHT FRONT WORK LIGHT [ LMP-RF_WL] (87695582) (Receptacle)
87695582 192
87695582
1 SP-111G-P-X 111G WORK LIGHT JUMPER VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
1 X-ROOF (Receptacle) pin 2 - 724A RIGHT FRONT WORK VT - 1.0 LIGHTS CAB ROOF, FRONT AND REAR
ROOF TO CAB (87700325) LIGHT
2 SP-949A-P-X 949B RIGHT FRONT WORK BK - 1.0
LIGHT GND
2 SP-949J-P-X 949J WORK LIGHT JUMPER BK - 1.0
X-RH-REAR-TAIL-EURO - RH-REAR-TAIL-EURO [ LMP-R-EURO-TAIL] (87694112) (Receptacle)
87694112 193
87694112
1 X-HD_N (Receptacle) pin 7 - 129D STOP PL23 EURO VT - 0.8 SHEET 30 SH30 - OLD EURO LIGHTING
2 X-HD_N (Receptacle) pin 4 - 131E TAIL EURO VT - 0.8
3 X-HD_N (Receptacle) pin 5 - 130H TA VT - 0.8
4 SP-124H-P-X 124J REVERSE LIGHTS PL23 VT - 0.8
5 SP-242H-P-X 242K GRND BK - 0.8
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X-RH-TAIL - RH REAR TAIL [ LMP-R-NA-TAIL] (87694101) (Receptacle)
87694101 194
87694101
1 SP-242A-P-X 242B TAIL LIGHTS GRND NA BK - 1.0 SHEET 29 SH29 - LIGHTING REAR TAILS
1 SP-243-P-X 243B TAIL LIGHTS GRND BK - 0.8
EURO
2 X-ENG (Plug) pin 21 - 129E STOP RH EURO VT - 0.8
(87696948)
2 X-HD_N (Receptacle) pin 7 - 129B RH BRAKE LAMP NA VT - 0.8
3 X-HD_N (Receptacle) pin 5 - 130C RH TAIL LAMP NA VT - 0.8
3 X-ENG (Plug) pin 11 - 130J TAIL RH EURO VT - 0.8
(87696948)
4 X-ENG (Plug) pin 6 - 131F TURN RH EURO VT - 0.8
ENGINE TO CAB [SH18:
C-6] (87696948)
4 X-HD_N (Receptacle) pin 4 - 131B RH REAR TURN LAMP VT - 0.8
HOOD TO ENG (87700325) NA
X-ROOF - ROOF TO CAB (87700325) (Receptacle)
87700325 195
87700325
1 X-LFWL (Receptacle) pin 1 - 111A LEFT FRONT WORK VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
LEFT FRONT WORK LIGHT LIGHT LIGHTS CAB ROOF, FRONT AND REAR
[LMP-LF_WL] (87695582)
2 X-RFWL (Receptacle) pin 1 - 724A RIGHT FRONT WORK VT - 1.0
RIGHT FRONT WORK LIGHT LIGHT
[LMP-RF_WL] (87695582)
3 X-BEA (Receptacle) pin 1 851A ROTATING BEACON VT - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
- BEACON [LMP-BEA_RT]
(84015523)
4 SP-114A-P-X 114A MIRROR HEAT SUPPLY TN - 1.0
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5 SP-859A-P-X 859A REAR WORK LIGHTS VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
6 SP-949A-P-X 949A FRONT WORK LIGHTS BK - 2.0 LIGHTS CAB ROOF, FRONT AND REAR
GND
7 SP-953A-P-X 953A ROOF GND BK - 2.0
X-RRWL - RIGHT REAR WORK LIGHT [ LMP-RR_WL] (87695582) (Receptacle)
87695582 196
87695582
1 SP-859A-P-X 859C RIGHTT REAR WORK VT - 0.8 SHEET 31 SH31 - LIGHTING WORKING
LIGHT LIGHTS CAB ROOF, FRONT AND REAR
2 SP-953A-P-X 953F RIGHT REAR WORK BK - 1.0
LIGHT GND
X-RWHE1 - REAR WINDOW HEATER [ R-WND_HTR] (87688695) (Receptacle)
87688695 197
87688695
1 X-LC3 (Receptacle) pin 801 REAR DEFROST PWR OR - 2.0 SHEET 36 SH36 - REAR DEFROST, BACKUP
R3_87 - LOADCENTER 3 ALARM
[SH35: B-6] (84529039)
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X-RWHE2 - REAR WINDOW HEATER [ SH13: C-3] (87688695) (Receptacle)
87688695 198
87688695
1 CG1-P-1 CAB GROUND RH 272 REAR DEFROST GND BK - 2.0 SHEET 36 SH36 - REAR DEFROST, BACKUP
HEADLINER ALARM
X-RWM - REAR WIPER MOTOR [ M-R_WPR_M] (87692862) (Plug)
87692862 199
87692862
B X-X6 (Receptacle) pin 12 - 108 REAR WIPER MOTOR TN - 1.0 SHEET 32 SH32 - CAB WIPER / WASHER
SFB [A-SFB] (47554341) LOW
X-RWM_G - REAR WIPER MOTOR GRND [ SH13: C-2] (87693744) (Plug)
87693744 200
87693744
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A X-CG3 (Receptacle) pin 955V REAR WIPER MOTOR BK - 1.0 SHEET 32 SH32 - CAB WIPER / WASHER
L - CAB GROUND RH GND
(84149207)
X-RWW - REAR WASHER MOTOR [ M-RW_M] (84015523) (Receptacle)
84015523 201
84015523
1 X-TRANS (Plug) pin 4 - 106A REAR WASHER MOTOR OR - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
TRANSMISSION TO CAB
(87696949)
2 SP-391A-P-X 391E WIPER GROUND BK - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
/ FAN CONTROL
X-SC - SEAT COMPRESSOR [ Y-SC] (87692855) (Plug)
87692855 202
87692855
A X-LC4 (Receptacle) pin 7A - 742 12V FUSED ACC PWR OR - 2.0 SHEET 35 SH35 - CABIN RADIO
LOADCENTER 4 [SH35: C-6] FOR SEAT COMP LOUDSPEAKER/12V CNVRTR
(87733595)
B X-CG4 (Receptacle) pin C - 955L SEAT COMPRESSOR BK - 2.0
(84149207)
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X-SCR1 - INLINE TO SCR SENSORS HARNESS (87695592) (Receptacle)
87695592 203
87695592
1 SP-201-P-X 201B SCR SENSORS CLEAN BK - 2.0 SHEET 18 SH18 - ENGINE CONTROL UNIT
GROUND 3, AT
4 SP-200-P-X 200B SCR SENSOR POWER RD - 2.0
5 X-ECU (Receptacle) pin 96 - 696 UREA DOSING VALVE 1 TN - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
(84300197)
6 X-ECU (Receptacle) pin 23 - 623 UREA DOSING VALVE 2 WH - 0.8
(84300197)
7 SP-610-P-X 610D TEMP SENSOR GROUND BK - 0.8
8 X-ECU (Receptacle) pin 16 - 616 DOC UPSTREAM TEMP YE - 0.8
(84300197)
9 SP-610-P-X 610B TEMP SENSOR GROUND BK - 0.8
10 X-ECU (Receptacle) pin 9 - 609 SCR DOWNSTREAM YE - 0.8
ECU CONNECTOR [A-ECU] TEMP
(84300197)
11 SP-CAN_H1-P-X CANC_HB CAN YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
12 SP-CAN_L1-P-X CANC_LB CAN GN - 0.8 3, AT
X-SCR2 - INLINE FROM SCR SENSORS HARNESS (87695724) (Plug)
87695724 204
87695724
1 SP-201D-P-X 201D SCR SENSORS CLEAN BK - 2.0 SHEET 18 SH18 - ENGINE CONTROL UNIT
GROUND 3, AT
4 SP-200D-P-X 200D SCR SENSOR POWER RD - 2.0
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5 X-DSR (Receptacle) pin 696A DOSING VALVE TN - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
[Y-DSV] (87709798)
6 X-DSR (Receptacle) pin 623A UREA DOSING VALVE 2 WH - 0.8
2 - UREA DOSING VALVE
[Y-DSV] (87709798)
7 X-CTS (Receptacle) pin 2 610E TEMP SENSOR GROUND BK - 0.8
- DOC UPSTREAM TEMP
[B-C_TS] (84532147)
8 X-CTS (Receptacle) pin 1 616A DOC UPSTREAM TEMP YE - 0.8
- DOC UPSTREAM TEMP
[B-C_TS] (84532147)
9 X-DTS (Receptacle) pin 2 - 610C TEMP SENSOR GROUND BK - 0.8
SCR DOWNSTREAM TEMP
[B-D_TS] (84532147)
10 X-DTS (Receptacle) pin 1 - 609A SCR DOWNSTREAM YE - 0.8
SCR DOWNSTREAM TEMP TEMP
[B-D_TS] (84532147)
11 SP-CANC_HC-P-X CANC_HC CAN YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
12 SP-CANC_LC-P-X CANC_LC CAN GN - 0.8 3, AT
X-SDM - SWITCH DIFF LOCK [ SW-SDM] (82012083) (Plug)
82012083 205
82012083
X-SFB_XCP - DIAG (87696093) (Receptacle)
87696093 206
87696093
1 X-X7 (Receptacle) pin 2 - SFB CANB_HF CAN WH - 0.8 SHEET 24 SH24 - CAN STRUCTURE
[SH3: A-3] (84538791)
2 X-X7 (Receptacle) pin 1 - SFB CANB_LF CAN BL - 0.8
[SH3: A-3] (84538791)
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X-SPK - RADIO TO SPKRS [ H-RADIO] (87709371) (Receptacle)
87709371 207
87709371
X-SP_PK1 - SPLICE PACK (87693718) (Receptacle)
87693718 208
87693718
X-SP_PK2 - SPLICE PACK (87693718) (Receptacle)
87693718 209
87693718
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X-SP_PK_CLN - SPLICE PACK CLEAN GRND [ SH25: C-1] (87352746) (Receptacle)
87352746 210
87352746
X-SRWP - SWITCH REAR WIPER [ SW-WPR_SW] (87716755) (Receptacle)
87716755 211
87716755
2 X-PG (Receptacle) pin L - 955M GROUND BK - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
PEDESTAL GROUND [SH28: WARNING, BLINKERS, DRIVING
B-6] (87705607)
3 X-PED_2 (Plug) pin 8 - 728A REAR WASHER SWITCH YE - 0.8
PEDESTAL TO CAB 2
(87705114)
5 X-PG (Receptacle) pin G - 955W PEDESTAL GROUND BK - 0.8
B-6] (87705607)
6 X-PED_2 (Plug) pin 9 - 727A REAR WIPER SWITCH YE - 0.8
PEDESTAL TO CAB 2
(87705114)
7 X-PG (Receptacle) pin F - 955D REAR WIPER SW BK - 0.8
PEDESTAL GROUND [SH28: INDICATOR GND
B-6] (87705607)
8 SP-981A-P-X 981C SWITCH BACK LIGHTING VT - 0.8
9 X-PG (Receptacle) pin C - 955G REAR WIPER SW GND BK - 0.8
B-6] (87705607)
10 X-PED_2 (Plug) pin 11 283A REAR WIPER INDICATOR VT - 0.8
- PEDESTAL TO CAB 2
(87705114)
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X-SSD - SS FLYBACK DIODE [ D-SS DIODE] (87692858) (Plug)
87692858 212
87692858
A X-S245 (Plug) pin 1 - 180A SEC STRG FLYBACK BK - 1.0 SHEET 21 SH21 - UCM-STEERING AUX JSS
GROUND (84426118) GRND
B X-S245 (Plug) pin 1 - 180 SEC STRG FLYBACK BK - 1.0
GROUND (84426118) GRND
C X-SSS (Plug) pin 1 - 441E SEC STRG FLY BACK OR - 1.0
SECONDARY STEERING PWR
MOTOR [M-SEC_STRG]
(84426118)
X-SSG - SECONDARY STEERING GROUND RING [ SH21: C-1] (84401307) (Plug)
84401307 213
84401307
1 X-S242 (Plug) pin 1 - 185 AUX STEERING BK - 62.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
GROUND [M-SEC_STRG] GROUND CABLE PWR DISTR
(84401307)
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X-SSS - SECONDARY STEERING MOTOR [ M-SEC_STRG] (84426118) (Plug)
84426118 214
84426118
1 X-SSD (Plug) pin C - SS 441E SEC STRG FLY BACK OR - 1.0 SHEET 21 SH21 - UCM-STEERING AUX JSS
FLYBACK DIODE [D-SS PWR
DIODE] (87692858)
1 SP-441B-P-X 441D SEC STRG IGN PWR OR - 1.0
X-SST - SEC STRG TO TRANS (87694152) (Plug)
87694152 215
87694152
1 SP-441B-P-X 441B SEC STRG IGN PWR OR - 1.0 SHEET 21 SH21 - UCM-STEERING AUX JSS
2 X-PSS (Receptacle) pin B 486W 5V PWR REF 1 PK - 0.8
- STEERING PRESSURE
SENSOR [B-PSS] (84078681)
3 X-PSS (Receptacle) pin A 482P 5V GRND1 BL - 0.8
- STEERING PRESSURE
4 X-PSS (Receptacle) pin C 176B AUX STRG PRESS YE - 0.8
- STEERING PRESSURE SIGNAL
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X-ST - START SIGNAL TO STARTER [ M-STRT_MTR] (84426134) (Plug)
84426134 216
84426134
1 X-LC7 pin 2 - LOAD CENTER 230 STARTER POWER RD - 5.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
7 (84563565) STARTER / KEY
X-STLK - STALK LEVER RH [ SW-HN_STLK] (84426133) (Receptacle)
84426133 217
84426133
1 X-PED (Receptacle) pin 113B RH STALK HORN BR - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
4 - PEDESTAL TO CAB SWITCH
(87700156)
3 X-PED (Receptacle) pin 19K IGN PWR OR - 0.8 SHEET 24 SH24 - CAN STRUCTURE
9 - PEDESTAL TO CAB
(87700156)
4 SP-LP-P-X CAN_LR CAN GN - 0.8
5 SP-HP-P-X CAN_HR CAN YE - 0.8
7 X-PG (Receptacle) pin D - 955F LH TURN SW GND BK - 0.8
B-6] (87705607)
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X-STW - STEERING WHEEL MOTION SENSOR [ B-ST_MTN] (84563557) (Receptacle)
84563557 218
84563557
1 SP-B_HP-P-X CANB_HR CAN WH - 0.8 SHEET 24 SH24 - CAN STRUCTURE
2 SP-B_LP-P-X CANB_LR CAN BL - 0.8
3 SP-799C-P-X 799F JSS IGN PWR OR - 0.8
4 SP-955Y-P-X 955Z JSS GROUND BK - 0.8
X-SW_DISC - DISCONNECT SWITCH [ SH37: C-4] (87694112) (Receptacle)
87694112 219
87694112
1 X-LC6 pin 15 - LOADCENTER 510 ECU IGN PWR OR - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
6 [SH16: A-3] (84380518) STARTER / KEY
3 SP-669A-P-X 669A EDC7 IGN PWR OR - 0.8
3 X-ECU (Receptacle) pin 69 - 669 ECU IGN PWR OR - 0.8
(84300197)
4 X-ENG-2 (Receptacle) pin J - 219 NON ISOLATED PWR RD - 0.8
5 X-HD (Receptacle) pin 2 - 533 HOOD LIFT SIGNAL RD - 1.0
HOOD LIFT SWITCH [SH3:
A-4] (84159859)
6 X-LC6 pin 6 - LOADCENTER 218 KEY_NON_DISCONNECT RD - 0.8
6 [SH16: A-3] (84380518) PWR
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X-SW_JSS - JOYSTICK STEERING SWITCH [ SW-SW_JSS] (87716755) (Receptacle)
87716755 220
87716755
1 X-LFT_A (Plug) pin 12 - 682A JSS ACTIVATION NC YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
(87700155)
2 SP-799A-P-X 799H JSS IGNITION POWER OR - 0.8
3 X-LFT_A (Plug) pin 9 - 678A JSS ACTIVATION WH - 0.8
(87700155)
7 SP-954-P-X 954N LH JSS GND BK - 0.8
8 X-LFT_2 (Plug) pin 2 - LEFT 981K BACKLIGHTING VT - 0.8
JS TO CAB (87700105)
9 SP-954-P-X 954C LH JSS GND BK - 0.8
10 X-LFT_2 (Plug) pin 1 - LEFT 691A JSS INDICATOR WH - 0.8
JS TO CAB (87700105)
X-SW_PD - SWITCH PAD [ SW-PD] (87694153) (Receptacle)
87694153 221
87694153
1 X-LC5 (Receptacle) pin 7A - 807 KEYPAD IGN POWER OR - 0.8 SHEET 10 SH10 - IGNITION PWR DISTR
LOADCENTER 5 [SH10: D-1] (FUSE BLOCK LC5)
(87733595)
2 X-SP_PK_CLN (Receptacle) 916 CAB CLEAN GROUND BK - 0.8 SHEET 24 SH24 - CAN STRUCTURE
pin X - SPLICE PACK CLEAN SW PD
GRND [SH25: C-1] (87352746)
3 SP-HJ-P-X CAN_HK CAN YE - 0.8
4 SP-LJ-P-X CAN_LK CAN GN - 0.8
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X-S_BU - CANCEL BACKUP ALARM [ SW-BCK_U_SW] (87716755) (Receptacle)
87716755 222
87716755
2 SP-954L-P-X 955S BACKUP ALARM BK - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
CANCEL SWITCH GND ALARM
3 X-X7 (Receptacle) pin 50 - 119 BACKUP ALARM YE - 0.8
SFB [SH3: A-3] (84538791) CANCEL
7 SP-954L-P-X 954T BACK LIGHTING GRND BK - 0.8
8 SP-981-P-X 981E BU ALARM CANCEL VT - 0.8
9 SP-954L-P-X 954G BACKUP ALARM BK - 0.8
CANCEL INDICATOR
GND
10 X-X3 (Receptacle) pin 6 - SFB 118 BACKUP ALARM YE - 0.8
[SH3: A-1] (47554344) CANCEL IND
X-S_HMR - SWITCH HEATED MIRRORS [ SH13: D-4] (87716755) (Receptacle)
87716755 223
87716755
2 X-CG3 (Receptacle) pin 955K MIRROR HEATER SW BK - 0.8 SHEET 13 SH13 - POWER DISTRIBUTION 2
C - CAB GROUND RH GND CAB GROUND BLK
(84149207)
3 X-X7 (Receptacle) pin 48 - 116 MIRROR HEATER SW YE - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
SFB [SH3: A-3] (84538791)
7 X-CG3 (Receptacle) pin 954B CAB GRND BK - 0.8
M - CAB GROUND RH
(84149207)
8 SP-981-P-X 981F BACKLIGHTING VT - 0.8
9 X-CG3 (Receptacle) pin 955J MIRROR HEATER BK - 0.8 SHEET 13 SH13 - POWER DISTRIBUTION 2
B - CAB GROUND RH INDICATOR GND CAB GROUND BLK
(84149207)
10 X-X4 (Receptacle) pin 13 - 115 MIRROR HEATER WH - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
SFB (47554343) INDICATOR
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X-S_HZD - SWITCH HAZARD [ SW-HZD_SW] (87716755) (Receptacle)
87716755 224
87716755
2 X-PG (Receptacle) pin K - 955C PED GROUND BK - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
PEDESTAL GROUND [SH28: WARNING, BLINKERS, DRIVING
B-6] (87705607)
3 X-PED (Receptacle) pin 141A HAZARD SWTICH YE - 0.8
6 - PEDESTAL TO CAB
(87700156)
7 X-PG (Receptacle) pin E - 955E HAZARD SW INDICATOR BK - 0.8
PEDESTAL GROUND [SH28: GND
B-6] (87705607)
8 SP-981A-P-X 981B SWITCH BACK LIGHTING VT - 0.8
9 X-PG (Receptacle) pin B - 955H HAZARD SW GND BK - 0.8
B-6] (87705607)
10 X-PED (Receptacle) pin 269 HAZARD INDICATOR BK - 0.8
8 - PEDESTAL TO CAB
(87700156)
X-S_RDF - SWITCH REAR DEFROST [ SW-R_DEF_SW] (87716755) (Receptacle)
87716755 225
87716755
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2 X-CG3 (Receptacle) pin 955R REAR DEFROST SWITCH BK - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
F - CAB GROUND RH GND ALARM
(84149207)
3 X-X7 (Receptacle) pin 68 - 117 REAR DEFROST SWITCH YE - 0.8
SFB [SH3: A-3] (84538791)
7 CG1-P-1 CAB GROUND RH 958 BACKLIGHTING REAR BK - 0.8
HEADLINER DEFROST SW
8 SP-981-P-X 981G BACKLIGHTING VT - 0.8
9 X-CG3 (Receptacle) pin 955A REAR DEFROST SWITCH BK - 0.8
A - CAB GROUND RH IND GND
(84149207)
10 X-X7 (Receptacle) pin 7 - SFB 122 REAR DEFROST SWITCH YE - 0.8
[SH3: A-3] (84538791) IND
X-TCOT - GEAR OIL TEMP [ B-GOT] (84364854) (Receptacle)
84364854 226
84364854
1 X-TRANS (Plug) pin 13 - 425A GEAR OIL TEMP WH - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
TRANSMISSION TO CAB
(87696949)
2 SP-697A-P-X 697B OIL TEMP RETURN BL - 0.8
X-TECM - TRANS CONTROLLER [ SH25: C-6] (84550089) (Receptacle)
84550089 227
84550089
1 X-SP_PK_CLN (Receptacle) 856 TRANS CONTROLER BK - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
pin X - SPLICE PACK CLEAN GRND
GRND [SH25: C-1] (87352746)
2 X-SP_PK_CLN (Receptacle) 855 TRANS CONTROLER BK - 0.8
pin X - SPLICE PACK CLEAN GRND
GRND [SH25: C-1] (87352746)
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3 SP-702A-P-X 702 SPEED SENSOR GRND BL - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
4 X-CAB_TR (Receptacle) pin 703 OUTPUT SPEED BL - 0.8
28 - CAB TO TRANSMISSION SENSOR
[SH26: A-2] (87696944)
8 SP-420C-P-X 420B TECM PWR WH - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
9 X-CAB_TR (Receptacle) pin 839 KV CLUTCH TN - 0.8
20 - CAB TO TRANSMISSION
[SH26: A-2] (87696944)
10 X-CAB_TR (Receptacle) pin 836 KR CLUTCH TN - 0.8
[SH26: A-2] (87696944)
12 SP-841-P-X 841B TRANS OUTPUT SW WH - 0.8
PWR VPS1
13 SP-841-P-X 841 TRANS OUTPUT SW WH - 0.8
PWR VPS1
15 X-ZF_DI (Plug) pin 2 - 37D DIAGNOSTIC WH - 0.8
DIAGNOSTIC [A-108F]
(84364851)
17 X-CAB_TR (Receptacle) pin 423 FILTER MAINTENANCE WH - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
31 - CAB TO TRANSMISSION SIGNAL
[SH26: A-2] (87696944)
18 X-ZF_DI (Plug) pin 4 - 167 DIAGNOSTIC SIL - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
DIAGNOSTIC [A-108F]
(84364851)
19 X-CAB_TR (Receptacle) pin 699 ENG SPEED SENSOR YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
[SH26: A-2] (87696944)
23 SP-165-P-X 165A TECM B+ RD - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
25 SP-HD-P-X CAN_HE CAN YE - 0.8 SHEET 24 SH24 - CAN STRUCTURE
26 SP-LD-P-X CAN_LE CAN GN - 0.8
32 X-CAB_TR (Receptacle) pin 837 K1 CLUTCH TN - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
[SH26: A-2] (87696944)
39 X-CAB_TR (Receptacle) pin 842 VALVE BODY TEMP SIG YE - 0.8
[SH26: A-2] (87696944)
41 X-CAB_TR (Receptacle) pin 700 TURBINE SPEED YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
[SH26: A-2] (87696944)
42 X-CAB_TR (Receptacle) pin 701 INTERMEDIATE SPEED YE - 0.8
[SH26: A-2] (87696944)
45 SP-19C-P-X 19E TECM IGN PWR OR - 0.8 SHEET 10 SH10 - IGNITION PWR DISTR
(FUSE BLOCK LC5)
46 X-CAB_TR (Receptacle) pin 697 TRANS SIGNL RETURN BL - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
[SH26: A-2] (87696944)
49 X-CAB_TR (Receptacle) pin 425 GEAR OIL TEMP YE - 0.8
[SH26: A-2] (87696944)
50 X-CAB_TR (Receptacle) pin 419 TRANS LOCKUP BR - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
15 - CAB TO TRANSMISSION SOLENOID
[SH26: A-2] (87696944)
53 SP-420C-P-X 420 TRANS LOCKUP WH - 0.8
SOLENOID
55 X-CAB_TR (Receptacle) pin 838 K3 CLUTCH TN - 0.8
[SH26: A-2] (87696944)
56 X-CAB_TR (Receptacle) pin 834 K4 CLUTCH TN - 0.8
[SH26: A-2] (87696944)
62 X-CAB_TR (Receptacle) pin 578A OUTPUT SPEED YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
[SH26: A-2] (87696944)
68 SP-165-P-X 165B TECM B+ RD - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
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X-TERM - TERMINATOR [ R-022] (87695580) (Receptacle)
87695580 228
87695580
A SP-HP-P-X CAN_HS CAN YE - 0.8 SHEET 24 SH24 - CAN STRUCTURE
B SP-LP-P-X CAN_LS CAN GN - 0.8
X-TERM2 - TERMINATOR CAN [ A-TERM2] (87695580) (Receptacle)
87695580 229
87695580
A SP-B_HC-P-X CANB_HA CAN WH - 0.8 SHEET 24 SH24 - CAN STRUCTURE
B SP-B_LC-P-X CANB_LA CAN BL - 0.8
X-TERM3 - TERMINATOR CAN [ A-TERM3] (87695580) (Receptacle)
87695580 230
87695580
A SP-B_HS-P-X CANB_HU CAN WH - 0.8 SHEET 24 SH24 - CAN STRUCTURE
B SP-B_LS-P-X CANB_LU CAN BL - 0.8
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X-TERM_C - CONTROLLER AREA NETWORK [ A-TERMC] (87695580) (Receptacle)
87695580 231
87695580
A SP-2HC-P-X CAN2_HC CAN YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
A SP-CANC_HG-P-X CANC_HK CAN YE - 0.8 3, AT
B SP-CANC_LG-P-X CANC_LK CAN GN - 0.8
B SP-2LC-P-X CAN2_LC CAN GN - 0.8
X-THRTL - THROTTLE CONTROL [ B-ACCEL] (84403598) (Receptacle)
84403598 232
84403598
A X-CAB_E-2 (Plug) pin A - 409 THROTTLE PEDAL YE - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
CAB TO ENG 2 [SH9: C-2] POSITION 1, GRID HEATER, FILTER HEATER
(87703902)
B X-CAB_E-2 (Plug) pin C - 651H 5V GND2 BL - 0.8
(87703902)
C X-CAB_E-2 (Plug) pin B - 471B 5V REF2 PK - 0.8
(87703902)
D X-CAB_E-2 (Plug) pin D - 408 THROTTLE IDLE SW WH - 0.8
(87703902)
F X-CAB_E-2 (Plug) pin E - 643C THROTTLE GRND BK - 0.8
(87703902)
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X-THV - SCR TANK HEATING VALVE [ Y-TNK_HTR] (84146685) (Receptacle)
84146685 233
84146685
X-TRANS - TRANSMISSION TO CAB (87696949) (Plug)
87696949 234
87696949
1 X-PRB1 (Receptacle) pin C - 443A RED BRAKE SW SIG YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
REDUNDANT BRAKE SW 1 INSTRUMENTATION
[B-PRB1] (84078681)
2 X-ESS (Receptacle) pin 2 - 702D SPEED SENSOR GRND BL - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
SPEED SENSOR ENGINE
[B-ES_S] (84364854)
3 SP-482A-P-X 482A 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
4 X-RWW (Receptacle) pin 1 106A REAR WASHER MOTOR OR - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
- REAR WASHER MOTOR
[M-RW_M] (84015523)
5 X-TRC (Receptacle) pin 8 842A VALVE BODY TEMP SIG YE - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
- TRANS CONTROLLER
ON TRANNY CNH [A-TRC]
(47669071)
6 X-FWW (Receptacle) pin 1 104A FRONT WASHER MOTOR TN - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
- FRONT WASHER MOTOR
[M-FW_M] (84015523)
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7 X-ESS (Receptacle) pin 1 - 699A ENG SPEED SENSOR YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
SPEED SENSOR ENGINE
[B-ES_S] (84364854)
8 X-TSS (Receptacle) pin 1 - 700A TURBINE SPEED YE - 0.8
SPEED SENSOR TURBINE SENSOR
[B-TS_S] (84364854)
9 X-ISS (Receptacle) pin 1 - 701A INTERMEDIATE SPEED YE - 0.8
SPEED SENSOR MIDDLE SENSOR
WHEEL CHAIN [B-IS_S]
(84364854)
10 X-OSS pin 2 - SPEED 578 OUTPUT SPEED YE - 0.8
SENSOR GEAR TRANS SENSOR SIGNAL
[B-OSS] (84062580)
11 X-ISS (Receptacle) pin 2 - 702B SPEED SENSOR GRND BL - 0.8
SPEED SENSOR MIDDLE
WHEEL CHAIN [B-IS_S]
(84364854)
12 SP-697A-P-X 697A TRANS SIGNL RETURN BL - 0.8
13 X-TCOT (Receptacle) pin 1 425A GEAR OIL TEMP WH - 0.8
- GEAR OIL TEMP [B-GOT]
(84364854)
14 X-TSS (Receptacle) pin 2 - 702C SPEED SENSOR GRND BL - 0.8
SPEED SENSOR TURBINE
[B-TS_S] (84364854)
15 X-YLS pin 1 - TRANS 419A TRANS LOCKUP BR - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
LOCKUP SOLENOID SOLENOID
(82012083)
16 X-TRC (Receptacle) pin 1 834A K4 CLUTCH TN - 0.8
- TRANS CONTROLLER
(47669071)
16 X-TRC (Receptacle) pin 2 834B PL23_26 KR CLUTCH TN - 0.8
- TRANS CONTROLLER
(47669071)
17 X-TRC (Receptacle) pin 2 836A KR CLUTCH TN - 0.8
- TRANS CONTROLLER
(47669071)
17 X-TRC (Receptacle) pin 1 836B PL23_26 K4 CLUTCH TN - 0.8
- TRANS CONTROLLER
(47669071)
- TRANS CONTROLLER
(47669071)
- TRANS CONTROLLER
(47669071)
20 X-TRC (Receptacle) pin 5 839A KV CLUTCH TN - 0.8
- TRANS CONTROLLER
(47669071)
- TRANS CONTROLLER
(47669071)
22 X-TRC (Receptacle) pin 7 841C TRANS OUTPUT SW WH - 0.8
- TRANS CONTROLLER PWR VPS1
(47669071)
23 X-PHF (Plug) pin 1 - 636A HYD FILTER SIGNAL YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
HYDRAULIC FILTER INSTRUMENTATION
SENSOR [SW-PHF]
(84352277)
23 X-PHF23 pin 2 - HYDRAULIC 236 HYDRAULIC OIL FILTER YE - 0.8
FILTER SENSOR PL23 SW
(82012083)
24 X-PRB2 (Receptacle) pin C - 638B RED BRAKE SW SIG YE - 0.8
REDUNDANT BRAKE SW 2
[B-PRB2] (84078681)
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25 X-YLS pin 2 - TRANS 420A TRANS LOCKUP WH - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
LOCKUP SOLENOID SOLENOID
(82012083)
26 SP-486N-P-X 486N 5V PWR REF 1 PK - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
27 X-YDL (Receptacle) pin 1 390A DIFF LOCK SIGNAL WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- DIFF LOCK SOL [Y-DL] / FAN CONTROL
(87695582)
28 X-OSS pin 1 - SPEED 703A OUTPUT SPEED BL - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
SENSOR GEAR TRANS SENSOR
[B-OSS] (84062580)
29 X-OSS pin 3 - SPEED 19T_H OUTPUT SP SENS IGN OR - 0.8
SENSOR GEAR TRANS PWR
[B-OSS] (84062580)
30 X-HOT (Receptacle) pin 1 634A HYD OIL TEMP SIG YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
- HYD OIL TEMP [B-HOT] INSTRUMENTATION
(84607243)
31 X-FM pin 2 - PRESSURE 423A FILTER MAINTENANCE WH - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
SWITCH OIL FILTER [B-FM] SIGNAL
(82012083)
X-TRC - TRANS CONTROLLER ON TRANNY CNH [ A-TRC] (47669071) (Receptacle)
47669071 235
47669071
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1 X-TRANS (Plug) pin 17 - 836B PL23_26 K4 CLUTCH TN - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
TRANSMISSION TO CAB
(87696949)
1 X-TRANS (Plug) pin 16 - 834A K4 CLUTCH TN - 0.8
TRANSMISSION TO CAB
(87696949)
2 X-TRANS (Plug) pin 17 - 836A KR CLUTCH TN - 0.8
TRANSMISSION TO CAB
(87696949)
2 X-TRANS (Plug) pin 16 - 834B PL23_26 KR CLUTCH TN - 0.8
TRANSMISSION TO CAB
(87696949)
TRANSMISSION TO CAB
(87696949)
TRANSMISSION TO CAB
(87696949)
5 X-TRANS (Plug) pin 20 - 839A KV CLUTCH TN - 0.8
TRANSMISSION TO CAB
(87696949)
TRANSMISSION TO CAB
(87696949)
7 X-TRANS (Plug) pin 22 - 841C TRANS OUTPUT SW WH - 0.8
TRANSMISSION TO CAB PWR VPS1
(87696949)
8 X-TRANS (Plug) pin 5 - 842A VALVE BODY TEMP SIG YE - 0.8
TRANSMISSION TO CAB
(87696949)
9 SP-697A-P-X 697D VALVE BODY TEMP BL - 0.8
RETURN
X-TS1 - TRANS SHIFTER1 [ A-PFNR] (87692817) (Plug)
87692817 236
87692817
A X-PED_2 (Plug) pin 6 - 4029 DW3 IGN PWR OR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
PEDESTAL TO CAB 2 / FAN CONTROL
(87705114)
B X-PED_2 (Plug) pin 3 - 683A STALK FNR F YE - 0.8
PEDESTAL TO CAB 2
(87705114)
C X-PED_2 (Plug) pin 1 - 679A STALK FNR R YE - 0.8
PEDESTAL TO CAB 2
(87705114)
D X-PED_2 (Plug) pin 2 - 680A STALK FNR N YE - 0.8
PEDESTAL TO CAB 2
(87705114)
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X-TS2 - TRANS SHIFTER 2 [ A-PFNR] (47702209) (Receptacle)
47702209 237
47702209
X-TSS - SPEED SENSOR TURBINE [ B-TS_S] (84364854) (Receptacle)
84364854 238
84364854
1 X-TRANS (Plug) pin 8 - 700A TURBINE SPEED YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
TRANSMISSION TO CAB SENSOR
(87696949)
2 X-TRANS (Plug) pin 14 - 702C SPEED SENSOR GRND BL - 0.8
TRANSMISSION TO CAB
(87696949)
X-TT - TELL TALE INDICATOR [ LMP-TTI] (87715979) (Receptacle)
87715979 239
87715979
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1 X-PG (Receptacle) pin A - 955T TELL TALE INDICATOR BK - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
PEDESTAL GROUND [SH28: GND WARNING, BLINKERS, DRIVING
B-6] (87705607)
2 X-PED (Receptacle) pin 188A LH TURN INDICATOR VT - 0.8
1 - PEDESTAL TO CAB
(87700156)
3 X-PED (Receptacle) pin 132G LH HIGH BEAM LAMP VT - 0.8
3 - PEDESTAL TO CAB
(87700156)
4 X-PED (Receptacle) pin 134A WARNING INDICATOR YE - 0.8
5 - PEDESTAL TO CAB LED
(87700156)
5 X-PED (Receptacle) pin 189A RIGHT TURN TELL TALE VT - 0.8
2 - PEDESTAL TO CAB
(87700156)
X-TURBO - INTERFACE WIRING HARNESS PLUG C [ SH12: B-3] (84152563) (Receptacle)
84152563 240
84152563
X-TURBO_2 - ENGINE HARNESS INTERFACE T2 [ SH18: B-5] (87694583) (Receptacle)
87694583 241
87694583
1 SP-2LC-P-X CAN2_LA CAN GN - 0.8 SHEET 12 SH12 - POWER DISTRIBUTION 1
5 X-GND_CENG1 (Plug) pin 203A EVGT CLN GRND BK - 1.0 CLEAN GROUND BLK
1 - GROUND CLEAN ENG
BLOCK (84140737)
6 X-LC6 pin 14 - LOADCENTER 202A T2 EVGT RD - 1.0 SHEET 11 SH11 - PWR DISTR ENG
7 SP-2HC-P-X CAN2_HA CAN YE - 0.8 SHEET 12 SH12 - POWER DISTRIBUTION 1
CLEAN GROUND BLK
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X-UCM1A - UCM (82016219) (Receptacle)
82016219 242
82016219
1 SP-482-P-X 482 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
2 SP-486-P-X 486 5V PWR REF 1 PK - 0.8 INSTRUMENTATION
3 SP-471-P-X 471 5V REF2 PK - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
CONTROL
4 SP-677-P-X 677B 5V REF3 OUT PK - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
5 X-CAB_B (Plug) pin 16 - CAB 3686 PARK BRAKE PRESS YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
TO BOTTOM [SH21: B-3] / FAN CONTROL
(87696945)
6 X-SP_PK1 (Receptacle) pin X 937 UCM CLEAN GROUND BK - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
- SPLICE PACK (87693718) INSTRUMENTATION
7 X-SP_PK2 (Receptacle) pin X 935 UCM CLEAN GROUND BK - 1.0
- SPLICE PACK (87693718)
8 X-CAB_B (Plug) pin 11 - CAB 176 AUX STRG PRESS YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
TO BOTTOM [SH21: B-3] SIGNAL
(87696945)
10 X-CAB_B (Plug) pin 6 - CAB 640 BRAKE SUPPLY PRESS YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
TO BOTTOM [SH21: B-3] INSTRUMENTATION
(87696945)
14 SP-466-P-X 466B IGNITION POWR FOR OR - 0.8
UCM
15 X-CAB_TR (Receptacle) pin 443 BRAKE ACCUMULATOR YE - 0.8
1 - CAB TO TRANSMISSION PRSR
[SH26: A-2] (87696944)
16 X-CAB_B (Plug) pin 15 - CAB 402 BRAKE PEDAL ANGLE YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
(87696945)
17 X-CAB_TR (Receptacle) pin 638 RED BRAKE SW SIG YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
24 - CAB TO TRANSMISSION INSTRUMENTATION
[SH26: A-2] (87696944)
20 X-LC2 (Receptacle) pin 1A - 465 CAB ISOLATED B+ RD - 1.0
(87733581)
21 X-CAB_EH (Plug) pin M - CAB 357 AUX 2 ENABLE BR - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
TO BOTTOM EH (87700159) CONTROL
22 X-CAB_B (Plug) pin 19 - CAB 389 PARK BRAKE SOL WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
(87696945)
26 SP-466-P-X 466A IGNITION POWR FOR OR - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
UCM INSTRUMENTATION
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X-UCM1B - UCM [ SH22: A-6] (87410946) (Receptacle)
87410946 243
87410946
1 SP-651-P-X 651 5V GND2 BL - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
2 X-CAB_EH (Plug) pin C - CAB 339 BOOM ENABLE BR - 0.8 CONTROL
TO BOTTOM EH (87700159)
10 X-CAB_EH (Plug) pin J - CAB 352 AUX 1 ENABLE BR - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
19 X-CAB_EH (Plug) pin S - CAB 647 BOOM ANGLE 1 YE - 0.8
20 X-CAB_B (Plug) pin 7 - CAB 641 BRAKE PRESSURE YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
TO BOTTOM [SH21: B-3] INSTRUMENTATION
(87696945)
21 X-CAB_EH (Plug) pin W 653 BUCKET ANGLE 1 YE - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- CAB TO BOTTOM EH CONTROL
(87700159)
22 X-CAB_EH (Plug) pin T - CAB 648 BOOM ANGLE 2 YE - 0.8
23 X-CAB_EH (Plug) pin X - CAB 654 BUCKET ANGLE 2 YE - 0.8
25 SP-LA-P-X CAN_LT CAN GN - 0.8
30 X-CAB_EH (Plug) pin F - CAB 347 BUCKET ENABLE BR - 0.8
34 SP-HA-P-X CAN_HT CAN YE - 0.8
82028493 244
82028493
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7 SP-448-P-X 448A CAB ISOLATED B+ RD - 1.0 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
10 X-CAB_P2 (Receptacle) pin 3 686 STALK FNR F YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- CAB TO PEDESTAL 2 [SH27: / FAN CONTROL
B-2] (87705101)
11 X-CAB_P2 (Receptacle) pin 1 679 STALK FNR R YE - 0.8
- CAB TO PEDESTAL 2 [SH27:
B-2] (87705101)
12 X-CAB_L (Receptacle) pin 5 630 JSS JOYSTICK 2 YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
(87700156)
13 SP-448-P-X 448B CAB ISOLATED B+ RD - 1.0 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
16 X-CAB_P2 (Receptacle) pin 2 680 STALK FNR N YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- CAB TO PEDESTAL 2 [SH27: / FAN CONTROL
B-2] (87705101)
17 X-CAB_E (Receptacle) pin 18 319 AIR FILTER REST SW T2 YE - 0.8
(84807216)
18 X-CAB_L (Receptacle) pin 2 670 JSS JOYSTICK 1 YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
(87700156)
20 SP-967-P-X 967B 5 V REF GRND3 BL - 0.8
21 X-CAB_E-2 (Plug) pin N - 692 FAN REVERSER SGNL BR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
CAB TO ENG 2 [SH9: C-2] / FAN CONTROL
(87703902)
22 X-CAB_E-2 (Plug) pin M - 582 HEAT LOAD VALVE BR - 0.8
CAB TO ENG 2 [SH9: C-2] SIGNAL
(87703902)
25 X-CAB_E-2 (Plug) pin P - 392 FAN CONTROL SGNL YE - 0.8
(87703902)
X-UCM2B - UCM [ A-UCM] (82028495) (Receptacle)
82028495 245
82028495
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1 SP-B_HM-P-X CANB_HK CAN WH - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
10 SP-B_LM-P-X CANB_LK CAN BL - 0.8 STARTER / KEY
12 X-CAB_L (Receptacle) pin 4 675 LH ARMREST POSITION GY - 0.8
- CAB TO JSS L ARMREST UP
(87700156)
14 X-X3 (Receptacle) pin 5 - SFB 220B SIG_IGNITION YE - 0.8
[SH3: A-1] (47554344) SWITCH_START
20 X-CAB_L (Receptacle) pin 8 673 LH ARMREST POSITION TN - 0.8
- CAB TO JSS L ARMREST DWN
(87700156)
21 X-CAB_P2 (Receptacle) pin 5 407 GEAR SELECT 3_4 YE - 0.8
B-2] (87705101)
84130757 246
84130757
5 X-CAB_E (Receptacle) pin 15 663 OK TO START YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- CAB TO ENGINE [SH7: B-5] / FAN CONTROL
(84807216)
INSTRUMENTATION
12 X-CAB_JSS (Receptacle) 676 JSS PILOT PRESS SIG YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
HARNESS [SH24: A-6]
(87694112)
13 SP-454-P-X 454B CAB ISOLATED B+ RD - 1.0 SHEET 19 SH19 - UCM PWR, GRND,
17 X-CAB_TR (Receptacle) pin 636 HYD FILTER YE - 0.8 INSTRUMENTATION
[SH26: A-2] (87696944)
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84130760 247
84130760
1 X-CAB_TR (Receptacle) pin 390 DIFF LOCK SIGNAL WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
27 - CAB TO TRANSMISSION / FAN CONTROL
[SH26: A-2] (87696944)
3 SP-461-P-X 461B CAB ISOLATED B+ RD - 1.0 INSTRUMENTATION
4 X-CAB_B (Plug) pin 9 - CAB 368 COUPLER VALVE RTRN BR - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
TO BOTTOM [SH21: B-3] CONTROL
(87696945)
6 X-CAB_B (Plug) pin 5 - CAB 366 RIDE CONTROL SIG WH - 0.8
(87696945)
7 X-CAB_B (Plug) pin 14 - CAB 367 COUPLER VALVE SIG WH - 0.8
(87696945)
8 SP-454-P-X 454C CAB ISOLATED B+ RD - 1.0 SHEET 19 SH19 - UCM PWR, GRND,
9 SP-454-P-X 454D CAB ISOLATED B+ RD - 1.0 INSTRUMENTATION
15 X-CAB_JSS (Receptacle) 273 JSS CUTOFF SIG B YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
HARNESS [SH24: A-6]
(87694112)
16 X-CAB_L (Receptacle) pin 9 678 JSS ACTIVATION WH - 0.8
(87700156)
17 X-CAB_EH (Plug) pin E - CAB 346 BUCKET ROLL WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
18 X-CAB_EH (Plug) pin A - CAB 344 PILOT ENABLE WH - 0.8
23 X-CAB_L (Receptacle) pin 12 682 JSS ACTIVATION NC YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
(87700156)
24 X-SDM pin 2 - SWITCH DIFF 401 DIFF LOCK WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
LOCK [SW-SDM] (82012083) / FAN CONTROL
25 X-CAB_EH (Plug) pin G - CAB 350 BUCKET DUMP WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
27 X-CAB_B (Plug) pin 18 - CAB 388 PARK BRAKE SOL WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
(87696945)
32 X-CAB_EH (Plug) pin H - CAB 351 AUX 1 LEFT WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
33 X-CAB_EH (Plug) pin K - CAB 355 AUX 1 RIGHT WH - 0.8
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82028493 248
82028493
INSTRUMENTATION
6 X-CAB_EH (Plug) pin D - CAB 341 BOOM LOWER WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
7 X-CAB_EH (Plug) pin B - CAB 340 BOOM RAISE WH - 0.8
8 SP-448-P-X 448D CAB ISOLATED B+ RD - 1.0 SHEET 19 SH19 - UCM PWR, GRND,
11 X-CAB_E (Receptacle) pin 8 633 FUEL LEVEL YE - 0.8 INSTRUMENTATION
(84807216)
12 X-CAB_E (Receptacle) pin 5 433 COOLANT TEMP YE - 0.8
(84807216)
13 X-CAB_EH (Plug) pin N - CAB 360 AUX 2 RIGHT WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
17 X-CAB_B (Plug) pin 17 - CAB 687 FRONT AXLE TEMP YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
(87696945)
18 X-CAB_TR (Receptacle) pin 634 HYD OIL TEMP SIG YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
30 - CAB TO TRANSMISSION INSTRUMENTATION
[SH26: A-2] (87696944)
19 X-CAB_EH (Plug) pin L - CAB 356 AUX 2 LEFT WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
82028495 249
82028495
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INSTRUMENTATION
9 X-CAB_P (Plug) pin 5 - CAB 134 WARNING INDICATOR YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
TO PEDESTAL [SH20: D-2] LED / FAN CONTROL
(87700155)
16 X-CAB_L2 (Receptacle) 691 JSS INDICATOR WH - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
pin 1 - CAB TO LEFT JSS
(87696138)
24 X-CAB_B (Plug) pin 13 - CAB 291 ROLL BACK PRESSURE YE - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
TO BOTTOM [SH21: B-3] SW CONTROL
(87696945)
30 X-CAB_E (Receptacle) pin 16 400 FAN SPEED SENSOR YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- CAB TO ENGINE [SH7: B-5] SGNL / FAN CONTROL
(84807216)
X-UTS - UPSTREAM OF SCR TEMP SENSOR [ B-U_TS] (84532147) (Receptacle)
84532147 250
84532147
1 X-ECU (Receptacle) pin 32 - 632 SCR UPSTREAM TEMP YE - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
(84300197)
2 SP-610-P-X 610A TEMP SENSOR GROUND BK - 0.8
X-WIF - WATER IN FUEL [ B-WIF] (87709663) (Receptacle)
87709663 251
87709663
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1 X-EDC7 (Plug) pin 42 - 613A WATER IN FUEL SIGNAL YE - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
ENGINE CONTROLLER T2/3 T2 2, AT
[SH18: C-5] (84160698)
1 X-ECU (Receptacle) pin 13 - 613 WATER IN FUEL YE - 0.8
(84300197)
2 SP-603-P-X 603K WIF GRND T2 BK - 0.8
2 SP-643-P-X 643B WATER IN FUEL BK - 0.8
3 SP-850A-P-X 850E KEY SWITCH FUSED OR - 0.8
POWER
X-WSH - WATER SEPERATOR HEATER [ Y-W_S_H] (87679438) (Receptacle)
87679438 252
87679438
A X-GND_ENG1 (Plug) pin 1 - 195 FUEL FILTER HTR GRND BK - 2.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
GROUND ENG BLOCK [SH16: 1, GRID HEATER, FILTER HEATER
A-1] (84140737)
B SP-421-P-X 421B WATER SEP HEATER OR - 2.0
PWR
X-X-PO1 - POWER OUTLET [ J-PO1] (84398827) (Receptacle)
84398827 253
84398827
A X-LC3 (Receptacle) pin 750 RH CONSOLE 12V PWR OR - 1.0 SHEET 35 SH35 - CABIN RADIO
F1_13 - LOADCENTER 3 OUTLET LOUDSPEAKER/12V CNVRTR
[SH35: B-6] (84529039)
C CG2-P-1 CAB GROUND 275 RH CONSOLE 12V PWR BK - 1.0
BLOCK OUTLET GND
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X-X1 - SFB [ SH6: D-1] (84344499) (Receptacle)
84344499 254
84344499
2 X-LC1 pin F1 - LOADCENTER 169 SWBAT_ISOLATOR_SFB RD - 8.0 SHEET 04 SH04 - POWER DISTRIBUTION
1 [SH10: A-6] (47728326) SUPPLY A SFB PWR AND GRNDS
X-X2 - SFB [ SH6: C-1] (84344499) (Receptacle)
84344499 255
84344499
1 X-LC1 pin C1 - LOADCENTER 172 ISOLATED_SFB SUPPLY RD - 8.0 SHEET 04 SH04 - POWER DISTRIBUTION
1 [SH10: A-6] (47728326) D SFB PWR AND GRNDS
2 X-LC1 pin D1 - LOADCENTER 171 ISOLATED_SFB SUPPLY RD - 8.0
1 [SH10: A-6] (47728326) C
X-X3 - SFB [ SH3: A-1] (47554344) (Receptacle)
47554344 256
47554344
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1 X-CAB_R (Plug) pin 2 - CAB 724 RIGHT FRONT WORK VT - 1.0 SHEET 08 SH08 - POWER DISTRIBUTION
TO ROOF (87695891) LIGHT (FUSE BLOCK LC3)
2 X-CAB_R (Plug) pin 1 - CAB 111 LEFT FRONT WORK VT - 1.0
TO ROOF (87695891) LIGHT
3 X-CAB_R (Plug) pin 3 - CAB 851 ROTATING BEACON VT - 0.8
TO ROOF (87695891)
5 X-UCM2B (Receptacle) pin 220B SIG_IGNITION YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
14 - UCM [A-UCM] (82028495) SWITCH_START STARTER / KEY
6 X-S_BU (Receptacle) pin 10 118 BACKUP ALARM YE - 0.8 SHEET 08 SH08 - POWER DISTRIBUTION
- CANCEL BACKUP ALARM CANCEL IND (FUSE BLOCK LC3)
[SW-BCK_U_SW] (87716755)
7 X-LC3 (Receptacle) pin 120 REAR DEFROST YE - 0.8
[SH35: B-6] (84529039)
8 X-LC5 (Receptacle) pin 86 - 222 SIG_IGNITION YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
LOADCENTER 5 [SH10: D-1] RELAY_COIL STARTER / KEY
(87733595)
11 X-LC4 (Receptacle) pin 86 - 226 ACCESSORY POWER YE - 0.8
(87733595)
12 X-CAB_E (Receptacle) pin 21 129 LH BRAKE LAMP VT - 0.8 SHEET 08 SH08 - POWER DISTRIBUTION
- CAB TO ENGINE [SH7: B-5] (FUSE BLOCK LC3)
(84807216)
14 CG5-P-1 CAB GROUND 1003 GND_SFB_PGND BK - 1.0 SHEET 04 SH04 - POWER DISTRIBUTION
SFB PWR AND GRNDS
15 X-LC3 (Receptacle) pin 192 SIG_DC_CONVERTER OR - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
R1_86 - LOADCENTER 3 STARTER / KEY
[SH35: B-6] (84529039)
16 X-CAB_P (Plug) pin 8 - CAB 269A HAZARD INDICATOR BK - 0.8 SHEET 08 SH08 - POWER DISTRIBUTION
TO PEDESTAL [SH20: D-2] LIGHT (FUSE BLOCK LC3)
(87700155)
17 X-CAB_E (Receptacle) pin 25 280 LICENSE PLATE LIGHT VT - 0.8
(84807216)
18 X-MAP (Receptacle) pin A 147 MAP LAMP VT - 0.8
- MAP LIGHT [SH13: C-6]
(84058093)
X-X31CF1-2 - CAB GROUND BLOCK (84122130) (Plug)
84122130 257
84122130
1 X-X31CF1-3 (Plug) pin 1 CABLE_ENG_ GROUND CABLE ENG BK - 62.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
- CAB GROUND BLOCK GRND BLCK TO REAR FRAME PWR DISTR
(84122130)
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X-X31CF1-3 - CAB GROUND BLOCK (84122130) (Plug)
84122130 258
84122130
1 X-X31CF1-2 (Plug) pin 1 CABLE_ENG_ GROUND CABLE ENG BK - 62.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
- CAB GROUND BLOCK GRND BLCK TO REAR FRAME PWR DISTR
(84122130)
X-X31CF2-1 - STEERING COLUMN GROUND (84122130) (Plug)
84122130 259
84122130
1 X-X31CF2-2 (Plug) pin STRAP1 BIG BRAIDED STRAP - - 50.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
1 - STEERING COLUMN CAB BTM TO REAR FRM PWR DISTR
GROUND (84122130)
X-X31CF2-2 - STEERING COLUMN GROUND (84122130) (Plug)
84122130 260
84122130
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1 X-X31CF2-1 (Plug) pin STRAP1 BIG BRAIDED STRAP - - 50.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
1 - STEERING COLUMN CAB BTM TO REAR FRM PWR DISTR
GROUND (84122130)
X-X4 - SFB (47554343) (Receptacle)
47554343 261
47554343
2 SP-981-P-X 981 SWITCH BACK LIGHTING VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
LIGHTS
3 X-CAB_P2 (Receptacle) pin 283 REAR WIPER INDICATOR VT - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
11 - CAB TO PEDESTAL 2
[SH27: B-2] (87705101)
4 SP-132-P-X 132 LH HIGH BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
5 CG5-P-1 CAB GROUND 1006 GND_SFB_REDUNDANT BK - 1.0 SHEET 04 SH04 - POWER DISTRIBUTION
GND SFB PWR AND GRNDS
6 X-FWM (Plug) pin A - FRONT 100 FRONT WIPER MOTOR TN - 2.0 SHEET 32 SH32 - CAB WIPER / WASHER
WIPER MOTOR (87692862) HIGH
8 CG5-P-1 CAB GROUND 1002 GND_SFB_MODULE BK - 1.0 SHEET 04 SH04 - POWER DISTRIBUTION
GND SFB PWR AND GRNDS
9 X-CAB_E (Receptacle) pin 6 131 RH REAR TURN LAMP VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
(84807216)
10 X-CAB_B (Plug) pin 25 - CAB 137 RH HIGH BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
TO BOTTOM [SH21: B-3] WARNING, BLINKERS, DRIVING
(87696945)
11 SP-219A-P-X 219C PWR NON-ISOLATED RD - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
STARTER / KEY
12 X-CAB_B (Plug) pin 24 - CAB 136 LH FRONT TURN VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
(87696945)
13 X-S_HMR (Receptacle) pin 10 115 MIRROR HEATER WH - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
- SWITCH HEATED MIRRORS INDICATOR
[SH13: D-4] (87716755)
17 X-CAB_E-2 (Plug) pin F - 250 ISOLATOR SET YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
CAB TO ENG 2 [SH9: C-2] STARTER / KEY
(87703902)
19 X-CAB_R (Plug) pin 5 - CAB 859 REAR WORK LIGHTS VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
TO ROOF (87695891) LIGHTS CAB ROOF, FRONT AND REAR
21 X-CAB_E (Receptacle) pin 7 121 BACKUP ALARM OR - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
- CAB TO ENGINE [SH7: B-5] ALARM
(84807216)
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X-X5 - SFB [ SH3: D-3] (47554342) (Receptacle)
47554342 262
47554342
1 SP-873-P-X 873 HVAC SFB POWER OR - 0.8 SHEET 33 SH33 - HEATING BLOWER
HEATER, HVAC
4 X-CAB_E (Receptacle) pin 26 228A ALTERNATOR VOLTAGE RD - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
- CAB TO ENGINE [SH7: B-5] STARTER / KEY
(84807216)
6 X-CAB_R (Plug) pin 4 - CAB 114 MIRROR HEAT SUPPLY TN - 1.0 SHEET 34 SH34 - MIRRORS, HORN BEACON
TO ROOF (87695891)
12 X-DM_P (Receptacle) pin 149 DOME LAMP SW OR - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
2 - DOME LIGHT POSITIVE LIGHTS
[LMP-DM] (84015523)
13 X-CAB_B (Plug) pin 26 - CAB 138 RH LOW BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
(87696945)
15 X-CAB_B (Plug) pin 28 - CAB 135 RH FRONT TURN VT - 0.8
(87696945)
16 X-CAB_P (Plug) pin 2 - CAB 189 RH TURN INDICATOR VT - 0.8
TO PEDESTAL [SH20: D-2]
(87700155)
18 X-CAB_E (Receptacle) pin 22 128 LH REAR TURN LAMP VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
(84807216)
21 X-CAB_B (Plug) pin 22 - CAB 133 LH LOW BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
(87696945)
X-X6 - SFB [ A-SFB] (47554341) (Receptacle)
47554341 263
47554341
1 SP-124-P-X 124 REVERSE VT - 0.8 SHEET 39 SH39 - MISCELLANOUS, REAR
LIGHTS_CAMERA CAMERA
2 X-CAB_E (Receptacle) pin 10 126 LH BRAKE LAMP VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
(84807216)
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3 SP-130-P-X 130 RH TAIL LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
5 CG2-P-1 CAB GROUND 279 WIPER GROUND BK - 2.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
BLOCK PWR DISTR
6 SP-127-P-X 127 LH POSITION/TAIL VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
8 X-AIR (Receptacle) pin 4 - 285 SWITCH BACK LIGHTING VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
HVAC CONSOLE [SH27: C-2] LIGHTS
(84309048)
9 X-CAB_TR (Receptacle) pin 106 REAR WASHER MOTOR OR - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
[SH26: A-2] (87696944)
12 X-RWM (Plug) pin B - 108 REAR WIPER MOTOR TN - 1.0
REAR WIPER MOTOR LOW
[M-R_WPR_M] (87692862)
17 X-DM_P (Receptacle) pin 148 EGRESS/DOME LAMP B+ VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
1 - DOME LIGHT POSITIVE LIGHTS
[LMP-DM] (84015523)
X-X7 - SFB [ SH3: A-3] (84538791) (Receptacle)
84538791 264
84538791
1 X-SFB_XCP (Receptacle) pin CANB_LF CAN BL - 0.8 SHEET 24 SH24 - CAN STRUCTURE
2 - DIAG (87696093)
2 X-SFB_XCP (Receptacle) pin CANB_HF CAN WH - 0.8
1 - DIAG (87696093)
4 SP-LF-P-X CAN_LG CAN GN - 0.8
5 SP-HF-P-X CAN_HG CAN YE - 0.8
7 X-S_RDF (Receptacle) pin 10 122 REAR DEFROST SWITCH YE - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
- SWITCH REAR DEFROST IND ALARM
[SW-R_DEF_SW] (87716755)
8 X-CAB_E-2 (Plug) pin G - 237 ISOLATOR RESET YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
CAB TO ENG 2 [SH9: C-2] STARTER / KEY
(87703902)
26 SP-113-P-X 113 HORN SWITCH BR - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
28 X-CAB_P (Plug) pin 6 - CAB 141 HAZARD SWITCH YE - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
TO PEDESTAL [SH20: D-2] WARNING, BLINKERS, DRIVING
(87700155)
30 X-KEY (Receptacle) pin B 220 SIG_IGNITION YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
- KEY SWITCH [SW-KEY] SWITCH_START STARTER / KEY
(87699176)
31 X-KEY (Receptacle) pin D 221 SIG_IGNITION YE - 0.8
- KEY SWITCH [SW-KEY] SWITCH_RUN
(87699176)
32 X-KEY (Receptacle) pin C 225 SIG_IGNITION YE - 0.8
- KEY SWITCH [SW-KEY] SWITCH_ACC
(87699176)
36 SP-258-P-X 258D AC ON SIGNAL YE - 0.8 SHEET 33 SH33 - HEATING BLOWER
HEATER, HVAC
48 X-S_HMR (Receptacle) pin 3 116 MIRROR HEATER SW YE - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
- SWITCH HEATED MIRRORS
[SH13: D-4] (87716755)
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50 X-S_BU (Receptacle) pin 3 119 BACKUP ALARM YE - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
- CANCEL BACKUP ALARM CANCEL ALARM
[SW-BCK_U_SW] (87716755)
55 X-CAB_P2 (Receptacle) pin 9 727 REAR WIPER SWITCH YE - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
B-2] (87705101)
56 X-CAB_P2 (Receptacle) pin 8 728 REAR WASHER SWITCH YE - 0.8
B-2] (87705101)
59 X-FWM (Plug) pin D - FRONT 102 FRONT WIPER MOTOR TN - 0.8
WIPER MOTOR (87692862) PARK
67 X-CAB_E (Receptacle) pin 17 239A ALT LAMP SIGNAL YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
- CAB TO ENGINE [SH7: B-5] STARTER / KEY
(84807216)
68 X-S_RDF (Receptacle) pin 3 117 REAR DEFROST SWITCH YE - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
- SWITCH REAR DEFROST ALARM
[SW-R_DEF_SW] (87716755)
80 X-DS (Receptacle) pin 1 - 151 LH DOOR AJAR SW YE - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
DOOR SWITCH [SH27: C-6] LIGHTS
(87382906)
X-XLP1 - LOUDSPEAKER RT [ H-LSP1] (84147089) (Receptacle)
84147089 265
84147089
1 X-SPK (Receptacle) pin X - LP1-1 LOUDSPEAKER RIGHT BL - 1.0 SHEET 35 SH35 - CABIN RADIO
RADIO TO SPKRS [H-RADIO] -1 LOUDSPEAKER/12V CNVRTR
(87709371)
2 X-SPK (Receptacle) pin X - LP1-2 LOUDSPEAKER RIGHT BK - 1.0
RADIO TO SPKRS [H-RADIO] -2
(87709371)
X-XLP2 - LOUDSPEAKER LF [ H-LSP2] (84147089) (Receptacle)
84147089 266
84147089
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1 X-SPK (Receptacle) pin X - LP2-1 LOUDSPEAKER LEFT -1 WH - 1.0 SHEET 35 SH35 - CABIN RADIO
RADIO TO SPKRS [H-RADIO] LOUDSPEAKER/12V CNVRTR
(87709371)
2 X-SPK (Receptacle) pin X - LP2-2 LOUDSPEAKER LEFT -2 BR - 1.0
RADIO TO SPKRS [H-RADIO]
(87709371)
X-XM1B - STARTER LUG FROM ISOLATOR (84596842) (Plug)
84596842 267
84596842
1 X-D(S) (Plug) pin 1 - MASTER CABLE-004 BATTERY CABLE RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
DISCONNECT SWITCHED STARTER / KEY
[K-ISOLATOR] (84163398)
X-XM1C - STARTER (84401295) (Plug)
84401295 268
84401295
1 X-ALT_B (Plug) pin 1 - 301 ALTERNATOR B+ RD - 13.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
ALTERNATOR B+ (84399576) STARTER / KEY
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X-X_TEL - TELEMATICS [ SH38: C-6] (87700156) (Receptacle)
87700156 269
87700156
1 X-SP_PK_CLN (Receptacle) 287 TELE GRND BK - 0.8 SHEET 24 SH24 - CAN STRUCTURE
pin X - SPLICE PACK CLEAN
GRND [SH25: C-1] (87352746)
2 X-LC5 (Receptacle) pin 4A - 168 TELEMATICS IGN OR - 0.8
LOADCENTER 5 [SH10: D-1] POWER
(87733595)
3 SP-HB-P-X CAN_HC CAN YE - 0.8
4 SP-LB-P-X CAN_LC CAN GN - 0.8
6 X-DIAG_T (Receptacle) pin 3 CAN_TL CAN LB - 0.8
- TELEMATICS DIAGNOSTIC
[SH38: B-1] (87694101)
7 X-DIAG_T (Receptacle) pin 2 CAN_TH CAN TN - 0.8
- TELEMATICS DIAGNOSTIC
[SH38: B-1] (87694101)
12 X-CAB_E-2 (Plug) pin H - 217A TELE NON- RD - 0.8
CAB TO ENG 2 [SH9: C-2] DISCONNECTED PWR
(87703902)
X-YDL - DIFF LOCK SOL [ Y-DL] (87695582) (Receptacle)
87695582 270
87695582
1 X-TRANS (Plug) pin 27 - 390A DIFF LOCK SIGNAL WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
TRANSMISSION TO CAB / FAN CONTROL
(87696949)
2 SP-391A-P-X 391B DIFF LOCK BK - 0.8
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X-YFN - SOLENOID FAN CONTROL [ Y-Y_FC] (87693821) (Receptacle)
87693821 271
87693821
A X-ENG-2 (Receptacle) pin P - 392A FAN CONTROL SGNL YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
ENGINE TO CAB 2 (87703931) / FAN CONTROL
X-YFR - FAN REVESER SOLENOID [ Y-Y_FR] (87695582) (Receptacle)
87695582 272
87695582
1 SP-852-P-X 852B FAN IGN PWR OR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
2 X-ENG-2 (Receptacle) pin N - 692A FAN REVERSER SGNL BR - 0.8 / FAN CONTROL
X-YLS - TRANS LOCKUP SOLENOID (82012083) (Plug)
82012083 273
82012083
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X-YLV - HEAT LOAD VALVE [ Y-YLV] (87695582) (Receptacle)
87695582 274
87695582
1 X-FAN2 (Plug) pin 2 - FAN 852A HEAT LOAD VALVE OR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
SPEED SENSOR JUMPER / FAN CONTROL
(87694152)
2 X-FAN2 (Plug) pin 1 - FAN 582B HEAT LOAD VALVE BR - 0.8
SPEED SENSOR JUMPER SIGNAL
(87694152)
X-YPB - VALVE PARKING BRAKE [ Y-Y_PB] (87695582) (Receptacle)
87695582 275
87695582
1 X-BTM (Receptacle) pin 18 388A PARK BRAKE SOL WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- BOTTOM TO CAB STD / FAN CONTROL
(87704523)
2 X-BTM (Receptacle) pin 19 389A PARK BRAKE SOL BK - 0.8
- BOTTOM TO CAB STD
(87704523)
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X-YPE - COUPLER VALVE [ Y-YPE] (87695582) (Receptacle)
87695582 276
87695582
1 X-FRNT (Receptacle) pin R 367B COUPLER SOL PWR WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- FRONT TO BOTTOM STD CONTROL
(87704426)
2 X-FRNT (Receptacle) pin S 368B COUPLER SOL RETURN BR - 0.8
(87704426)
X-YPP - PILOT PRESSURE SOLENOID [ Y-Y_PL] (87692855) (Plug)
87692855 277
87692855
A X-A_RT_2B (Receptacle) pin 344E PILOT ENABLE PILOT YE - 0.8 SHEET 23 SH23 - PILOT LOADER
2 (84281913)
B SP-954U-P-X 954Y CHASSIS GROUND BK - 0.8
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X-YRC - RIDE CONTROL SOLENOID [ Y-YRC] (84607243) (Receptacle)
84607243 278
84607243
1 X-FRNT (Receptacle) pin P 366B RIDE CONTROL SOL WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- FRONT TO BOTTOM STD PWR CONTROL
(87704426)
2 SP-624D-P-X 624C RIDE CONTROL GND BK - 0.8
X-YSS - SEC STEERING VALVE SOL [ Y-Y_SS] (87695582) (Receptacle)
87695582 279
87695582
1 SP-441B-P-X 441C SEC STRG IGN PWR OR - 1.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
PWR DISTR
X-ZF_DI - DIAGNOSTIC [ A-108F] (84364851) (Plug)
84364851 280
84364851
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1 SP-19C-P-X 19F DIAG CON IGN PWR OR - 0.8 SHEET 10 SH10 - IGNITION PWR DISTR
2 X-TECM (Receptacle) pin 37D DIAGNOSTIC WH - 0.8 (FUSE BLOCK LC5)
[SH25: C-6] (84550089)
3 X-SP_PK_CLN (Receptacle) 946 CLEAN GROUND BK - 0.8
pin X - SPLICE PACK CLEAN
GRND [SH25: C-1] (87352746)
4 X-TECM (Receptacle) pin 167 DIAGNOSTIC SIL - 0.8
[SH25: C-6] (84550089)
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X-10A - DENSO (Receptacle)
1 X-12 (Receptacle) pin 8 - 903A 903A BK - 2.5 SHEET 33 SH33 - HEATING BLOWER
DENSO (41200689)
3 X-12 (Receptacle) pin 10 - 265A 265A GN - 2.0
DENSO (41200689)
4 X-12 (Receptacle) pin 11 - 266A 266A YE - 2.0
DENSO (41200689)
DENSO (41200689)
X-10B - DENSO (Receptacle)

1 X-12 (Receptacle) pin 1 - 258A 258A YE - 0.8 SHEET 33 SH33 - HEATING BLOWER
2 X-12 (Receptacle) pin 2 - 262C 262C WH - 0.8
DENSO (41200689)
3 X-12 (Receptacle) pin 3 - 260A 260A PRP - 0.8
DENSO (41200689)
X-11A - DENSO (Receptacle)

1 X-12 (Receptacle) pin 4 - 285A 285A VT - 0.8 SHEET 33 SH33 - HEATING BLOWER
2 X-12 (Receptacle) pin 5 - 256D 256D BK - 0.8
DENSO (41200689)
X-11B - DENSO (Receptacle)

1 X-12 (Receptacle) pin 5 - 256E 256E BK - 0.8 SHEET 33 SH33 - HEATING BLOWER
2 X-12 (Receptacle) pin 4 - 285B 285B VT - 0.8
DENSO (41200689)
X-12 - DENSO (41200689) (Receptacle)

1 X-10B (Receptacle) pin 1 - 258A 258A YE - 0.8 SHEET 33 SH33 - HEATING BLOWER
DENSO HEATER, HVAC
2 X-10B (Receptacle) pin 2 - 262C 262C WH - 0.8
DENSO
3 X-10B (Receptacle) pin 3 - 260A 260A PRP - 0.8
DENSO
4 X-11B (Receptacle) pin 2 - 285B 285B VT - 0.8
DENSO
4 X-11A (Receptacle) pin 1 - 285A 285A VT - 0.8
DENSO
5 X-11A (Receptacle) pin 2 - 256D 256D BK - 0.8
DENSO
5 X-11B (Receptacle) pin 1 - 256E 256E BK - 0.8
DENSO
6 X-08 (Receptacle) pin 1 - 873E HVAC PWR YE - 0.8
DENSO
DENSO
8 X-10A (Receptacle) pin 1 - 903A 903A BK - 2.5
DENSO
9 X-10A (Receptacle) pin 2 - 264A 264A GY - 1.0
DENSO
10 X-10A (Receptacle) pin 3 - 265A 265A GN - 2.0
DENSO
11 X-10A (Receptacle) pin 4 - 266A 266A YE - 2.0
DENSO
12 X-10A (Receptacle) pin 5 - 267A 267A GY - 2.5
DENSO
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X-PHF23 - HYDRAULIC FILTER SENSOR PL23 (82012083) (Plug)
82012083 1
82012083
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X-S242 - GROUND [ M-SEC_STRG] (84401307) (Plug)
84401307 1
84401307
1 X-SSG (Plug) pin 1 - 185 AUX STEERING BK - 62.0 SHEET 21 SH21 - UCM-STEERING AUX JSS
SECONDARY STEERING GROUND CABLE
GROUND RING [SH21: C-1]
(84401307)
X-S244 - 20157 AUX STRG PWR RT ANGLE CONN [ SH21: D-3] (Plug)
1 X-B4 (Plug) pin 1 - 1990 AUX STEERING POWER RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
ALTERNATOR TO STARTER CABLE STARTER / KEY
B+ (84401309)
X-S245 - GROUND (84426118) (Plug)
84426118 2
84426118
1 X-SSD (Plug) pin A - SS 180A SEC STRG FLYBACK BK - 1.0 SHEET 21 SH21 - UCM-STEERING AUX JSS
FLYBACK DIODE [D-SS GRND
DIODE] (87692858)
1 X-SSD (Plug) pin B - SS 180 SEC STRG FLYBACK BK - 1.0
FLYBACK DIODE [D-SS GRND
DIODE] (87692858)
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X-563 - BATTERY LUG [ G-001] (Plug)
1 X-BAT-GND (Plug) pin CABLE-001 CABLE BATTERY BK - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
1 - BATTERY GROUND NEGATIVE STARTER / KEY
(84140737)

1 X-567 (Plug) pin 1 - BATTERY CABLE-002 BATTERY CABLE RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
LUG [G-001] STARTER / KEY
X-566 - BATTERY POSITIVE [ G-002] (Plug)

1 X-D(B) (Plug) pin 1 - MASTER CABLE-003 BATTERY POWER RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
DISCONNECT BATTERY STARTER / KEY
(84140737)

1 X-564 (Plug) pin 1 - BATTERY CABLE-002 BATTERY CABLE RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
LUG [G-002] STARTER / KEY
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X-P5320 - JUMP START [ G-002] (Plug)
PIN1 X-JS+ (Plug) pin PIN1 - JUMP CABLE09 JUMP START RD - 32.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
START STUD POS [J-JS+] STARTER / KEY
X-P5321 - JUMP START [ G-001] (Plug)

PIN1 X-JS- (Plug) pin PIN1 - JUMP CABLE08 JUMP START MINUS BK - 32.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
START STUD NEG [J-JS-] STARTER / KEY
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X-P1002 - B+ POWER STUD (84140737) (Plug)
84140737 1
84140737
1 X-LC2 (Receptacle) pin 7B - 532 CAB ISOLATED POWER RD - 3.0 SHEET 07 SH07 - BATTERY PWR DISTR
LOADCENTER 2 [SH7: B-3] (FUSE BLOCK LC2)
(87733581)
84140737 2
84140737
1 X-LC3 (Receptacle) pin F8_8 917 CAB ISOLATED POWER RD - 3.0 SHEET 08 SH08 - POWER DISTRIBUTION
- LOADCENTER 3 [SH35: B-6] (FUSE BLOCK LC3)
(84529039)
1 X-LC3 (Receptacle) pin F6_6 541 CAB ISOLATED POWER RD - 2.0
- LOADCENTER 3 [SH35: B-6]
(84529039)
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X-P1031 - B+ ON POWER STUD (84140737) (Plug)
84140737 1
84140737
1 P1310-P-1 B+ ON LC1 518 B+ CAB POWER RD - 19.0 SHEET 06 SH06 - BATTERY PWR DISTR
(FUSE BLOCK LC1)
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84140737 1
84140737
1 X-LC2 (Receptacle) pin 2B - 527 CAB ISOLATED B+ RD - 3.0 SHEET 07 SH07 - BATTERY PWR DISTR
LOADCENTER 2 [SH7: B-3] (FUSE BLOCK LC2)
(87733581)
1 X-LC2 (Receptacle) pin 3B - 528 CAB ISOLATED B+ RD - 3.0
(87733581)
(87733581)
(87733581)
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X-J1333 - DENSO (Receptacle)
1 M-BLOWER 24V-P-1 WIRE4390 WIRE4390 SHEET 33 SH33 - HEATING BLOWER
2 M-BLOWER 24V-P-2 WIRE4389 WIRE4389 HEATER, HVAC
X-J1338 - DENSO (Receptacle)

1 SW-LOW PRESSURE WIRE4702 DENSO SHEET 33 SH33 - HEATING BLOWER
SWITCH N-P-1 HEATER, HVAC
2 SW-LOW PRESSURE WIRE4703 DENSO
SWITCH N-P-2
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Index

Electrical components - Diode description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical components - ECU description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical components - Fuse description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical components - Ground description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical components - Lamp description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical components - Load description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electrical components - Motor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Electrical components - Power outlet description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical components - Relay description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrical components - Resistor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electrical components - Sensor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical components - Solenoid description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Electrical components - Speaker description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical components - Switch description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical components - Voltage source description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wire connectors - Component diagram 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Wire connectors - Component diagram 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Wire connectors - Component diagram 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Wiring harnesses - Electrical schematic sheet 03 SH03 - PWR DISTR-BATTERY / STARTER / KEY
...................................................................................... 36
Wiring harnesses - Electrical schematic sheet 04 SH04 - POWER DISTRIBUTION SFB PWR AND
GRNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wiring harnesses - Electrical schematic sheet 06 SH06 - BATTERY PWR DISTR (FUSE BLOCK
LC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Wiring harnesses - Electrical schematic sheet 07 SH07 - BATTERY PWR DISTR (FUSE BLOCK
LC2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Wiring harnesses - Electrical schematic sheet 08 SH08 - POWER DISTRIBUTION (FUSE BLOCK
LC3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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Wiring harnesses - Electrical schematic sheet 09 SH09 - ACCESSORY PWR DIST (FUSE BLOCK
LC4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Wiring harnesses - Electrical schematic sheet 10 SH10 - IGNITION PWR DISTR (FUSE BLOCK
LC5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Wiring harnesses - Electrical schematic sheet 11 SH11 - PWR DISTR ENG COMPARTMENT (FUSE
BLOCK LC6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Wiring harnesses - Electrical schematic sheet 12 SH12 - POWER DISTRIBUTION 1 CLEAN
GROUND BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Wiring harnesses - Electrical schematic sheet 13 SH13 - POWER DISTRIBUTION 2 CAB GROUND
BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Wiring harnesses - Electrical schematic sheet 14 SH14 - CAB & CHASSIS GROUND PWR DISTR 58
Wiring harnesses - Electrical schematic sheet 15 SH15 - POWER DISTRIBUTION 4 ENGINE
GROUND BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Wiring harnesses - Electrical schematic sheet 16 SH16 - ENGINE CONTROL UNIT 1, GRID
HEATER, FILTER HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Wiring harnesses - Electrical schematic sheet 17 SH17 - ENGINE CONTROL UNIT 2, AT . . . . . . . 64
Wiring harnesses - Electrical schematic sheet 18 SH18 - ENGINE CONTROL UNIT 3, AT . . . . . . . 66
Wiring harnesses - Electrical schematic sheet 19 SH19 - UCM PWR, GRND, INSTRUMENTATION 68
Wiring harnesses - Electrical schematic sheet 20 SH20 - UCM VEHICLE DRIVELINE / FAN CON-
TROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Wiring harnesses - Electrical schematic sheet 21 SH21 - UCM-STEERING AUX JSS . . . . . . . . . . . 72
Wiring harnesses - Electrical schematic sheet 22 SH22 - UCM-LOADER BOOM CONTROL . . . . . 74
Wiring harnesses - Electrical schematic sheet 23 SH23 - PILOT LOADER CONTROLS . . . . . . . . . 76
Wiring harnesses - Electrical schematic sheet 24 SH24 - CAN STRUCTURE . . . . . . . . . . . . . . . . . . 78
Wiring harnesses - Electrical schematic sheet 25 SH25 - GEAR CONTROL UNIT 1 . . . . . . . . . . . . 80
Wiring harnesses - Electrical schematic sheet 26 SH26 - GEAR CONTROL UNIT 2 . . . . . . . . . . . . 82
Wiring harnesses - Electrical schematic sheet 27 SH27 - LIGHTING DOME, MAP LIGHTS . . . . . . 84
Wiring harnesses - Electrical schematic sheet 28 SH28 - LIGHTING HAZARD WARNING, BLINK-
ERS, DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Wiring harnesses - Electrical schematic sheet 29 SH29 - LIGHTING REAR TAILS . . . . . . . . . . . . . . 88
Wiring harnesses - Electrical schematic sheet 30 SH30 - OLD EURO LIGHTING . . . . . . . . . . . . . . . 90
Wiring harnesses - Electrical schematic sheet 31 SH31 - LIGHTING WORKING LIGHTS CAB ROOF,
FRONT AND REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Wiring harnesses - Electrical schematic sheet 32 SH32 - CAB WIPER / WASHER . . . . . . . . . . . . . . 94
Wiring harnesses - Electrical schematic sheet 33 SH33 - HEATING BLOWER HEATER, HVAC . . 96
Wiring harnesses - Electrical schematic sheet 34 SH34 - MIRRORS, HORN BEACON . . . . . . . . . . 98
Wiring harnesses - Electrical schematic sheet 35 SH35 - CABIN RADIO LOUDSPEAKER/12V CN-
VRTR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Wiring harnesses - Electrical schematic sheet 36 SH36 - REAR DEFROST, BACKUP ALARM . . . 102
Wiring harnesses - Electrical schematic sheet 37 SH37 - HOOD LIFT . . . . . . . . . . . . . . . . . . . . . . . . . 104
Wiring harnesses - Electrical schematic sheet 38 SH38 - MISCELLANOUS, TELEMATICS . . . . . . 106
Wiring harnesses - Electrical schematic sheet 39 SH39 - MISCELLANOUS, REAR CAMERA . . . . 108
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Engine starting system - 201

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Contents
SERVICE
Engine starter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electrical systems - Engine starting system
Engine starter - Remove

Raise the engine hood. Put the timed disconnect
Wait approximately 5 min until the battery isolator
opens. Alternatively remove the negative battery ca-
ble.
LEIL15WHL0663AA 1
3. Place an identification tag on the starter switch wire

(1). Remove the starter switch wire (1) from the engine
starter.
LEIL15WHL1299AB 2
4. Place identification tags on the cables. Remove the

negative cable (starter to ground) (1), the negative ca-
ble (battery to starter) (2) from the engine starter. Re-
move the positive cable (battery isolator to starter) and
the connectors (4) and (5) from the engine starter.
LEIL16WHL1527AB 3
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5. Remove the three flange nuts (1) from the engine

starter. Remove the engine starter.
LEIL15WHL1331BB 4
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Engine starter - Install

1. Position the engine starter on the machine.
Install the three flange nuts (1) to secure the engine
starter to the engine. Tighten the flange nuts (1) to 40
– 48 N·m (30 – 35 lb ft).
LEIL15WHL1331BB 1
2. Install the negative cable (starter to ground) (1), the

negative cable (battery to starter) (2) on the engine
starter. Tighten the related nut. Install the positive ca-
ble (battery isolator to starter) (3) and the connectors
(4) and (5) on the engine starter. Remove the identifi-
cations cab from the cables.
LEIL16WHL1527AB 2
3. Install and tighten the starter switch wire (1).
LEIL15WHL1299AB 3
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4. Put the timed disconnect switch (1) in the ON position.

Press the hood switch (2) to lower the engine hood.
LEIL15WHL0663AA 4
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Index

Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Alternator - 301

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Contents
Alternator - 301
SERVICE
Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Alternator
Alternator - Remove
Raise the engine hood. Put the timed disconnect
Wait approximately 5 min until battery isolator opens.
Alternatively remove the negative battery cable.
LEIL15WHL0663AA 1
3. Disconnect the wires from the alternator. Identify and

tag the wires to aid in reassembly.
LEIL15WHL0818AB 2
4. Use a breaker bar to actuate the belt tensioner to re-

lease the tension on the drive belt. Remove the drive
belt.
LEIL15WHL1296AA 3
5. Remove the bolt (1). Remove the bolt (2), the washer
(3) and the nut (4). Remove the alternator.
LEIL15WHL1297AB 4
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Alternator - Install
1. Place the alternator onto the engine. Install the bolt (1).
Install the bolt (2), the washer (3) and the nut (4).
LEIL15WHL1297AB 1
2. Use a wrench to move the belt tensioner. Install the

drive belt.
NOTE: belt routing instructions are on belt cover.
LEIL15WHL1296AA 2
3. Connect the wires to the alternator, place the rubber

boot over the positive post.
LEIL15WHL0818AB 3
4. If removed, reinstall the negative battery cable. Put the

timed disconnect switch (1) in the ON position. Press
hood switch (2) to lower the engine hood.
LEIL15WHL0663AA 4
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Belt installation (with air conditioning)
LEIL15WHL1298AA 5
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Index
Alternator - 301
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cab controls - 512

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Contents
Cab controls - 512
SERVICE
Joystick and Electric Hydraulic (EH) control

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove (Two/three control levers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install (Two/three control levers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Electrical systems - Cab controls
Joystick and Electric Hydraulic (EH) control - Remove

Joystick removal
bucket to the floor.
2. Stop the engine. Make sure the parking brake is ap-
plied.
3. Wait a few seconds and turn the ignition key to the ON
position. Move the joystick in both directions several
times to relieve pressure. Turn the ignition key to the
OFF position.
RCPH10WHL106AAH 1
5. Remove the three lower armrest mounting bolts (1) and

washers (2) on the right-hand side of the armrest (3).
6. Lift the arm pad to the top of its adjustment. Reach
the latch located under the arm pad and push the latch
forward to release the mechanism. Turn the arm pad
of 90° to access the two top mounting bolts (1) and
washers (2).
7. Remove the two top mounting bolts (1) and the washer
(2).
LEIL16WHL0484BB 2
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8. Remove the left-hand shell (1) by removing the three

mounting screws (2) and washers (3) located on the
outside of the left-hand shell.
9. Remove the bolt (4) under the arm pad.
LEIL16WHL0485AB 3
10. Remove the right-hand shell (1) by removing the four

mounting screws (2) and bolt (3) from the main sup-
port bracket (4).
LEIL16WHL0486AB 4
11. Remove the bezel (1) by removing the six screws (2)
from the back of the bezel.
Disconnect the wire harness from the back of bezel
(1).
LEIL16WHL0487AB 5
12. Remove the joystick (1) from the mounting bracket (2)
by removing the four flange nuts (3).
LEIL17WHL1627AB 6
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Joystick and Electric Hydraulic (EH) control - Install

1. Install the joystick (1) to the joystick mounting bracket
(2) by using the flange nuts (3).
LEIL17WHL1627AB 1
2. Install the bezel (1) to the joystick mounting bracket (2)

using the same six screws (3) previously removed.
3. Plug the wire harness into the joystick connector (see
the arrow).
LEIL16WHL0487AB 2
4. Install the right-hand shell (1) to the support bracket (4),

using the four mounting screws (2) and bolt (3).
LEIL16WHL0486AB 3
5. Reinstall the left-hand shell (1) reusing the bolt (4), and
then the three bolts (2) and washers (3).
LEIL16WHL0485AB 4
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6. Reinstall the two mounting bolts (1) and washers (2)

located on the top side of the armrest, and then the
three bolts (1) and washers (2) located on the lower
side of the armrest.
LEIL16WHL0489BB 5
RCPH10WHL106AAH 6
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Joystick and Electric Hydraulic (EH) control - Remove (Two/three

control levers)
bucket to the floor.
2. Stop the engine. Make sure the parking brake is ap-
plied.
3. Wait a few seconds and turn the ignition key to the
ON position. Move the two/three control levers in both
directions several times to relieve any pressure. Turn
the ignition key to the OFF position.
RCPH10WHL106AAH 1
5. Remove the three lower armrest mounting bolts (1) and

washers (2) on the right-hand side of the armrest (3).
6. Lift the arm pad to the top of its adjustment. Reach
the latch located under the arm pad and push the latch
forward to release the mechanism.
Turn the arm pad of 90° to access the two top mounting
bolts (1) and washers (2).
7. Remove the two top mounting bolts (1) and the washer
(2).
LEIL16WHL0483BB 2
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8. Remove the left-hand shell (1) by removing the three

mounting screws (2) and washers (3) located on the
outside of the left-hand shell.
9. Remove the bolt (4) under the arm pad.
LEIL16WHL0475AB 3
10. Remove the right-hand shell (1) by removing the four

mounting screws (2) and bolt (3) from the main sup-
port bracket (4).
LEIL16WHL0476AB 4
11. Disconnect the wire harness (1) from the main

bracket.
LEIL17WHL1624AB 5
12. Remove the control lever mounting bracket (1) from

the main bracket (2) by removing the bolts (3) and bolt
(4).
LEIL16WHL0478AB 6
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Two control levers

13. Take off the bezel (1) by removing the six screws (2)
LEIL17WHL1625AB 7
14. Disassemble the boom lever (1) and bucket lever (2)
from bracket (5) by removing the light screws (3) and
washers (4).
LEIL16WHL0480AB 8
Three control levers

13. Take off the bezel (1) by removing the six screws (2)
LEIL16WHL0481AB 9
14. Disassemble the boom lever (1) and bucket lever (2)
from the bracket (5), by removing the twelve screws
(3) and washers (4).
15. Unplug the harness from the auxiliary function control
lever (6), and then disassemble the auxiliary function
control lever (6) from bracket (5) as well.
LEIL17WHL1626AB 10
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Joystick and Electric Hydraulic (EH) control - Install (Two/three

control levers)
Two control levers
1. Reassemble the boom lever (1) and bucket lever (1) to
the mounting bracket (5), by using the eight screws (3)
and washers (4).
LEIL16WHL0480AB 1
2. Plug the harness (1) by mounting clips to the main

bracket.
LEIL17WHL1624AB 2
3. Install the bezel (1) to the mounting bracket by using

the six screws (2) from the back of bezel.
LEIL17WHL1625AB 3
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Three control levers

1. Install the boom lever (1), bucket lever (2) and auxiliary
function control lever (6) to the mounting bracket (5),
by using the twelve screws (3) and washers (4).
LEIL17WHL1626AB 4
2. Plug the harness (1) by mounting clips to the main

bracket, and than plug the auxiliary harness mounting
clip to the main bracket.
LEIL17WHL1624AB 5
3. Reinstall the bezel (1) to the mounting bracket by using

the six screws (2) from the back of bezel.
LEIL16WHL0481AB 6
4. Reinstall the right-hand shell (1) to the main support

bracket (4), by using the four screws (2) and bolt (3).
LEIL16WHL0476AB 7
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5. Reinstall the left-hand shell (1). Reuse the bolt (4) and
three bolts (2) and washers (3).
LEIL16WHL0475AB 8
6. Reinstall the armrest (3) to the seat. Reuse the five

bolts (1) and washers (2).
LEIL16WHL0483BB 9
RCPH10WHL106AAH 10
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Index
Cab controls - 512

Joystick and Electric Hydraulic (EH) control - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Joystick and Electric Hydraulic (EH) control - Install (Two/three control levers) . . . . . . . . . . . . . . . . . 10
Joystick and Electric Hydraulic (EH) control - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Joystick and Electric Hydraulic (EH) control - Remove (Two/three control levers) . . . . . . . . . . . . . . . 7
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Heating, Ventilation, and Air-Conditioning (HVAC) control system -

050

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55.5 [55.050] / 1
Contents
Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050
SERVICE
Blower
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
Blower - Remove
1. Park the machine on a firm, level surface. Lower the
Discharge the air conditioning system following the
specified procedures.
2. Turn the timed disconnect switch to the OFF position
3. Discharge the air conditioning system following the
specified procedures.
4. Open the cab window to facilitate the removal of bolts
(arrows).
Remove the six bolts (arrows) and related washers to
LEIL16WHL1190AB 1

LEIL16WHL1209AB 2
6. Remove the grommet.
LEIL18WHL0452AB 3
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55.5 [55.050] / 3
7. Remove the three retaining knobs that hold the cab air
recirculation filter cover in place.
LEIL18WHL0453AB 4
8. Extract the cab air recirculation filter.
LEIL18WHL0454AB 5
9. Remove the 16 screws holding the cover case. Re-

move the cover case from the machine.
figure 6.
LEIL18WHL0459AB 6
10. Disconnect the electrical connector from the blower.
LEIL18WHL0460AB 7
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55.5 [55.050] / 4
11. Remove the two screws to unfix the blower assembly.
LEIL18WHL0461AB 8
12. Extract not completely the blower assembly to discon-

nect the electrical connector.
Remove the blower assembly from the machine.
LEIL18WHL0467AB 9
13. On bench, remove the four screws to separate the

blower from the flange.
LEIL18WHL0462AB 10
14. Separate the blower.
LEIL18WHL0463AB 11
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Blower - Install
1. On bench, fasten the blower to the flange with four
screws.
LEIL18WHL0462AB 1
2. Insert not completely the blower assembly in the case.

Connect the electrical connector.
LEIL18WHL0467AB 2
3. Insert completely the blower assembly in the case. In-

stall the two screws to fix the blower assembly.
LEIL18WHL0461AB 3
4. Connect the electrical connector to the blower.
LEIL18WHL0460AB 4
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55.5 [55.050] / 6

with 16 screws.
figure 5.
LEIL18WHL0459AB 5
6. Insert the cab air recirculation filter.
LEIL18WHL0454AB 6
7. Install the cab air recirculation filter cover with the three
retaining knobs.
LEIL18WHL0453AB 7
8. Install the grommet.
LEIL18WHL0452AB 8
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LEIL16WHL1209AB 9
10. Open the cab window to facilitate the installation of

bolts (arrows). Tighten the six mounting bolts and
washers to install the HVAC cover.
LEIL16WHL1190AB 10

12. Put the timed disconnect switch to ON position.
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Index
Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050

Blower - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Blower - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Loader arm and bucket control system - 415

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Contents
SERVICE
Loader arm and bucket control system

Remove - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassemble - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assemble - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Check - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassemble - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assemble - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Check - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Electrical systems - Loader arm and bucket control system
Loader arm and bucket control system - Remove - Electro-Hydraulic

(EH) lift sensor
bucket to the ground. Stop the engine and make sure
the parking brake is applied.
2. With the engine stopped, move the joystick or control
lever(s) to release any pressure in the hydraulic circuit.
3. Locate the Electro-Hydraulic (EH) lift sensor assembly
on the right-hand of the front frame.
LEIL17WHL2277AB 1
4. Disconnect the electrical connector X-BOA from the

Electro-Hydraulic (EH) lift sensor.
LEIL17WHL2278AB 2
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5. Loosen and remove the three bolts (5), the three wash-
ers (4) and the three spacers (3) that fix the EH lift sen-
sor assembly (1) to the front frame.
6. Remove the hexagonal socket screw (2) from the arm
fork of the EH lift sensor assembly (1). Remove the EH
lift sensor assembly (1) from the machine.
NOTE: the figure 3 is referred to the 1021G model while
the 4 is referred to the 1121G model.
LEIL17WHL2276AB 3
LEIL17WHL2279AB 4
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Loader arm and bucket control system - Disassemble -

Electro-Hydraulic (EH) lift sensor
LEIL17WHL0557FB 1
1021G
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LEIL17WHL0562FB 2
1121G
1. Loosen and remove the two bolts (6), the four washers
(4), the two spacers (2), and the two nuts (5). Separate
the Electro-Hydraulic (EH) lift sensor (1) from the cover
(3).
2. Loosen and remove the bolt (9), the two washers (8),
and the nut (10) to unfix the EH lift sensor (1) from the
arm fork (7).
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Loader arm and bucket control system - Assemble -

Electro-Hydraulic (EH) lift sensor
LEIL17WHL0557FB 1
1021G
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LEIL17WHL0562FB 2
1121G
1. Use the bolt (9), the two washers (8), and the nut (10)
to secure the Electro-Hydraulic (EH) lift sensor (1) to
the arm fork (7). Tighten to 2.9 – 4 N·m (2.14 – 2.95 lb
ft).
NOTE: after installation, make sure the flat side of sensor
pin (see arrow) lines up with the bottom of the arm fork (7).
2. Use the two bolts (6), the four washers (4), the two
spacers (2), and the two nuts (5) to assembly the EH
lift sensor (1) to the sensor cover (3).
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Loader arm and bucket control system - Install - Electro-Hydraulic

(EH) lift sensor
3. Fix the arm fork of the Electro-Hydraulic (EH) lift sen-
sor assembly (1) to the front frame with the hexagonal
socket screw (2).
4. Use the three bolts (5), the three washers (4), and the
three spacers (3) to install the EH lift sensor assembly
NOTE: the figure 1 is referred to the 1021G model while
the 2 is referred to the 1121G model.
LEIL17WHL2276AB 1
LEIL17WHL2279AB 2
5. Connect the electrical connector X-BOA to the EH lift

sensor.
LEIL17WHL2278AB 3
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Loader arm and bucket control system - Check - Electro-Hydraulic

(EH) lift sensor
NOTE: set the input voltage according to the “Sensor I/O Table”.
Check the functional output of the Electro-Hydraulic
(EH) lift sensor with the next steps:
1. Check the assembly output at 0°. Check the output
voltage (see “Sensor I/O Table”).
2. Rotate the assembly 45° counter-clockwise. Check
the output voltage (see “Sensor I/O Table”).
3. Rotate the assembly back to 0°. Check the output
Sensor I/O Table

Sensor input 5V ± 0.25 V
(A) 0° Output 50% Vs ± 0.20 V
(B) 45°Clockwise Output 88.6% Vs ± 0.20 V
(C) 45°Counter clockwise Output 11.4% Vs ± 0.20 V
LEIL17WHL0558FB 1
1021G
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LEIL17WHL0559FB 2
1121G
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Loader arm and bucket control system - Remove - Electro-Hydraulic

(EH) tilt sensor
Z-bar models
ing brake.
3. Locate the Electro-Hydraulic (EH) tilt sensor assembly
on the right-hand of the front frame.
LEIL17WHL0556AB 1
4. Disconnect the electrical connector X-BUA from the

Electro-Hydraulic (EH) tilt sensor.
LEIL17WHL2280AB 2
5. Loosen and remove the two bolts (5), the two washers
(4), and the two spacers (3) that fix the EH tilt sensor
assembly (1) to the front frame.
6. Remove the hexagonal socket screw (2) from the arm
fork of the EH tilt sensor assembly (1). Remove the EH
tilt sensor assembly (1) from the machine.
LEIL17WHL2282AB 3
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Loader arm and bucket control system - Disassemble -

Electro-Hydraulic (EH) tilt sensor
LEIL17WHL2281FB 1
1. Loosen and remove the two bolts (8),the four wash-

ers (7), and the two nuts (9). Separate the Electro-Hy-
draulic (EH) tilt sensor (1) from the cover (6).
2. Loosen and remove the bolt (4), the two washers (3),
and the nut (5) to unfix the EH tilt sensor (1) from the
arm fork (2).
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Loader arm and bucket control system - Assemble -

Electro-Hydraulic (EH) tilt sensor
LEIL17WHL2281FB 1
1. Use the bolt (4), the two washers (3), and the nut (5) to
secure the Electro-Hydraulic (EH) tilt sensor (1) to the
arm fork (2). Tighten to 2.9 – 4 N·m (2.14 – 2.95 lb ft).
NOTE: after installation, make sure the flat side of sensor
pin (see arrow) lines up with the bottom of the arm fork (2).
2. Use the two bolts (8), the four washers (7), and the two
nuts (9) to assembly the EH tilt sensor (1) to the sensor
cover (6).
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Loader arm and bucket control system - Install - Electro-Hydraulic

(EH) tilt sensor
3. Fix the arm fork of the Electro-Hydraulic (EH) tilt sen-
sor assembly (1) to the front frame with the hexagonal
socket screw (2).
4. Use the two bolts (5), the two washers (4), and the two
spacers (3) to install the EH tilt sensor assembly (1) to
the front frame.
LEIL17WHL2282AB 1
5. Connect the electrical connector X-BUA to the EH tilt

sensor.
LEIL17WHL2280AB 2
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Loader arm and bucket control system - Check - Electro-Hydraulic

(EH) tilt sensor
NOTE: set the input voltage according to the “Sensor I/O Table”.
Check the functional output of the Electro-Hydraulic
(EH) tilt sensor with the next steps:
1. Check the assembly output at 0°. Check the output
2. Rotate the assembly 45° counter-clockwise. Check
the output voltage (see “Sensor I/O Table”).
3. Rotate the assembly back to 0°. Check the output
Sensor I/O Table

Sensor input 5V ± 0.25 V
(A) 0° Output 50% Vs ± 0.20 V
(B) 45°Clockwise Output 88.6% Vs ± 0.20 V
(C) 45°Counter clockwise Output 11.4% Vs ± 0.20 V
LEIL17WHL2270FB 1
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Index

Loader arm and bucket control system - Assemble - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . 7
Loader arm and bucket control system - Assemble - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . 14
Loader arm and bucket control system - Check - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . . 10
Loader arm and bucket control system - Check - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . . 16
Loader arm and bucket control system - Disassemble - Electro-Hydraulic (EH) lift sensor . . . . . . . . 5
Loader arm and bucket control system - Disassemble - Electro-Hydraulic (EH) tilt sensor . . . . . . . . 13
Loader arm and bucket control system - Install - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . . . 9
Loader arm and bucket control system - Install - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . . . 15
Loader arm and bucket control system - Remove - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . 12
Loader arm and bucket control system - Remove - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . 3
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Camera - 530

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Contents
Camera - 530
SERVICE
Camera
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Monitor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Electrical systems - Camera
Camera - Remove
LOCKED position.
LEIL15WHL1782AA 1
2. Locate the rearview camera on the rear grill of the en-

gine hood.
LEIL16WHL1843AB 2
3. Raise the engine hood and turn the timed disconnect

switch to the OFF position.
LEIL15WHL0663AA 3
4. Remove the cable ties (2) to separate the extension

cable (3) of the rearview camera from the rear grill.
Disconnect the connector (1) of the extension cable (3)
of the rearview camera.
LEIL16WHL1844AB 4
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5. Loosen the two bolts (3) with the four washers and the
two nuts. Separate the mounting bracket (1) from the
mounting bracket (2).
LEIL16WHL1846AB 5
6. Remove the two nuts (4), the four washers (5). to sepa-
rate the mounting bracket (2) from the rearview camera
(1) and from the gasket (3).
LEIL16WHL1850AB 6
7. Remove the rearview camera.
LEIL16WHL0959AA 7
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Camera - Install
Prior operation:
Camera - Remove (55.530)
1. Place the rearview camera (1) and the gasket (3), in the
correct position on the mounting bracket (2). Secure
the rearview camera (1) with the two nuts (4) and the
two washers (5).
Tighten the two nuts (4) with a torque of 5.0 – 6.0 N·m
(3.7 – 4.4 lb ft).
NOTE: the gasket (2), the two washer (3) and the two nuts
(4) are provided with the camera.
LEIL16WHL1850AB 1
2. Use the two bolts (3), and related washers and nuts to
install the mounting bracket (1) (installed on the rear
grill) with the mounting bracket (2).
Tighten the bolts (3) to a torque of 0.8 – 1.0 N·m (0.6 –
0.7 lb ft).
NOTE: Align dots (5) and (6) with indention on the mount-
ing bracket for proper vertical and horizontal camera (4)
alignment.
LEIL16WHL1851AB 2
3. Route the extension cable (3) of the rearview camera

inside the engine hood. Connect the connector (1).
Use new cable ties (2) to secure the extension cable
(3) of the rearview camera to the rear grill inner side.
LEIL16WHL1844AB 3
4. Lower the engine hood. Turn the timed disconnect

switch to the ON position.
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Monitor - Remove
1. Locate the multifunction display inside the cab.
LEIL16WHL0996AB 1
2. Disconnect the connector (4).

3. Remove the three bolts (2), the three washers (3) to
separate the multifunction display (1) from the related
support.
LEIL16WHL0854AB 2
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Monitor - Install
1. Connect the connector (4).
2. Tighten the three bolts (2) and the three washers (3) to
install the multifunction display (1) to the related sup-
port.
LEIL16WHL0854AB 1
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Index
Camera - 530
Camera - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Camera - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Monitor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Monitor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Wiper and washer system - 518

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Contents
SERVICE
Windshield wiper motor

Remove wiper front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install wiper front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove wiper rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install wiper rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Electrical systems - Wiper and washer system
Windshield wiper motor - Remove wiper front

to the ground.
4. Cut the tie-strap and remove the washer hose (1) of the
windshield fluid.
LEIL18WHL0795AB 1
5. Remove the four bolts (1) with the relevant hexagonal

nuts to separate the wiper arm assembly (2) from the
wiper motor assembly.
6. Remove the wiper arm (2) from the wiper motor assem-
bly.
LEIL18WHL0804AB 2
7. Remove the four bolts (1) with the relevant washers

to separate the wiper motor assembly from the front
mounting plate.
LEIL18WHL0805AB 3
8. Separate the washer hose (3) from the wiper motor

assembly.
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9. Disconnect the connectors X-FWM_G (1) and X-FWM

(2) from the wiper motor harness.
LEIL18WHL0728AB 4
10. On bench, remove the two caps (1).

11. Loosen the two hexagonal nuts (2) with the relevant
flat washers (3) and the washers (4).
12. Separate the mounting plate (5) from the wiper motor
(7).
13. Remove and discard the seal (6).
14. Remove the remaining two flat washers (3) and the
two washers (4) from the two parallel knurlings of the
wiper motor (7).
LEIL18WHL0739BB 5
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Windshield wiper motor - Install wiper front

NOTE: follow the call-out to be sure to install the component on the correct position. Repeat the operation for each
part.
NOTE: all the change in design, composition or processing, must be previously approved from CNH engineering
approval.
1. Install the two flat washers (3) and the two washers (4)
on the two parallel knurlings of the wiper motor (7).
2. Install the seal (6) on the plate-mounting front wiper-
motor (5).
3. Install the plate-mounting front wiper-motor (5) on the
two parallel knurlings of the wiper motor (7).
4. Tighten the two hexagonal nuts (2) with the relevant flat
washers (3) and the washers (4).
5. Torque to 35.0 N·m (309.8 lb in) – 40.0 N·m (354.0 lb
in) the two hexagonal nuts (2).
6. Install the two caps (1) to the two hexagonal nuts (2).
LEIL18WHL0739BB 1
7. Hold the motor assembly and connect the connectors

X-FWM_G (1) and X-FWM (2) with the wiper motor har-
ness.
8. Attach the water hose (3) of the windshield fluid. Pull
until the wiper motor assembly is install in the correct
position.
LEIL18WHL0728AB 2
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9. Tighten the four bolts and relative washers (1) to install

the wiper motor assembly to the machine.
LEIL18WHL0805AB 3
10. Install the wiper arm assembly (2) on the wiper motor
assembly with the four bolts (1) and related nuts.
11. Torque to 12.0 N·m (106.2 lb in) – 16.0 N·m (141.6 lb
in) the four bolts (1).
LEIL18WHL0804AB 4
12. Install the water hose (1) of the windshield fluid.

13. Pull until it is install on the correct position and secure
it with a tie-strap.
LEIL18WHL0795AB 5
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Windshield wiper motor - Remove wiper rear

to the ground.
4. Loosen the four screws (1) and remove the upper rear
grab handle assembly (2).
LEIL18WHL0750AB 1
5. Separate the washer hose (1) of the windshield fluid

from the plate-mounting rear wiper-motor (2).
LEIL18WHL0743AB 2
6. Lift the cap in order to reach the bolt and the washer.
LEIL18WHL0751AA 3
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7. Remove the nut (1) and the related washer (2).
LEIL18WHL0752AB 4
8. Remove the wiper arm assembly.

9. Remove the nut and the washer (1) from the knurling
(2).
LEIL18WHL0753AB 5
10. Remove the six bolts with the relevant washers (1) to
separate the plate-mounting rear wiper-motor (2) from
the machine.
LEIL18WHL0742AB 6
11. Disconnect the connectors X-RWM (2) and

X-RWM_G (3) from the harness of the wiper motor
assembly (1).
LEIL18WHL0755AB 7
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12. Remove the bolts with the relevant nuts and washers
(5) to separate the plate-mounting rear wiper-motor
(4) from the wiper-motor (1).
13. Remove the washer hose (2) of the windshield fluid.
14. Remove and discard the seal (3) from the
plate-mounting front wiper-motor (4).
LEIL18WHL0754BB 8
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Windshield wiper motor - Install wiper rear

NOTE: follow the call-out to be sure to install the component on the correct position.
NOTE: all the change in design, composition or processing, must be previously approved from CNH industrial engi-
neering approval.
1. Joint the wiper motor (1) with the he plate-mounting
rear wiper-motor (4).
2. Secure the wiper motor (1) with the he plate-mounting
rear wiper-motor (4) with fixing hardware (5). Torque to
14.0 N·m (10.3 lb ft) - 18.0 N·m (13.3 lb ft).
3. Apply the seal (3) on the plate-mounting rear wiper-
motor (4).
4. Install the water hose (2) of the windshield fluid.
Pull until it is install on the correct position.
LEIL18WHL0754BB 1
5. Place the wiper motor assembly and the plate-mount-

ing rear wiper-motor in the correct position on the cab.
Connect the connector X-RWM (2) and the connector
X-RWM_G (3) to the harness of the wiper motor as-
sembly (1).
LEIL18WHL0755AB 2
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6. Tighten the six bolts with the relevant washers (1) to

install the plate-mounting rear wiper-motor (2) to the
machine.
LEIL18WHL0742AB 3
7. Install the hardware (2) on the knurling (1)of the rear

wiper motor assembly.
LEIL18WHL0753AB 4
8. Tighten the nut (1) and related washer (2) to install

the wiper arm assembly on the plate-mounting rear
wiper-motor. Torque to 14.0 N·m (10.3 lb ft) - 18.0 N·m
(13.3 lb ft).
LEIL18WHL0752AB 5
9. Install the cap.
LEIL18WHL0751AA 6
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10. Tighten the four screws (1) to install the upper rear
grab handle assembly (2).
LEIL18WHL0750AB 7
11. Attach the water hose (1) of the windshield fluid.

Pull until it is install on the correct position on the plate-
mounting rear wiper-motor (2).
LEIL18WHL0743AB 8
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Index

Windshield wiper motor - Install wiper front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Windshield wiper motor - Install wiper rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Windshield wiper motor - Remove wiper front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Windshield wiper motor - Remove wiper rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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FAULT CODES - DTC

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Contents
FAULT CODES - DTC
DIAGNOSTIC
91.19 - Engine Source Address Cyclic Timeout [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

96-00 - Fuel Level Sensor Over Resistance [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
96-01 - Fuel Level Sensor Under Resistance [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
110-00 - Engine coolant temperature is very high [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
110-16 - Engine coolant temperature is high [GHMI - Faults list]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
158-03 - Short to Power at Key Switch Crank [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
177-00 - Transmission oil temperature is very high [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
177-16 - Transmission oil temperature is high [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3997-03 - Electrical Accessory Power Relay - Short Circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3997-05 - Electrical Accessory Power Relay - Open Circuit [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3997-06 - Electrical Accessory Power Relay - Short Circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . 28
5000-12 - Logical error at gear range signal [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5010-12 - Logical error at direction select signal [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5110-03 - Short circuit to battery voltage or open circuit at transmission sump temperature sensor input
[TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5110-04 - Short circuit to ground at transmission sump temperature sensor input [TCU] . . . . . . . . . . . . . 37
5120-03 - Short circuit to battery voltage or open circuit at retarder / torque converter temperature sensor
input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5120-04 - Short circuit to ground at retarder / torque converter temperature sensor input [TCU] . . . . . . 41
5140-03 - Short circuit to battery voltage or open circuit at engine speed input [TCU] . . . . . . . . . . . . . . . 43
5140-04 - Short circuit to ground at engine speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5140-12 - Logical error at engine speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5150-03 - Short circuit to battery voltage or open circuit at turbine speed input [TCU] . . . . . . . . . . . . . . . 49
5150-04 - Short circuit to ground at turbine speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5150-12 - Logical error at turbine speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5160-03 - Short circuit to battery voltage or open circuit at internal speed input [TCU] . . . . . . . . . . . . . . . 55
5160-04 - Short circuit to ground at internal speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5160-12 - Logical error at internal speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5170-03 - Short circuit to battery voltage or open circuit at output speed input [TCU] . . . . . . . . . . . . . . . . 61
5170-04 - Short circuit to ground at output speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5170-12 - Logical error at output speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5180-02 - Output speed zero doesn't fit to other speed signals [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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5211-09 - Speedlimit_Prop1 Can message timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5212-09 - Speedlimit_Prop2 Can message timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
521-03 - Inch Pedal Position Sensor over voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
521-04 - Inch Pedal Position Sensor under voltage [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
619-03 - Short to Power at Park Brake High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
619-04 - Short to Ground at Park Brake High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
619-05 - Open Circuit at Park Brake High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
624-03 - Short to Power at Warning LED High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
624-04 - Short to Ground at Warning LED High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
624-05 - Open Circuit at Warning LED High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
746-03 - Short to Power at Differential Lock Valve [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
746-04 - Short to Ground at Differential Lock Valve [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
746-05 - Open Circuit at Differential Lock Valve [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1049-01 - Front Brake Accumulator Low Pressure [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1049-03 - Short to Power at Front Brake Accumulator Pressure Sensor [UCM]. . . . . . . . . . . . . . . . . . . . . 96
1049-04 - Short to Ground at Front Brake Accumulator Pressure Sensor [UCM]. . . . . . . . . . . . . . . . . . . . 97
1052-01 - Rear Brake Accumulator Low Pressure [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1052-03 - Short to Power at Rear Brake Accumulator Pressure Sensor [UCM] . . . . . . . . . . . . . . . . . . . . 101
1052-04 - Short to Ground at Rear Brake Accumulator Pressure Sensor [UCM] . . . . . . . . . . . . . . . . . . . 103
1565-02 - Armrest Signals not plausible [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2580 - Low Brake Pressure [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2661-14 - Roller X Hall cell plausibility error [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2662-03 - Hall cell X1/X2 voltage abnormally high [Keypad and Joystick]. . . . . . . . . . . . . . . . . . . . . . . . . 113
2662-04 - Hall cell X1/X2 voltage abnormally low [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . 114
2662-13 - Roller X out of neutral at power-up [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2662-14 - Roller X Hall cell plausibility error [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2663-03 - Hall cell Y1/Y2 voltage abnormally high [Keypad and Joystick]. . . . . . . . . . . . . . . . . . . . . . . . . 119
2663-04 - Hall cell Y1/Y2 voltage abnormally low [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . 120
2663-13 - Roller Y out of neutral at power-up [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2663-14 - Roller Y Hall cell plausibility error [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2664-03 - Hall cell Z1/Z2 voltage abnormally high [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . 123
2664-04 - Hall cell Z1/Z2 voltage abnormally low [Keypad and Joystick]. . . . . . . . . . . . . . . . . . . . . . . . . . 126
2664-13 - Roller Z out of neutral at power-up [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2664-14 - Roller Z Hall cell plausibility error [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3509-02 - 5V internal fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3651-02 - Primary FNR Fault [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5123-19 - Display Source Address Cyclic Timeout [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5220-09 - Brakes timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5230-09 - Zftc1 Timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5260-09 - Dct1 Timeout = Vehicle_1 Timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5270-09 - Jss Timeout =Vehicle_2 Timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5271-09 - DISPID1 CAN message timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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5280-09 - Engine Conf timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5290-09 - EEC1 Timeout [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5300-09 - EEC3 Timeout [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5310-09 - Engine speed limit function during gearshifts does not work properly [TCU]. . . . . . . . . . . . . . 151
5370-02 - Shift lever signal defective [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5390-02 - Aeb request signal defective [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5420-02 - Starting gear signal defective [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5430-02 - Enginge torque signal defective [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5431-09 - Engine speed limit function does not work properly during stall or output speed limit function
[TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5440-02 - Reference engine torque signal defective [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5450-02 - Actual engine torque signal defective [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5460-02 - Nom friction torque signal defective [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5470-02 - EEC2 Timeout [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5480-03 - Short circuit to battery voltage at clutch K1 [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5480-04 - Short circuit to ground at clutch K1 [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5480-05 - Open circuit at clutch K1 [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5520-03 - Short circuit to battery voltage at clutch Kv [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
5520-04 - Short circuit to ground at clutch Kv [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5520-05 - Open circuit at clutch Kv [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
5530-03 - Short circuit to battery voltage at clutch Kr [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
5530-04 - Short circuit to ground at clutch Kr [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5530-05 - Open circuit at clutch Kr [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5536-00 - Hydraulic oil temperature is very high [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
5536-16 - Hydraulic oil temperature is high [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5540-03 - Short circuit to battery voltage at converter clutch (regulator valve) [TCU] . . . . . . . . . . . . . . . 195
5540-04 - Short circuit to ground at converter clutch (regulator valve) [TCU] . . . . . . . . . . . . . . . . . . . . . . 197
5540-05 - Open circuit at converter clutch (regulator valve) [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5560-03 - Short circuit to battery voltage at relay reverse warning alarm [TCU]. . . . . . . . . . . . . . . . . . . . 201
5560-05 - Open circuit at relay reverse warning alarm [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5657-02 - Incorrect Anti-tamper checksum sent by Engine Controller [UCM] . . . . . . . . . . . . . . . . . . . . . . 205
5657-09 - Anti-tamper checksum not sent by Engine Controller [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5660-02 - Slippage at clutch K1 [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5680-02 - Slippage at clutch Kv [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
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5685-02 - Slippage at clutch Kr [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5700-00 - Overtemp Sump [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5710-00 - Overtemp Retarder [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
5720-00 - Overspeed Engine [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
5730-00 - Differential pressure oil filter [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
5740-02 - Slippage at converter lockup clutch [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
5745-15 - Overspeed output [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
5755-15 - Transmission input torque overload [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
5760-00 - Overtemp converter output [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5810-03 - Short circuit to battery voltage at power supply for sensors [TCU] . . . . . . . . . . . . . . . . . . . . . . 231
5810-04 - Short circuit to ground at power supply for sensors [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
5820-03 - High voltage at battery [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5820-04 - Low voltage at battery [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
5830-02 - Error at valve power supply VPS1 [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
5840-02 - Error valve power supply VPS2 [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
5860-03 - Short circuit to battery voltage at display output [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
5860-04 - Short circuit to ground at display output [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
5880-02 - Illegal ID request via Can [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
5890-02 - General EEPROM fault [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
5900-13 - Configuration lost [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
5910-13 - Application error [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
5930-07 - Clutch failure [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
5930-13 - Clutch adjustment data lost or inchpedal calibration data lost [TCU] . . . . . . . . . . . . . . . . . . . . 246
5940-11 - Substitute clutch control [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
65562-03 - Terminal 50 - Always On [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
65564-03 - Water detected in Fuel [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
65574-03 - Engine Controller battery voltage too High [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
65574-04 - Engine Controller battery voltage too Low [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
65576-03 - Engine Controller High side supply #2 to Grid heater - Short to battery [ECU]. . . . . . . . . . . 255
65579-02 - Engine Controller Grid Heater relay circuit driver - No Load [ECU] . . . . . . . . . . . . . . . . . . . . 256
65579-03 - Engine Controller Grid Heater relay circuit driver - Short circuit to Battery [ECU] . . . . . . . . 258
65579-04 - Engine Controller Grid Heater relay circuit driver - Short circuit to Ground [ECU] . . . . . . . . 260
65585-03 - Engine Coolant Temperature Sensor - Signal Above Range Max [UCM] . . . . . . . . . . . . . . . 262
65585-04 - Engine Coolant Temperature Sensor - Signal Below Range Min [UCM] . . . . . . . . . . . . . . . . 264
65585-12 - Engine Coolant Temperature Sensor - Signal Not Plausible [UCM] . . . . . . . . . . . . . . . . . . . . 266
65596-03 - Ambient Air Temperature Sensor failure - Signal too high [UCM] . . . . . . . . . . . . . . . . . . . . . . 268
65596-04 - Ambient Air Temperature Sensor failure - Signal too low [UCM] . . . . . . . . . . . . . . . . . . . . . . . 270
65646-03 - Minimum Number of Injections Not Reached – Stop Engine [ECU] . . . . . . . . . . . . . . . . . . . . 272
65660-02 - Injection Processor (CY33X) Error – Injections Limited By Software [ECU] . . . . . . . . . . . . . 273
65660-03 - Injection Processor (CY33X) Error – Internal Reset / Clock Loss / Voltage Too Low [ECU] 274
65660-04 - Injection Processor (CY33X) Error – Unlocked / Initialization Failure [ECU] . . . . . . . . . . . . . 276
65660-12 - Injection Processor (CY33X) Error – SPI Communication Failure [ECU]. . . . . . . . . . . . . . . . 277
48083742_EN 31/07/2018
55.9 [55.DTC] / 5
65683-03 - Turbine speed - Signal too high [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
65683-04 - Turbine speed - Signal too low [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
65694-04 - Torque Reduction due to Smoke Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
65717-02 - Timeout of CAN Message VCM2EDC [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
65734-03 - Timeout of CAN message TSC1-PE Torque (When Active) [ECU] . . . . . . . . . . . . . . . . . . . . . 286
65736-03 - Timeout of CAN message TSC1-VE Speed (When Active) [ECU] . . . . . . . . . . . . . . . . . . . . . 289
65745-03 - ECM Internal SPI Communication Error – CJ940 [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
65747-12 - ECM (Locked) Recovery Occurred [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
65748-12 - ECM Processor – Watchdog Not Plausible [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
65749-02 - Shutoff Paths During Initialization – Supply Voltage Too High [ECU] . . . . . . . . . . . . . . . . . . . 295
65749-04 - Shutoff Paths During Initialization - Watchdog [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
65749-12 - Shutoff Paths During Initialization – Supply Voltage Too Low [ECU] . . . . . . . . . . . . . . . . . . . 297
65750-12 - TPU Monitoring – Time Deviation between TPU and System Not Plausible [ECU] . . . . . . . 298
65752-12 - Controller Watchdog – SPI Communication Failure [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
65753-02 - ADC Monitoring – Test Impulse Error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
65753-03 - ADC Monitoring – Reference Voltage Too High [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
65753-04 - ADC Monitoring – Reference Voltage Too Low [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
65753-12 - ADC Monitoring – Queue Error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
65763-03 - Overrun Monitoring – Injection Time Too Long [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
65764-03 - Redundant Engine Speed in Overrun Monitoring – Speed Signal Not Plausible [ECU] . . . 305
65765-03 - Engine regulated 12 Volt sensor supply - Voltage High [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . 306
65765-04 - Engine regulated 12 Volt sensor supply - Voltage Low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . 308
65766-03 - Sensor Supply Voltage 1 - High [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
65766-04 - Sensor Supply Voltage 1 - Low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
65769-03 - ECM Internal Supply Voltage Too High – CJ940 Above Limit [ECU] . . . . . . . . . . . . . . . . . . . 322
65770-04 - ECM Internal Supply Voltage Too Low – CJ940 Below Limit [ECU] . . . . . . . . . . . . . . . . . . . . 324
131112-04 - Engine Controller High side supply #2 to Grid heater - Short to ground . . . . . . . . . . . . . . . 326
131122-12 - Coolant Temperature Test Failure [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
131151-03 - Emergency start time expired and shutdown initiated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
131196-02 - Injection Processor Error – Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
131196-03 - Injection Processor Error – Internal Reset / Clock Loss / Voltage Too Low [ECU] . . . . . . . 332
131196-04 - Injection Processor Error – Unlocked / Initialization Failure [ECU] . . . . . . . . . . . . . . . . . . . . 334
131196-12 - Injection Processor Error – SPI Communication Failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . 335
131246-03 - Humidity Sensor possibly saturated with water droplets – Signal Ratio above Limit . . . . 336
131246-04 - Humidity Sensor possibly saturated with water droplets – Signal Ratio below Limit . . . . 337
131252-02 - Timeout of CAN Message BC2EDC2 [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
131270-02 - Timeout of CAN message TSC1-PE Torque (When Inactive) . . . . . . . . . . . . . . . . . . . . . . . . 341
131272-03 - Timeout of CAN Message TSC1-VR (When Active) [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . 344
48083742_EN 31/07/2018
55.9 [55.DTC] / 6
131283-12 - ECM Recovery which is suppressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
196685-04 - Speed limitation activates torque limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
196766-04 - Torque limitation due to turbo charger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
196804-02 - CAN message not received from XXXX1 (TSC1-AE passive) [ECU]. . . . . . . . . . . . . . . . . . 350
196808-02 - Timeout of CAN message TSC1-VE Speed (When Inactive) . . . . . . . . . . . . . . . . . . . . . . . . 353
196819-12 - ECU Recovery (Visible) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
262302-04 - Torque Limitation due to Engine Protection (Against Excessive Torque, Engine Overspeed
and Overheat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
262344-02 - Timeout of CAN Message TSC1-VR (When Inactive) [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . 358
393292-04 - Overheat protection activates torque limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
393374-04 - Torque Limitation due to Fuel Quantity Limitation because of Injection System Errors . . 362
517755-09 - EJM Message Timeout (AUX FNR, AUX I, AUX II) [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . 363
517755-19 - BJM Message Timeout (Boom, Bucket, Kick down) [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . 365
518032-03 - Aux FNR Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
518036-03 - Beacon Light Switch Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
518047-03 - Declutch Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
518052-03 - Differential Lock Up Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
518056-03 - Fan Mode Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
518058-03 - Float Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
518063-03 - Implement Coupler Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
518066-03 - Implement Enable Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
518069-02 - Joystick Steering Activation Button Signals not plausible [UCM] . . . . . . . . . . . . . . . . . . . . . 376
518070-03 - Key_2 Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
518074-03 - Key_18 Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
518078-03 - Key_20 Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
518083-03 - Park Brake Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
518089-03 - Short to Power at Ride Control Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . 383
518089-04 - Short to Ground at Ride Control Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . 385
518089-05 - Open Circuit at Ride Control Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . 387
518093-03 - Return ToTravel Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
518101-03 - Torque Converter Lock Up Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . 390
518103-03 - Transmission Auto Mode Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . 391
518106-03 - WorkLight 1 Key Fault [Keypad and Joystick]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
518108-03 - WorkLight 2 Key Fault [Keypad and Joystick]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
518110-02 - Boom Angle Sensor signals not plausible [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
518110-03 - Boom Angle Sensor Channel 1 Over Voltage [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
518110-04 - Boom Angle Sensor Channel 1 Under Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
518111-02 - Bucket Angle Sensor signals not plausible [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
518111-03 - Bucket Angle Sensor Channel 1 Over Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
518111-04 - Bucket Angle Sensor Channel 1 Under Voltage [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
518112-01 - Radiator Coolant Temperature Sensor under resistance Short to Ground [UCM] . . . . . . . 411
518112.00 - Radiator Coolant Temperature Sensor over resistance Open Circuit/Short to Power [UCM]413
518113-02 - Low Brake Pressure [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
48083742_EN 31/07/2018
55.9 [55.DTC] / 7
518113-03 - Short to Power at Brake Supply Line Pressure Sensor [UCM] . . . . . . . . . . . . . . . . . . . . . . . 416
518113-04 - Short to Ground at Brake Supply Line Pressure Sensor [UCM] . . . . . . . . . . . . . . . . . . . . . . 417
518114-03 - Short to Power at Brake Line (declutch) Pressure Sensor [UCM] . . . . . . . . . . . . . . . . . . . . . 420
518114-04 - Short to Ground at Brake Line (declutch) Pressure Sensor [UCM] . . . . . . . . . . . . . . . . . . . . 421
518115-01 - Auxiliary Steering lack of pressure [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
518115-03 - Aux Steering Pressure Sensor Over Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
518115-04 - Aux Steering Pressure Sensor Over Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
518116-09 - Hydraulic Filter is Clogged [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
518119-03 - Short to Power at Implement Coupler High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . 431
518119-04 - Short to Ground at Implement Coupler High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . 433
518119-05 - Open Circuit at Implement Coupler High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . 435
518122-00 - Axle oil temperature is very high [GHMI - Faults list]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
518122-00 - Front Axle Oil Temp Sensor Over Resistance [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
518122-01 - Front Axle Oil Temp Sensor Under Resistance [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
518122-16 - Axle oil temperature high [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
518122-31 - Axle oil temperature sensor out of range [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . 445
518129-03 - Short to Power at Boom Raise Valve High Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . . . 446
518129-04 - Short to Ground at Boom Raise Valve High Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . . 448
518129-05 - Open Circuit at Boom Raise Valve High Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . 450
518130-03 - Short to Power at Boom Lower Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . 453
518130-04 - Short to Ground at Boom Lower Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . 455
518130-05 - Open Circuit at Boom Lower Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . 457
518131-03 - Short to Power/Open Circuit at Boom Valve Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . 460
518131-04 - Short to Ground at Boom Valve Low Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
518132-03 - Short to Power at Bucket Roll Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . 464
518132-04 - Short to Ground at Bucket Roll Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . 466
518132-05 - Open Circuit at Bucket Roll Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . 468
518133-03 - Short to Power at Bucket Dump Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . 471
518133-04 - Short to Ground at Bucket Dump Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . 473
518133-05 - Open Circuit at Bucket Dump Valve High Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . 475
518134-03 - Short to Power/Open Circuit at Bucket Valve Low Side Driver [UCM] . . . . . . . . . . . . . . . . . 478
518134-04 - Short to Ground at Bucket Valve Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
518135-03 - Boom Angle Sensor Channel 2 Over Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
518135-04 - Boom Angle Sensor Channel 2 Under Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
518136-03 - Bucket Angle Sensor Channel 2 Over Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
518136-04 - Bucket Angle Sensor Channel 2 Under Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
518137-03 - Short to Power at AUX 1 Left High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
518137-04 - Short to Ground at AUX 1 Left High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
518137-05 - Open Circuit at AUX 1 Left High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
518138-03 - Short to Power at AUX 1 Right High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
518138-04 - Short to Ground at AUX 1 Right High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
518138-05 - Open Circuit at AUX 1 Right High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
48083742_EN 31/07/2018
55.9 [55.DTC] / 8
518139-03 - Short to Power/Open Circuit at AUX 1 Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . 506
518139-04 - Short to Ground at AUX 1 Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
518140-03 - Short to Power at AUX 2 Left High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
518140-04 - Short to Ground at AUX 2 Left High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
518140-05 - Open Circuit at AUX 2 Left High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
518141-03 - Short to Power at AUX 2 Right High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
518141-04 - Short to Ground at AUX 2 Right High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
518141-05 - Open Circuit at AUX 2 Right High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
518142-03 - Short to Power/Open Circuit at AUX 2 Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . 524
518142-04 - Short to Ground at AUX 2 Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
518143-03 - Short to Power/Open Circuit at Implement Coupler Low Side Driver [UCM]. . . . . . . . . . . . 528
518143-04 - Short to Ground at Implement Coupler Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . 530
518144-03 - Short to Power at Aux Steering Enable High Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . 532
518144-04 - Short to Ground at Aux Steering Enable High Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . 534
518144-05 - Open Circuit at Aux Steering Enable High Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . . . 536
518145-03 - Short to Power/Open Circuit at Park Brake Low Side Driver [UCM]. . . . . . . . . . . . . . . . . . . 538
518145-04 - Short to Ground at Park Brake Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
518146-03 - Short to Power at FAN Control High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
518146-04 - Short to Ground at FAN Control High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
518146-05 - Open Circuit at FAN Control High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
518147-03 - Short to Power FAN Reverser Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
518147-04 - Short to Ground at FAN Reverser Low Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . 550
518150-03 - Electrical Crank Power Relay- Short Circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
518150-03 - Electrical Ignition Power Relay- Short Circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
518150-04 - Short to Ground at Crank Request High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . 556
518150-05 - Electrical Crank Power Relay- Open Circuit [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
518150-05 - Electrical Ignition Power Relay- Open Circuit [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
518150-06 - Electrical Crank Power Relay- Short Circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . 562
518150-06 - Electrical Ignition Power Relay- Short Circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . 564
518176-03 - Joystick Steering Signal 2 High voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
518176-04 - Joystick Steering Signal 2 Low voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
518176-09 - Joystick Steering Signals not plausible [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
518176-15 - Joystick Steering Signal 1 High voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
518176-17 - Joystick Steering Signal 1 Low voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
518177-03 - Short to Power at Pilot Enable Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . 576
518177-04 - Short to Ground at Pilot Enable Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . 578
518177-05 - Open Circuit at Pilot Enable Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . 580
518267-02 - WatchDog Reset [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
518280-31 - Error at 5VREF1 Output [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
518283-31 - Error at 24VF2 Supply Rail [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
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518287-31 - Error at 24VS1 Supply Rail [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598
518289-31 - Error at 24VA Supply Rail [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
518290-31 - Error at 24VB Supply Rail [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
518291-31 - Error at 24VLP Supply Rail [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
518292-31 - Error at 24VP Supply Rail [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
518293-31 - Error at 2.5V Ref1 Supply [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
518294-31 - Error at 2.5V Ref2 Supply [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
518296-31 - Error at 5VREFIN [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
518390-00 - Hydraulic Oil Temp Sensor Over Resistance [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
518390-01 - Hydraulic Oil Temp Sensor Under Resistance [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
518498-00 - Engine oil temperature is very high [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
518499-18 - Engine Oil pressure Low [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
518501-09 - Air Filter Clogged [GHMI - Faults list]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
520332-19 - TCU Source Address Cyclic Timeout [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
520333-19 - Keypad Source Address Cyclic Timeout [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
520334-19 - Smart Fuse Box Source Address Cyclic Timeout [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
520335-19 - Joystick Steering Controller Source Address Cyclic Timeout [UCM] . . . . . . . . . . . . . . . . . . 622
520444-02 - Memory Integrity RAM [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
520444-31 - Memory Integrity ROM [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
520519-19 - Bus Off [Keypad and Joystick]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
520572-03 - 24v to 12v Converter Enable - Short Circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
520572-05 - 24v to 12v Converter Enable - Open Circuit [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
520572-06 - 24v to 12v Converter Enable - Short Circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . 631
520578-03 - Battery Isolator SET - Short Circuit to B+ [SFB]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
520578-03 - Battery Isolator RESET - Short Circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
520578-06 - Battery Isolator SET - Short Circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
520578-06 - Battery Isolator RESET - Short Circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
520584-00 - Left Brake Indicator Light - Too many loads or faulty load [SFB]. . . . . . . . . . . . . . . . . . . . . . 645
520584-03 - Left Brake Indicator Light - Short circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
520584-05 - Left Brake Indicator Light - Open Circuit [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 649
520584-06 - Left Brake Indicator Light - Short circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
520585-00 - Right Brake Indicator Light - Too many loads or faulty load [SFB] . . . . . . . . . . . . . . . . . . . . 653
520585-03 - Right Brake Indicator Light - Short circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
520585-05 - Right Brake Indicator Light - Open Circuit [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657
520585-06 - Right Brake Indicator Light - Short circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659
520588-03 - Alternator Excitation Driver - Short Circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661
520588-06 - Alternator Excitation Driver - Short Circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
520591-00 - Backup Alarm - Too many loads or faulty load [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
520591-03 - Backup Alarm - Short circuit to B+ [SFB]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668
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520591-05 - Backup Alarm - Open Circuit [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 671
520591-06 - Backup Alarm - Short circuit to GND [SFB]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
520596-03 - VSUP A - Out of Range - High [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
520596-04 - VSUP A - Out of Range - Low [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
520597-03 - VSUP B - Out of Range - High [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
520597-04 - VSUP B - Out of Range - Low [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683
520598-03 - VSUP C - Out of Range - High [SFB]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685
520598-04 - VSUP C - Out of Range - Low [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 687
520599-03 - VSUP D - Out of Range - High [SFB]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
520599-04 - VSUP D - Out of Range - Low [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691
522809-02 - Memory Integrity EEPROM [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693
522810-09 - Joystick Steering Cut Off Valves not plausible [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694
523438-31 - Joystick loss of communication [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698
524262-13 - Primary EEPROM configuration CRC validation fault [Keypad and Joystick] . . . . . . . . . . . 701
524263-13 - Redundant EEPROM configuration CRC validation fault [Keypad and Joystick] . . . . . . . . 702
524264-13 - Configuration parameter read error [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . 703
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Electrical systems - FAULT CODES
91.19 - Engine Source Address Cyclic Timeout

Control Module: UCM
Context:
The A-UCM does not receive messages from the Engine Source Address within the maximum interval time;
as a consequence:
• Use last ECU CAN message received;
• Disable cranking;
• KOER logic;
• Set engine speed to Standard Idle when EEC1.EngSpd not available.
Cause:
Incoming cycle time message interval > 10 times of maximum defined cycle time.
Possible failure modes:
1. The fault is intermittent and not currently active.

2. The harness of busses CAN 1 or CAN 2 is damaged.
3. The connectors X-UCM1B or X-UCM2B are damaged.
4. The A-UCM is damaged.
Solution:
1. Verify that the fault is present and active.
Use the Electronic Service Tool (EST) to check the status of this fault.
A. If the fault is present and active, continue with Step 2.
B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active.
2. Visually check the integrity of the harness of busses CAN 1 ( X-UCM1B).
A. If the harness is damaged, replace the harness.
B. If the harness is not damaged, continue with Step 3.


4. Check the integrity of connector X-UCM1B.
Disconnect the connector X-UCM1B from the A-UCM and visually check the integrity of pins 25 and 34.
A. If one pin is damaged, replace the harness.
B. If pins are not damaged, continue with Step 5.

B. If pins are not damaged, replace the A-UCM.
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Wiring harnesses - Electrical schematic sheet 22 (55.100)

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96-00 - Fuel Level Sensor Over Resistance

Control Module: UCM
Context:
The A-UCM detects a value of resistance of the FUEL LEVEL SENSOR ( B-RFLG) higher than the upper limit; as a
consequence the fuel level is not available:
Cause:
The A-UCM detects on pin 11 of connector X-UCM4A a resistance value > 269 Ω (last index is 254 Ω ± 5.0 Ω).

2. The harness between A-UCM and the FUEL LEVEL SENSOR is damaged.
3. The connectors X-CAB_E or X-ENG or X-FL or X-UCM4A are damaged.
4. The harness between connectors X-FL and ground is damaged.
5. The harness between connectors X-ENG and the FUEL LEVEL SENSOR is damaged.
6. The harness between connectors X-UCM4A and X-CAB_E is damaged.
7. The FUEL LEVEL SENSOR is damaged.
Solution:
2. Visually check the integrity of the harness between the connector X-UCM4A and the connector X-FL for any dam-
age.

3. Check the integrity of connector X-FL.
Disconnect the connector X-FL from the FUEL LEVEL SENSOR and visually check the integrity of pins 1 and 2
of the connector.
A. If one pin is damaged, replace the harness relevant to the connector.
B. If all pins are not damaged, continue with Step 4.

4. Check the integrity of harness between the connector X-FL and ground.
Disconnect the connector X-FL from the FUEL LEVEL SENSOR. Use a multimeter to perform the following check:
From To Value
Connector X-FL pin 2 Ground Short circuit
A. If the measurement is not correct, replace the harness.
B. If the measurement is correct, continue with Step 5.

5. Check the integrity of connectors X-ENG and X-CAB_E.
Disconnect the connector X-ENG from the connector X-CAB_E and visually check the integrity of pins 8 and 9 of
both connectors.
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A. If one pin is damaged, replace the harness relevant to the damaged connector.

6. Check the integrity of connector X-UCM4A.
Disconnect the connector X-UCM4A from the A-UCM and visually check the integrity of pin 11.
A. If the pin is damaged, replace the harness.
B. If the pin is not damaged, continue with Step 7.

7. Check the integrity of harness between the connector X-ENG and the FUEL LEVEL SENSOR.
Disconnect the connector X-FL from the FUEL LEVEL SENSOR.
Use a multimeter to perform the following check:
From To Value
Connector X-ENG pin 8 Connector X-FL pin 2 Short circuit

8. Check the integrity of harness between the connectors X-UCM4A and X-CAB_E.
From To Value
Connector X-UCM4A pin 11 Connector X-CAB_E pin 18 Short circuit

9. Replace the FUEL LEVEL SENSOR.
A. If the functionality is restored, the procedure ends.
B. If the functionality is not restored, replace the A-UCM.
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96-01 - Fuel Level Sensor Under Resistance

Control Module: UCM
Context:
The A-UCM detects a value of resistance of the FUEL LEVEL SENSOR ( B-RFLG) lower than the low limit; as a
consequence the fuel level is not available.
Cause:
The A-UCM detects on pin 11 of connector X-UCM4A a resistance value < 20 Ω 20 Ω (last index is 27.5 Ω ± 2.5 Ω).

2. The harness between A-UCM and the FUEL LEVEL SENSOR is damaged.
4. The connectors X-CAB_E or X-ENG or X-FL or X-UCM4A are damaged.
5. The harness of FUEL LEVEL SENSOR is damaged.
6. The harness between connectors X-ENG and X-FL is damaged.
7. The harness between connectors X-CAB_E and X-UCM4A is damaged.
Solution:
2. Visually check the integrity of the harness between the connector X-UCM4A and the connector X-FL for any dam-
age.

3. Replace the FUEL LEVEL SENSOR.
B. If the functionality is not restored, continue with Step 4.

4. Check the integrity of connector X-FL.
Disconnect the connector X-FL from the FUEL LEVEL SENSOR and visually check the integrity of pins 1 and 2.
B. If the pins are not damaged, continue with Step 5.

5. Check the integrity of harness of the FUEL LEVEL SENSOR.
Disconnect the connector X-FL from the FUEL LEVEL SENSOR.
From To Value
Connector X-FL pin 2 Connector X-FL pin 1 Open circuit
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6. Check the integrity of connectors X-ENG and X-CABLE_E.
Disconnect the connector X-ENG from the connector X-CABLE_E and visually check the integrity of pins 8 and 9
of both connectors.

7. Check the integrity of harness between the connector X-ENG and the FUEL LEVEL SENSOR.
Connect the connector X-FL to the FUEL LEVEL SENSOR.
From To Value
Connector X-ENG pin 8 Connector X-ENG pin 9 > 20 Ω


9. Check the integrity of harness between the connectors X-UCM4A and X-CAB_E.
Use a multimeter to perform the following checks:
From To Value
Connector X-UCM4A pin 11 Connector X-CAB_E pin 8 Short circuit
Connector X-CAB_E pin 9 Connector X-CAB_E pin 8 Open circuit
B. If the measurement is correct, replace the A-UCM.
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110-00 - Engine coolant temperature is very high

Control Module: GHMI - Faults list
Context:
The Universal Control Module (UCM) receives the engine coolant temperature signal from the coolant temperature
sensor B-RECTD. This fault occurs if the engine coolant temperature is higher than 110 °C.
Cause:
The UCM detected that the engine coolant temperature is higher than 110 °C.
1. Engine overheating.
2. The radiator doesn’t work properly.
3. Insufficient level of the coolant.
4. Defective engine coolant temperature sensor B-RECTD, internal failure.
5. Defective engine coolant temperature sensor B-RECTD circuit wiring, open circuit.
6. Defective UCM, software or internal failure.
Solution:
A. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active.
B. If the fault is present and active, continue with Step 2.

2. Check the presence of the following related faults:
Electronic module - Malfunction (55.640)
A. If one or more of the listed faults is detected, resolve the fault. Then, repeat the Step 1.
B. If no other fault is detected, continue with Step 3.

3. Check the engine coolant for over-temperature (the temperature should be lower than 110 °C).
A. If the engine coolant temperature is too high, stop the engine and wait until the temperature falls within the
operative range. Then continue with Step 4.
B. If the engine coolant temperature is normal, continue with Step 6.

4. Clean the radiator or operate the fan reverser. Start the engine and wait until the coolant reaches the proper
temperature. Verify that the radiator works properly.
A. If the coolant temperature remains under 105 °C, clear the error and return to the machine to service.
B. If the coolant temperature rises over 110 °C, continue with Step 5.
5. Check the coolant level and add coolant if necessary. Start the engine and wait until the coolant reaches the
proper temperature.
A. If the coolant temperature remains under 105 °C, clear the error and return to the machine to service.
B. If the coolant temperature rises over 110 °C, continue with Step 6.
6. Check the integrity of the harness and the connectors.
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Visually inspect the relevant harness and connector for damage, bent or dislocated pins, corroded terminals or
broken wires. Verify that the connectors are fully installed. Flex the harness involved to reveal intermittent breaks
or shorts in the wiring concerned. Operate the machine while you monitor the display.
A. If you find damage or the display indicates other than normal display readings, then repair the damage discov-
ered during the inspection or locate and repair the other than normal display condition and verify that the error
has been resolved.
B. If you do not find damage and the display indicates only normal readings, then continue with Step 7.
7. Check the UCM for the appropriate software and re-flesh, if necessary.
A. If the fault has been resolved, return to the machine to service.
B. If the fault has not been resolved, continue with step 8.

8. Check the integrity of the coolant temperature sensor B-RECTD.
The key must be in the OFF position.
Disconnect the connector X-RECT and remove the sensor.
Use a multimeter to perform the resistance measurement of the sensor.
A. If Resistance > 2000 Ω, replace the B-RECTD COOLANT TEMP sensor.
B. If the resistance value is correct, leave the connector X-RECT disconnected and continue with Step 9.
9. Check the integrity of the harness.
Disconnect the connector X-UCM4A.
Use a multimeter to perform the following continuity checks:
From To Value
Connector X-RECT pin 1 Connector X-ENG pin 5 There should be continuity
Connector X-CAB_E pin 5 Connector X-UCM4A pin 12 There should be continuity
Connector X-RECT pin 2 Connector X-ENG pin 9 There should be continuity
Connector X-CAB_E pin 9 Chassis ground There should be continuity
A. If there is no continuity, there is an open circuit condition. Locate the fault and repair the conductor.
B. If there is continuity, replace the UCM.
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110-16 - Engine coolant temperature is high

Context:
Engine coolant temperature is high.
Cause:

2. The engine coolant temperature is between 105 – 110 °C.
Solution:
2. Idle the machine and monitor the temperature. Wait until the coolant temperature reach the proper temperature
and restart the machine.
A. If the coolant temperature rises again, idle the machine and continue with Step 3.
B. If the coolant temperature within proper range continue to work monitoring the temperature.
3. Clean the radiator or operate the fan reverser. Wait until the coolant temperature reach the proper temperature
A. If the coolant temperature rises again, idle the machine and continue with Step 4.
4. Check the coolant level and add coolant if necessary. Wait until the coolant temperature reach the proper temper-
ature and restart the machine.
A. If the coolant temperature rises again, idle the machine and replace the coolant temperature sensor.
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158-03 - Short to Power at Key Switch Crank

Control Module: UCM
Context:
The A-UCM detects a voltage on the Key Switch Crank greater than the expected one; as a consequence is disabled
the cracking request.
Cause:
The system detects, on 14 of connector X-UCM2B, a > 15 V.

2. The connector X-UCM2B is damaged.
3. The A-UCM component is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM2B and X-X3 for any damage.

Disconnect the connector X-UCM2B from the A-UCM and visually check the integrity of pin 14.
A. If the pin is damaged, replace the relevant harness.

4. Check the integrity of harness between the A-UCM and the connector X-X3.
From To Value
Connector X-UCM2B pin 14 Ground ≤ 15 V
A. If the measurement is correct, replace the A-UCM.
B. If the measurement is not correct, check the correct functioning of the circuit relevant to the SMART FUSE
BOX (see procedure 518150-03 – Electrical Crank Power Relay- Short Circuit to B+).

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177-00 - Transmission oil temperature is very high

Context:
Transmission oil temperature is very high.
Cause:

2. The transmission oil temperature is over 125 °C.
Solution:
2. Bring the machine to a safe stop, and turn the engine OFF immediately. Replace the transmission oil temperature
sensor.
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177-16 - Transmission oil temperature is high

Context:
Transmission oil temperature is high.
Cause:

2. The engine coolant temperature is between 120 – 125 °C.
Solution:
2. Idle the machine and monitor the temperature. Wait until the oil temperature goes below 90 °C and restart the
machine.
A. If the oil temperature rises again, idle the machine and 3.
B. If the oil temperature within range of 75 – 90 °C continue to work monitoring the temperature.
3. Clean the cooler or operate the fan reverser. Wait until the oil temperature goes below 90 °C and restart the
machine.
A. If the oil temperature rises again, idle the machine and continue with Step 4.
4. Wait until the oil temperature goes below 90 °C, restart the machine and use a lower gear.
A. If the oil temperature rises again, idle the machine and replace the transmission oil temperature sensor.
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3997-03 - Electrical Accessory Power Relay - Short Circuit to B+

Control Module: SFB
Context:
Electrical Accessory Power Relay - Short Circuit to B+.
Cause:
The Smart Fuse box detects a Short Circuit to B+ from the Electrical Accessory Power Relay ( X-X3 pin 11) when the
key is OFF.

2. The harness between Smart Fuse Box and Electrical Accessory Power Relay is damaged.
3. The X-LC4 connector (pin 86) is damaged.
4. The Smart Fuse Box connector ( X-X3 pin 11) is damaged.
5. The harness between Electrical Accessory Power Relay and Smart Fuse Box is defective.
6. The Electrical Accessory Power Relay is defective.
7. The Smart Fuse Box is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and Electrical Accessory Power Relay.
Visually check the integrity of the harness and check for any damage.

3. Check the integrity of the Electrical Accessory Power Relay connector.
Disconnect Electrical Accessory Power Relay ( X-LC4 pin 86) and visually check the integrity of the pin.
A. If the pin is damaged, replace the X-LC4 connector.

4. Check the integrity of the Smart Fuse Box connector.
Disconnect X-X3 connector and visually check the integrity of the pin 11.
A. If the pin is damaged, replace the X-X3 connector.

5. Check the Electrical Accessory Power Relay signal circuit.
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Use a multimeter to perform the following voltage check:
From To Value
Connector X-LC4 pin 86 Chassis ground There should not be voltage
A. If there is a battery voltage value, replace the Electrical Accessory Power Relay.
B. If there is not a voltage value, continue to Step 6.

6. Check the Smart Fuse Box signal circuit.
From To Value
Connector A-SFB pin OUT_01_H Chassis ground There should not be voltage
A. If there is a battery voltage value, replace the Smart Fuse Box.

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3997-05 - Electrical Accessory Power Relay - Open Circuit

Control Module: SFB
Context:
Electrical Accessory Power Relay - Open Circuit.
Cause:
The Smart Fuse box detects an Open Circuit from the Electrical Accessory Power Relay ( X-X3 pin 11) when the key
is OFF.

Solution:



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From To Value
Connector X-LC4 pin 86 Chassis ground There should be a resistance
A. If there is a battery voltage value, replace the Electrical Accessory Power Relay.
B. If there is not a voltage value, continue to Step 6.

From To Value
Connector A-SFB pin OUT_01_H Chassis ground There should be a resistance

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3997-06 - Electrical Accessory Power Relay - Short Circuit to GND

Control Module: SFB
Context:
Electrical Accessory Power Relay - Short Circuit to GND.
Cause:
The Smart Fuse box detects a Short Circuit to GND from the Electrical Accessory Power Relay ( X-X3 pin 11) when
the key is OFF.

Solution:



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From To Value
Connector X-LC4 pin 86 Chassis ground There should be an open circuit
A. If there is a short circuit to GND, replace the Electrical Accessory Power Relay.
B. If there is an open circuit, continue to Step 6.

From To Value
Connector A-SFB pin OUT_01_H Chassis ground There should be an open circuit

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5000-12 - Logical error at gear range signal

Control Module: TCU
Context:
The Transmission Control Unit A-TRANS detects a severe failure that disables control of the transmission.
The Transmission Control Unit A-TRANS shuts off the solenoid valves for the clutches and also the common power
supply (VPS1). Transmission shifts to neutral position. The park brake will operate normally, also the other functions
which use ADM 1 to ADM 8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
Cause:
The Unit Control Module A-UCM detects a wrong signal combination for the gear range.

2. The harnesses or the connectors are damaged or the connectors are not installed.
3. The harness between the shift lever A-PFNR and the Unit Control Module A-UCM is defective.
4. The shift lever A-PFNR is defective.
5. The Unit Control Module A-UCM is defective.
Solution:
1. Verify that fault is present and active.
2. Check if the connector X-TS2 is connected to the shift lever A-PFNR.
Check if the connector X-PED_2 is connected to the connector X-CAB_P2.
Check if the connector X-UCM2B is connected to the Unit Control Module A-UCM.
A. If a problem is found, restore the connection.
B. If there are no problems,continue with Step 3.

3. Disconnect the connector X-TS2 from the shift lever A-PFNR.
Check the integrity of the connector X-TS2 and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-TS2.
B. If there are no problems, connect the connector X-TS2 to the shift lever A-PFNR and continue with Step 4.
4. Disconnect the connector X-PED_2 from the connector X-CAB_P2.
Check the integrity of the connectors X-PED_2 and X-CAB_P2, visually check for any damage to the connectors
and to the pins 4 and 5.
A. If a problem is found, replace the damaged connector.
B. If there are no problems, connect the connector X-PED_2 to the connector X-CAB_P2 and continue with Step
5.
5. Disconnect the connector X-UCM2B from the Unit Control Module A-UCM.
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Check the integrity of the connector X-UCM2B and visually check for any damage to the connector and to the pins
21 and 22.
A. If a problem is found, replace the connector X-UCM2B.
B. If there are no problems, connect the connector X-UCM2B to the Unit Control Module A-UCM and continue
with Step 6.
6. Check to see if the harness between the shift lever A-PFNR and the Unit Control Module A-UCM is defective.
A. If a problem is found, replace defective harness.
B. If there are no problems, continue with Step 7.

7. Check if the shift lever A-PFNR is defective.
Check the signal combinations of the shift lever A-PFNR positions for gear range.
Disconnect the connector X-UCM2B from the Unit Control Module A-UCM.
Use a multimeter to check the signal combination.
The key must be in the ON position.
Put the shift lever A-PFNR in 1ST and 4TH position.
Perform the following check:
From To Value
Connector X-UCM2B pin 22 Chassis ground There should be more then 0 V
Connector X-UCM2B pin 21 Chassis ground There should be 0 V
A. If are detected both the signals, replace the shift lever A-PFNR.
B. If is detected only the signal on the connector X-UCM2B pin 22, continue with Step 8.
8. Use a multimeter to check the signal combination.
Put the shift lever A-PFNR in 3RD and 4TH position.
From To Value
Connector X-UCM2B pin 22 Chassis ground There should be 0 V
Connector X-UCM2B pin 21 Chassis ground There should be more then 0 V
A. If are detected both the signals, replace the shift lever A-PFNR.
B. If is detected only the signal on the connector X-UCM2B pin 21, replace the Unit Control Module A-UCM.
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5010-12 - Logical error at direction select signal

Control Module: TCU
Context:
The Transmission Control Unit A-TRANS detects a severe failure that disables control of the transmission.
The Transmission Control Unit A-TRANS shuts off the solenoid valves for the clutches and also the common power
supply (VPS1). Transmission shifts to neutral position. The park brake will operate normally, also the other functions
which use ADM 1 to ADM 8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
Cause:
The Unit Control Module A-UCM detects a wrong signal combination for the direction.

3. The harness between the shift lever A-PFNR and the Unit Control Module A-UCM is defective.
4. The shift lever A-PFNR is defective.
Solution:
2. Check if the connector X-TS1 is connected to the shift lever A-PFNR.
Check if the connector X-PED_2 is connected to the connector X-CAB_P2.
Check if the connector X-UCM2A is connected to the Unit Control Module A-UCM.

3. Disconnect the connector X-TS1 from the shift lever A-PFNR.
Check the integrity of the connector X-TS1 and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-TS1.
B. If there are no problems, connect the connector X-TS1 to the shift lever A-PFNR and continue with Step 4.
4. Disconnect the connector X-PED_2 from the connector X-CAB_P2.
Check the integrity of the connectors X-PED_2 and X-CAB_P2, visually check for any damage to the connectors
and to the pins 1, 2 and 3.
B. If there are no problems, connect the connector X-PED_2 to the connector X-CAB_P2 and continue with Step
5.
5. Disconnect the connector X-UCM2A from the Unit Control Module A-UCM.
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Check the integrity of the connector X-UCM2A and visually check for any damage to the connector and to the pins
11, 16 and 10.
A. If a problem is found, replace the connector X-UCM2A.
B. If there are no problems, connect the connector X-UCM2A to the Unit Control Module A-UCM and continue
with Step 6.
6. Check to see if the harness between the shift lever A-PFNR and the Unit Control Module A-UCM is defective.

7. Check if the shift lever A-PFNR is defective.
Check the signal combinations of the shift lever A-PFNR positions F-N-R.
Disconnect the connector X-UCM2A from the Unit Control Module A-UCM.
Use a multimeter to check the signal combination.
Put the shift lever A-PFNR in FORWARD position.
From To Value
Connector X-UCM2A pin 10 Chassis ground There should be more then 0 V
Connector X-UCM2A pin 11 Chassis ground There should be 0 V
A. If are detected other signals then the one on the connector X-UCM2A pin 10, replace the shift lever A-PFNR.
B. If is detected only the signal on the connector X-UCM2A pin 10, continue with Step 8.
Put the shift lever A-PFNR in NORMAL position.
From To Value
B. If is detected only the signal on the connector X-UCM2A pin 16, continue with Step 9.
Put the shift lever A-PFNR in REVERSE position.
From To Value
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B. If is detected only the signal on the connector X-UCM2A pin 11, replace the Unit Control Module A-UCM.
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5110-03 - Short circuit to battery voltage or open circuit at

transmission sump temperature sensor input
Control Module: TCU
Context:
The Transmission Control Unit A-TRANS uses the default temperature.
There is no failure detected in the transmission system or the failure has no or slight effects on the transmission
control.
The Transmission Control Unit A-TRANS works without or, in special cases, with little limitations.
Cause:
There is a short circuit to battery voltage or an open circuit at the supply circuit of the hydraulic oil temperature sensor
B-HOT. The measured voltage is too high.

3. The harness between hydraulic oil temperature sensor B-HOT and Unit Control Module A-UCM is defective.
4. The hydraulic oil temperature sensor B-HOT is defective.
Solution:
2. Check if the connector X-HOT is connected to the hydraulic oil temperature sensor B-HOT.
Check if the connector X-TRANS is connected to the connector X-CAB_TR.

3. Disconnect the connector X-HOT from the hydraulic oil temperature sensor B-HOT.
Check the integrity of the connector X-HOT and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-HOT.
B. If there are no problems, connect the connector X-HOT to the hydraulic oil temperature sensor B-HOT and
continue with Step 4.
4. Disconnect the connector X-TRANS from the connector X-CAB_TR.
Check the integrity of the connectors X-TRANS and X-CAB_TR, visually check for any damage to the connectors
and to the pin 30 and 3.
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B. If there are no problems, connect the connector X-CAB_TR to the connector X-TRANS and continue with Step
5.
Check the integrity of the connector X-UCM4A and visually check for any damage to the connector and to the pin
18.
with Step 6.
1.
with Step 7.
7. Check the harness between the hydraulic oil temperature sensor B-HOT and the Unit Control Module A-UCM for
a short circuit to battery voltage condition.
From To Value
Connector X-UCM4A pin 18 Chassis ground There should be no voltage
A. If there is a voltage, find and replace the wire 634 and/or 634A.
B. If there is no voltage, continue with Step 8.

an open circuit condition.
Disconnect the connector X-HOT from the hydraulic oil temperature sensor B-HOT.
From To Value
Connector X-UCM4A pin 18 Connector X-HOT pin 1 There should be continuity
A. If there is no continuity, find and repair or replace the wire 634 and/or 634A.
B. If there is continuity, continue with Step 9.

9. Check if the hydraulic oil temperature sensor B-HOT is defective.
A. If a problem is found, replace the hydraulic oil temperature sensor B-HOT.
B. If there are no problems, replace the Unit Control Module A-UCM.
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5110-04 - Short circuit to ground at transmission sump temperature

sensor input
Control Module: TCU
Context:
control.
Cause:
There is a short circuit to ground at the hydraulic oil temperature sensor B-HOT. The measured voltage is too low.

3. The harness between hydraulic oil temperature sensor B-HOT and the ground is defective.
Solution:
2. Check if the connector X-HOT is connected to the hydraulic oil temperature sensor B-HOT.

3. Disconnect the connector X-HOT from the hydraulic oil temperature sensor B-HOT.
Check the integrity of the connector X-HOT and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-HOT.
B. If there are no problems, connect the connector X-HOT to the hydraulic oil temperature sensor B-HOT and
and to the pin 30 and 3.
5.
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18.
with Step 6.
1.
with Step 7.
short circuit to ground condition.
From To Value
Connector X-UCM4A pin 18 Chassis ground There should be no continuity
A. If there is continuity, find and replace the wire 634 and/or 634A.
B. If there is no continuity, connect the connector X-UCM4A to the Unit Control Module A-UCM and continue with
Step 8.
8. Disconnect the X-HOT connector from the hydraulic oil temperature sensor B-HOT.
Check if the hydraulic oil temperature sensor B-HOT is defective.
A. If a problem is found, replace the hydraulic oil temperature sensor B-HOT.
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5120-03 - Short circuit to battery voltage or open circuit at retarder /

torque converter temperature sensor input
Control Module: TCU
Context:
control.
Cause:
There is a short circuit to battery voltage or an open circuit at the supply circuit of the gear oil temperature sensor
B-GOT. The measured voltage is too high.

3. The harness between the gear oil temperature sensor B-GOT and the Transmission Control Unit A-TRANS is
defective.
4. The gear oil temperature sensor B-GOT is defective.
5. The Transmission Control Unit A-TRANS is defective.
Solution:
2. Check if the connector X-TCOT is connected to the gear oil temperature sensor B-GOT.
Check if the connector X-TECM is connected to the Transmission Control Unit A-TRANS.

3. Disconnect the connector X-TCOT from the gear oil temperature sensor B-GOT.
Check the integrity of the connector X-TCOT and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-TCOT.
B. If there are no problems, connect the connector X-TCOT to the gear oil temperature sensor B-GOT and con-
tinue with Step 4.
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5.
5. Disconnect the connector X-TECM from the Transmission Control Unit A-TRANS.
Check the integrity of the connector X-TECM and visually check for any damage to the connector and to the pins
46 and 49.
A. If a problem is found, replace the connector X-TECM.

6. Check the harness between the gear oil temperature sensor B-GOT and the Transmission Control Unit A-TRANS
for a short circuit to battery voltage condition.
From To Value
Connector X-TECM pin 49 Chassis ground There should be no voltage

for an open circuit condition.
Disconnect the connector X-TCOT from the gear oil temperature sensor B-GOT.
From To Value
Connector X-TECM pin 49 Connector X-TCOT pin 1 There should be continuity

8. Check if the gear oil temperature sensor B-GOT is defective.
A. If a problem is found, replace the gear oil temperature sensor B-GOT.
B. If there are no problems, replace the Transmission Control Unit A-TRANS.
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5120-04 - Short circuit to ground at retarder / torque converter

temperature sensor input
Control Module: TCU
Context:
control.
Cause:
There is a short circuit to ground at the supply circuit of the gear oil temperature sensor B-GOT. The measured voltage
is too low.

defective.
Solution:

tinue with Step 4.
Check the integrity of the connector X-TRANS and X-CAB_TR, visually check for any damage to the connectors
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5.
46 and 49.

for a short circuit to ground condition.
From To Value
Connector X-TECM pin 49 Chassis ground There should be no continuity
B. If there is no continuity, connect the connector X-TECM from the Transmission Control Unit A-TRANS and
7. Disconnect the X-TCOT connector from the gear oil temperature sensor B-GOT.
Check if the gear oil temperature sensor B-GOT is defective.
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5140-03 - Short circuit to battery voltage or open circuit at engine

speed input
Control Module: TCU
Context:
The Transmission Control Unit A-TRANS can not change the gears or the direction under the control of the normal
clutch modulation. The Transmission Control Unit A-TRANS uses the substitute strategy for clutch control. All mod-
ulations are only time controlled.
Cause:
There is a short circuit to battery voltage or an open circuit at the supply circuit of the engine speed sensor B-ES_S.
The Transmission Control Unit A-TRANS measures a voltage higher than 7.00 V at speed input pin.

3. The harness between the engine speed sensor B-ES_S and the Transmission Control Unit A-TRANS is defective.
4. The engine speed sensor B-ES_S is defective.
Solution:
2. Check if the connector X-ESS is connected to the engine speed sensor B-ES_S.

3. Disconnect the connector X-ESS from the engine speed sensor B-ES_S.
Check the integrity of the connector X-ESS and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-ESS.
B. If there are no problems, connect the connector X-ESS to the engine speed sensor B-ES_S and continue with
Step 4.
5.
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3 and 19.

6. Check the harness between the engine speed sensor B-ES_S and the Transmission Control Unit A-TRANS for a
short circuit to battery voltage condition.
From To Value

7. Check the harness between the engine speed sensor B-ES_S and the Transmission Control Unit A-TRANS for
Disconnect the connector X-ESS from the engine speed sensor B-ES_S.
From To Value
Connector X-TECM pin 19 Connector X-ESS pin 1 There should be continuity

8. Check if the engine speed sensor B-ES_S is defective.
A. If a problem is found, replace the engine speed sensor B-ES_S.
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5140-04 - Short circuit to ground at engine speed input

Control Module: TCU
Context:
Cause:
There is a short circuit to ground at the supply circuit of the engine speed sensor B-ES_S. The Transmission Control
Unit A-TRANS measures a voltage lesser than 0.45 V at speed input pin.

Solution:

Step 4.
5.
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3 and 19.

From To Value
B. If there is no continuity, continue with Step 7.

7. Disconnect the X-ESS connector from the engine speed sensor B-ES_S.
Check if the engine speed sensor B-ES_S is defective.
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5140-12 - Logical error at engine speed input

Control Module: TCU
Context:
Cause:
There is a logical error at the supply circuit of the engine speed sensor B-ES_S. The Transmission Control Unit
A-TRANS measures an engine speed over the threshold value and the next moment the measured speed is zero.

4. The engine speed sensor B-ES_S gap has the wrong size.
Solution:

Step 4.
5.
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3 and 19.
B. If there are no problems, connect the connector X-TECM to the Transmission Control Unit A-TRANS and con-
tinue with Step 6.
6. Check if the harness between the engine speed sensor B-ES_S and the Transmission Control Unit A-TRANS is
defective.

7. Check the sensor gap at the engine speed sensor B-ES_S.
A. If a problem is found, adjust the gap or replace the engine speed sensor B-ES_S.

8. Disconnect the X-ESS connector from the engine speed sensor B-ES_S.
Check if the engine speed sensor B-ES_S is defective.
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5150-03 - Short circuit to battery voltage or open circuit at turbine

speed input
Control Module: TCU
Context:
If the failure is at the output speed, the system has strong limitations to transmission control. The Transmission Control
Unit A-TRANS can engage only one gear in each direction. In some cases only one direction will be possible.
The Transmission Control Unit A-TRANS will shift the transmission into neutral at the first occurrence of the failure.
First, the operator must shift the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into forward or
reverse, the Transmission Control Unit A-TRANS will select the limp-home gear.
If output speed is less than a threshold for reversal speed and the Transmission Control Unit A-TRANS has changed
into the limp-home gear and the operator selects a shuttle shift, the Transmission Control Unit A-TRANS will shift
immediately into the limp-home gear of the selected direction
If output speed is greater than the threshold, the Transmission Control Unit A-TRANS will shift the transmission into
neutral. The operator has to slow down the vehicle and must shift the gear selector into neutral position.
Cause:
There is a short circuit to battery voltage or an open circuit at the supply circuit of the turbine speed sensor B-TS_S.

3. The harness between the turbine speed sensor B-TS_S and the Transmission Control Unit A-TRANS is defective.
4. The turbine speed sensor B-TS_S is defective.
Solution:
2. Check if the connector X-TSS is connected to the turbine speed sensor B-TS_S.

3. Disconnect the connector X-TSS from the turbine speed sensor B-TS_S.
Check the integrity of the connector X-TSS and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-TSS.
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B. If there are no problems, connect the connector X-TSS to the turbine speed sensor B-TS_S and continue with
Step 4.
5.
3 and 41.

6. Check the harness between the turbine speed sensor B-TS_S and the Transmission Control Unit A-TRANS for a
From To Value

7. Check the harness between the turbine speed sensor B-TS_S and the Transmission Control Unit A-TRANS for
Disconnect the connector X-TSS from the turbine speed sensor B-TS_S.
From To Value
Connector X-TECM pin 41 Connector X-TSS pin 1 There should be continuity

8. Check if the turbine speed sensor B-TS_S is defective.
A. If a problem is found, replace the turbine speed sensor B-TS_S.
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5150-04 - Short circuit to ground at turbine speed input

Control Module: TCU
Context:
reverse, the Transmission Control Unit A-TRANS will select the limp-home gear .
immediately into the limp-home gear of the selected direction.
Cause:
There is a short circuit to ground at the supply circuit of the turbine speed sensor B-TS_S. The Transmission Control

Solution:

Step 4.
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5.
3 and 41.

6. Check the harness between the turbine speed sensor B-TS_S and the Transmission Control Unit A-TRANS for a
From To Value

7. Disconnect the X-TSS connector from the turbine speed sensor B-TS_S.
Check if the turbine speed sensor B-TS_S is defective.
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5150-12 - Logical error at turbine speed input

Control Module: TCU
Context:
reverse, the Transmission Control Unit A-TRANS will select the limp-home gear .
Cause:
There is a logical error at the supply circuit of the turbine speed sensor B-TS_S. The Transmission Control Unit
A-TRANS measures a turbine speed over the threshold value and the next moment the measured speed is zero.

4. The turbine speed sensor B-TS_S gap has the wrong size.
Solution:

Step 4.
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5.
3 and 41.
tinue with Step 6.
6. Check if the harness between the turbine speed sensor B-TS_S and the Transmission Control Unit A-TRANS is
defective.

7. Check the sensor gap at the turbine speed sensor B-TS_S.
A. If a problem is found, adjust the gap or replace the turbine speed sensor B-TS_S.

8. Disconnect the X-TSS connector from the turbine speed sensor B-TS_S.
Check if the turbine speed sensor B-TS_S is defective.
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5160-03 - Short circuit to battery voltage or open circuit at internal

speed input
Control Module: TCU
Context:
Cause:
There is a short circuit to battery voltage or an open circuit at the supply circuit of the intermediate speed sensor
B-IS_S. The Transmission Control Unit A-TRANS measures a voltage higher than 7.00 V at speed input pin.

3. The harness between the intermediate speed sensor B-IS_S and the Transmission Control Unit A-TRANS is de-
fective.
4. The intermediate speed sensor B-IS_S is defective.
Solution:
2. Check if the connector X-ISS is connected to the intermediate speed sensor B-IS_S.

3. Disconnect the connector X-ISS from the intermediate speed sensor B-IS_S.
Check the integrity of the connector X-ISS and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-ISS.
B. If there are no problems, connect the connector X-ISS to the intermediate speed sensor B-IS_S and continue
with Step 4.
5.
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3 and 42.

6. Check the harness between the intermediate speed sensor B-IS_S and the Transmission Control Unit A-TRANS
From To Value

Disconnect the connector X-ISS from the intermediate speed sensor B-IS_S.
From To Value
Connector X-TECM pin 42 Connector X-ISS pin 1 There should be continuity

8. Check if the intermediate speed sensor B-IS_S is defective.
A. If a problem is found, replace the intermediate speed sensor B-IS_S.
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5160-04 - Short circuit to ground at internal speed input

Control Module: TCU
Context:
Cause:
There is a short circuit to ground at the supply circuit of the intermediate speed sensor B-IS_S. The Transmission
Control Unit A-TRANS measures a voltage lesser than 0.45 V at speed input pin.

fective.
4. The intermediate speed sensor B-IS_S defective.
Solution:

with Step 4.
5.
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3 and 42.

for a short circuit to ground condition.
From To Value

7. Disconnect the X-ISS connector from the intermediate speed sensor B-IS_S.
Check if the intermediate speed sensor B-IS_S is defective.
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5160-12 - Logical error at internal speed input

Control Module: TCU
Context:
Cause:
There is a logical error at the supply circuit of the intermediate speed sensor B-IS_S. The Transmission Control Unit
A-TRANS measures an intermediate speed over the threshold value and the next moment the measured speed is
zero.

fective.
4. The intermediate speed sensor B-IS_S gap has the wrong size.
5. The intermediate speed sensor B-IS_S is defective.
Solution:

with Step 4.
4. Disconnect the connector A-TRANS from the connector X-CAB_TR.
5.
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3 and 42.
tinue with Step 6.
6. Check if the harness between the intermediate speed sensor B-IS_S and the Transmission Control Unit A-TRANS
is defective.

7. Check the sensor gap at the intermediate speed sensor B-IS_S.
A. If a problem is found, adjust the gap or replace the intermediate speed sensor B-IS_S.

8. Disconnect the X-ISS connector from the intermediate speed sensor B-IS_S.
Check if the intermediate speed sensor B-IS_S is defective.
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5170-03 - Short circuit to battery voltage or open circuit at output

speed input
Control Module: TCU
Context:
If the failure is at the turbine speed, the system has strong limitations to transmission control. The Transmission
Control Unit A-TRANS can engage only one gear in each direction. In some cases only one direction will be possible.
First, the operator must shift the gear selector into neutral position. If output speed is less than a threshold for neutral
to gear and the operator shifts the gear selector into forward or reverse, the Transmission Control Unit A-TRANS will
select the limp-home gear. If output speed is less than a threshold for reversal speed and the Transmission Control
Unit A-TRANS has changed into the limp-home gear and the operator selects a shuttle shift, the Transmission Control
Unit A-TRANS will shift immediately into the limp-home gear of the selected direction.
Cause:
There is a short circuit to battery voltage or an open circuit at the supply circuit of the output speed sensor B-OSS.

3. The harness between the output speed sensor B-OSS and the Transmission Control Unit A-TRANS is defective.
4. The output speed sensor B-OSS is defective.
Solution:
2. Check if the connector X-OSS is connected to the output speed sensor B-OSS.

3. Disconnect the connector X-OSS from the output speed sensor B-OSS.
Check the integrity of the connector X-OSS and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-OSS.
B. If there are no problems, connect the connector X-OSS to the output speed sensor B-OSS and continue with
Step 4.
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B. If there are no problems, connect the connector X-TRANS from the connector X-CAB_TR and continue with
Step 5.
4 and 62.

6. Check the harness between the output speed sensor B-OSS and the Transmission Control Unit A-TRANS for a
From To Value

7. Check the harness between the output speed sensor B-OSS and the Transmission Control Unit A-TRANS for an
open circuit condition.
Disconnect the connector X-OSS from the output speed sensor B-OSS.
From To Value
Connector X-TECM pin 62 Connector X-OSS pin 2 There should be continuity

8. Check if the output speed sensor B-OSS is defective.
A. If a problem is found, replace the output speed sensor B-OSS.
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5170-04 - Short circuit to ground at output speed input

Control Module: TCU
Context:
clutch modulation. The Transmission Control Unit A-TRANS uses the substitute strategy for clutch control. All modu-
lations are only time controlled. If the failure is at the turbine speed, the system has strong limitations to transmission
control. The Transmission Control Unit A-TRANS can engage only one gear in each direction. In some cases only
one direction will be possible.
Cause:
There is a short circuit to ground at the supply circuit of the output speed sensor B-OSS. The Transmission Control

Solution:
2. Check the fuse F-5F3 TECM ( 7.5 V).
A. If a problem is found, replace the fuse F-5F3 TECM ( 7.5 V).


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Step 5.
Step 6.
4 and 62.

From To Value

8. Disconnect the X-OSS connector from the output speed sensor B-OSS.
Check if the output speed sensor B-OSS is defective.
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5170-12 - Logical error at output speed input

Control Module: TCU
Context:
clutch modulation. The Transmission Control Unit A-TRANS uses the substitute strategy for clutch control. All modu-
lations are only time controlled. If the failure is at the turbine speed, the system has strong limitations to transmission
control. The Transmission Control Unit A-TRANS can engage only one gear in each direction. In some cases only
one direction will be possible.
Cause:
There is a logical error at the supply circuit of the output speed sensor B-OSS. The Transmission Control Unit
A-TRANS measures an output speed over the threshold value and the next moment the measured speed is zero.

4. The output speed sensor B-OSS gap has the wrong size.
Solution:

Step 4.
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Step 5.
4 and 62.
tinue with Step 6.
6. Check if the harness between the output speed sensor B-OSS and the Transmission Control Unit A-TRANS is
defective.

7. Check the sensor gap at the output speed sensor B-OSS.
A. If a problem is found, adjust the gap or replace the output speed sensor B-OSS.

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5180-02 - Output speed zero doesn't fit to other speed signals

Control Module: TCU
Context:
If the failure is at the turbine speed, the system has strong limitations to transmission control. The Transmission
Control Unit A-TRANS can engage only one gear in each direction. In some cases only one direction will be possible.
reverse, the Transmission Control Unit A-TRANS will select the limp-home gear. If output speed is less than a thresh-
old for reversal speed and the Transmission Control Unit A-TRANS has changed into the limp-home gear and the
operator selects a shuttle shift, the Transmission Control Unit A-TRANS will shift immediately into the limp-home gear
of the selected direction.
Cause:
The output speed is zero and does not fit to the other speed signals. If the transmission is not neutral and the shifting
has finished, the Transmission Control Unit A-TRANS measures an output speed equal to zero and a turbine speed
or an intermediate speed not equal to zero.

3. The output speed sensor B-OSS gap has the wrong size.
Solution:
2. Check if the harness between the output speed sensor B-OSS and the Transmission Control Unit A-TRANS is
defective.

3. Check the sensor gap at the output speed sensor B-OSS.
A. If a problem is found, adjust the gap or replace the output speed sensor B-OSS.

Check the signal of the output speed sensor B-OSS.
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5211-09 - Speedlimit_Prop1 Can message timeout

Control Module: TCU
Context:
The Transmission Control Unit A-TRANS keeps the last valid sent Speed_Limit_Request.
Cause:
The Unit Control Module A-UCM does not send message like CAN-message SpeedLimit_Prop1.

2. The CAN connector or the harness are damaged or the connectors are not installed.
3. There are interference on the CAN-Bus .
Solution:
2. Check the integrity of the CAN-Bus harnesses and connectors.
Visually inspect the relevant harness and connectors for damage, bent or dislocated pins, corroded terminals or
broken wires. Verify that the connectors are fully installed. Flex the harness involved to revel intermittent breaks
A. f you find damage or the display indicates other than normal display readings, repair the damage discovered
during the inspection or locate and repair the other than normal display condition and verify that the error has
been resolved.
B. If you do not find damage and the display indicates only normal readings, continue with Step 3.
3. Check the wires of CAN-Bus for a contact to vehicle ground condition.
A. If a problem is found, find and replace the damaged wire.

4. Check the wires of CAN-Bus for a contact to battery voltage condition.

5. Check if there are interference on the CAN-Bus.
A. If a problem is found, repair or replace the defective component.

6. Check the harness and the connector of the CAN-Bus connected to the Unit Control Module A-UCM.
25 and 34.
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A. If a problem is found, replace the connector X-UCM1B.

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5212-09 - Speedlimit_Prop2 Can message timeout

Control Module: TCU
Context:
The Transmission Control Unit A-TRANS keeps the last valid sent Speed_Limit_Request.
Cause:
The Unit Control Module A-UCM does not send message like CAN-message SpeedLimit_Prop2.

3. There are interference on the CAN-Bus.
Solution:
A. If you find damage or the display indicates other than normal display readings, repair the damage discovered
been resolved.



6. Check the harness and the connector of the CAN-Bus connected to the Unit Control Module A-UCM.
1 and 10.
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B. If there are no problems, replace the connector X-UCM2B.

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521-03 - Inch Pedal Position Sensor over voltage

Control Module: UCM
Context:
The A-UCM detects a value from BRAKE PEDAL ANGLE ( B-BPP) out of higher limit.
Cause:
On pin 16 of connector X-UCM1A of A-UCM, the detected value is > 4.75 V.

2. The BRAKE PEDAL ANGLE ( B-BPP) is damaged.
Solution:
1. Power inch disabled.
Default position sensor to minimum value (0%).
Verify that the fault is present and active.
2. Check the BRAKE PEDAL ANGLE sensor integrity.
Remove the BRAKE PEDAL ANGLE sensor.
Use a multimeter to perform the B-BPP check:
From To Value
Connector X-BPP pin 2 Connector X-BPP pin 1 Resistance
A. If the resistance is an open circuit, replace the BRAKE PEDAL ANGLE.
B. If resistance value is correct, continue with Step 3.

3. Move the cursor of the sensor and, by using a multimeter, perform the B-BPP check:
From To Value
Connector X-BPP pin 2 Connector X-BPP pin 3 Resistance changing
A. If the value is a short circuit, replace the BRAKE PEDAL ANGLE.
B. If the resistance changes, replace the A-UCM.
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521-04 - Inch Pedal Position Sensor under voltage

Control Module: UCM
Context:
The A-UCM detects a value from BRAKE PEDAL ANGLE ( B-BPP) out of lower limit.
Cause:
On pin 16 of connector X-UCM1A of A-UCM, the detected value is < 0.25 V.
Power inch disabled

Default position sensor to minimum value (0%)
2. The harness between A-UCM and the B-BPP is damaged.
3. The BRAKE PEDAL ANGLE ( B-BPP) is not correctly supplied
4. The BRAKE PEDAL ANGLE ( B-BPP) is damaged.
5. The harness between BRAKE PEDAL ANGLE ( B-BPP) and A-UCM is damaged.
Solution:
2. Check the integrity of the harness between A-UCM and the BRAKE PEDAL ANGLE ( B-BPP).

3. Check the output voltage of A-UCM.
Disconnect the connector X-CAB_B from connector X-BTM.
Use a multimeter to perform the following Voltage check:
From To Value
Connector X-CAB_B pin 4 Connector X-CAB_B pin 3 (ref) Voltage = 5 V
A. If the value is correct, reconnect the connector and continue with Step 6.
B. If the value is not correct, continue with Step 4.

4. Check the integrity of the X-CAB_B connector.
Visually check the integrity of the pins 3 and 4.
B. If both pins are not damaged, continue with Step 5.

5. Check the harness of connector X-CAB_B for a proper condition.
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Use a multimeter to perform the following resistance check:
From To Value
Connector X-CAB_B pin 4 Connector X-UCM1A pin 3 Short circuit
Connector X-CAB_B pin 3 Connector X-UCM1B pin 1 Short circuit
A. If one value is not correct, replace the harness between the connector and the A-UCM.
B. If the value is correct, continue with Step 6.

6. Check the BRAKE PEDAL ANGLE sensor integrity.
Remove the BRAKE PEDAL ANGLE sensor.
Use a multimeter to perform the B-BPP check:
From To Value
Connector X-BPP pin 2 Connector X-BPP pin 1 Resistance
A. If the resistance is an open circuit, replace the BRAKE PEDAL ANGLE.

7. Move the cursor of the sensor and, by using a multimeter, perform the B-BPP check:
From To Value
Connector X-BPP pin 2 Connector X-BPP pin 3 Resistance changing
A. If the resistance does not change, replace the BRAKE PEDAL ANGLE.
B. If the resistance changes, continue with Step 8.

8. Check the integrity of the X-BTM connector.
Disconnect X-BTM connector and visually check the integrity of the pins 15 on both connectors.
A. If one pin is damaged, replace the relevant harness.

9. Check the B-BPP to X-BTM harness for a proper condition.
From To Value
Connector X-BPP pin 3 Connector X-BTM pin 15 Short circuit
A. If the value is not correct, replace the harness between the connector and the B-BPP.

10. Check the A-UCM to X-CAB_B harness for a proper condition.
From To Value
Connector X-UCM1A pin 16 Connector X-CAB_B pin 15 Short circuit
A. If the value is not correct, replace the harness.
B. If the value is correct, replace the A-UCM.
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619-03 - Short to Power at Park Brake High Side Driver

Control Module: UCM
Context:
The A-UCM detects a value from Park Brake High Side Driver greater than the higher limit; as a consequence:
• If Vehicle moving TRUE
- None;
• If Vehicle moving FALSE
- Park Brake Function disabled ( PB always active)
- Open PB LSD
- Command PB HSD to OFF
- Set B.PBrakeAct = 01(Park Brake Actuator Active).
Cause:
The A-UCM detects, on pin 27 of connector X-UCM3B, a short circuit to power risen by BSP.

2. The harness between A-UCM and the PARKING BRAKE SOLENOID ( Y-Y_PB) is damaged.
3. The PARKING BRAKE SOLENOID is damaged.
4. The connectors X-BTM or X-CAB_B or X-YPB or X-UCM3B or X-UCM1A are damaged.
5. The harness between the connector X-BTM and the PARKING BRAKE SOLENOID is damaged.
6. The harness between the connector X-CAB_B and the A-UCM is damaged.
Solution:
2. Check the integrity of the harness between the A-UCM and the PARKING BRAKE SOLENOID.

3. Check the PARKING BRAKE SOLENOID integrity.
Remove the PARKING BRAKE SOLENOID sensor.
Use a multimeter to perform the resistance measurement of the solenoid.
A. If the resistance is an open circuit, replace the PARKING BRAKE SOLENOID.
B. If the resistance is not an open circuit, continue with Step 4.

4. Check the integrity of connectors X-BTM and X-CAB_B.
Disconnect the connector X-BTM from the connector X-CAB_B and visually check the integrity of pins 18 and 19
of both connectors.
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5. Check the integrity of harness between the connectors X-BTM and X-YPB.
From To Value
Connector X-BTM pin 18 Connector X-YPB pin 1 Short circuit
A. If one measurement is not correct, replace the harness.
B. If the measurements are correct, continue with Step 6.

Disconnect the connector X-UCM3B from the connector A-UCM and visually check the integrity of pin 27.
A. If the pin is damaged, replace the harness relevant to the damaged connector.

Disconnect the connector X-UCM1A from the connector A-UCM and visually check the integrity of pin 22.

8. Check the integrity of harness between the connector X-CAB_B and the A-UCM.
From To Value
A. If one measurement is not correct, replace the harness between the connector X-CAB_B and the A-UCM.
B. If the measurements are correct, replace the A-UCM.
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619-04 - Short to Ground at Park Brake High Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding at Park Brake High Side Driver; as a consequence:
• Park Brake Function disabled (PB always active)
- Open PB LSD
Cause:
The A-UCM detects, on pin 27 of connector X-UCM3B, a short circuit to ground risen by BSP.

Solution:

A. If the resistance is an open circuit, replace the PARKING BRAKE SOLENOID.

of both connectors.

5. Check the integrity of harness between the connectors X-BTM and X-YPB.
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From To Value



8. Check the integrity of harness between the connector X-CAB_B and the A-UCM.
From To Value
A. If one measurement is not correct, replace the harness between the connector X-CAB_B and the A-UCM.

9. Check the integrity of harness between connectors X-UCM3B and X-UCM1A.
Be sure the PARKING BRAKE SOLENOID sensor is installed and the connectors X-BTM and X-CAB_B are con-
nected.
From To Value
Connector X-UCM3B pin 27 Connector X-UCM1A pin 22 The PARKING BRAKE SOLENOID
resistance
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619-05 - Open Circuit at Park Brake High Side Driver

Control Module: UCM
Context:
The A-UCM detects a value of current from the Park Brake High Side Driver out of limit; as a consequence:
• Park Brake Function disabled (PB always active)
- Open PB LSD
Cause:
The A-UCM detects, on pin 27 of connector X-UCM3B, an open circuit or a low current risen by BSP.

4. The harness relevant to the A-UCM is damaged.
Solution:



5. Check the integrity of harness relevant to the A-UCM.
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From To Value
Connector X-UCM3B pin 27 Connector X-UCM1A pin 22 The PARKING BRAKE SOLENOID
resistance
B. If the measurement is not correct, continue with Step 6.

of both connectors.

7. Check the integrity of harness between connector X-CAB_B and the A-UCM.
From To Value
Connector X-UCM3B pin 27 Connector X-CAB_B pin 18 Short circuit

8. Check the integrity of harness between connectors X-BTM and X-YPB.
From To Value
B. If the measurements are correct, replace the PARKING BRAKE SOLENOID.
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624-03 - Short to Power at Warning LED High Side Driver

Control Module: UCM
Context:
The A-UCM, driving of the Warning LED, detects an output high level.
Cause:

2. The harness between A-UCM and the LED WARNING is damaged.
3. The LED WARNING is damaged.
4. The connectors X-CAB_B or X-PED or X-TT or X-UCM4B are damaged.
5. The harness between connectors X-TT and ground is damaged.
6. The harness between connectors X-PED and the TELL TALE INDICATOR ( LMP-TTI) is damaged.
7. The harness between connectors X-UCM4A and X-CAB_P is damaged.
Solution:
2. Visually check the integrity of the harness between the connector X-UCM4B and the connector X-XTT for any
damage.

3. Replace the LED WARNING.

4. Check the integrity of connector X-TT.
Disconnect the connector X-TT from the TELL TALE INDICATOR and visually check the integrity of pins 4 and 1
of the connector.

5. Check the integrity of harness of the connector X-TT.
Disconnect the connector X-TT from the TELL TALE INDICATOR.
From To Value
Connector X-TT pin 1 Ground Short circuit
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6. Check the integrity of connectors X-PED and X-CAB_B.
Disconnect the connector X-PED from the connector X-CAB_B and visually check the integrity of pin 5 of both
connectors.

7. Check the integrity of harness between the connector X-PED and the connector X-TT.
From To Value
Connector X-PED pin 5 Connector X-TT pin 4 Short circuit


9. Check the integrity of harness between the connectors X-UCM4B and X-CAB_P.
From To Value
Connector X-UCM4B pin 9 Connector X-CAB_P pin 5 Short circuit

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624-04 - Short to Ground at Warning LED High Side Driver

Control Module: UCM
Context:
The A-UCM, driving of the Warning LED, detects a short circuit to ground.
Cause:

Solution:
damage.


of the connector.

5. Check the integrity of harness of the connector X-TT.
From To Value
Connector X-TT pin 5 Connector X-TT pin 1 Open circuit
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connectors.

From To Value
Connector X-PED pin 5 Connector X-TT pin 1 Open circuit


From To Value
Connector X-CAB_P pin 5 Ground Open circuit

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624-05 - Open Circuit at Warning LED High Side Driver

Control Module: UCM
Context:
The A-UCM, driving of the Warning LED, detects an open circuit or a low current.
Cause:

Solution:
damage.

of the connector.

4. Check the integrity of harness between the connector X-TT and ground.
From To Value
Connector X-TT pin 1 Ground Short circuit

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connectors.

From To Value


From To Value


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746-03 - Short to Power at Differential Lock Valve

Control Module: UCM
Context:
The A-UCM detects the supply voltage on pin 3 of connector X-UCM3B.
Cause:
The DIFF LOCK SOLENOID is not correctly working.

2. The harness between A-UCM and the DIFF LOCK SOLENOID is damaged.
3. The DIFF LOCK SOLENOID is damaged.
4. The connector X-TRANS is damaged.
5. The harness between connector X-TRANS and component A-UCM is damaged.
Solution:
1. Disable Differential Lock function.

ZFTC1DisengageDifflockRequest = On (TBC if 2 is possible).
Icon and keypad LED blink (indicating always active) TBC.
Set the key in OFF position.
2. Check the integrity of the harness between A-UCM and the DIFF LOCK SOLENOID.

3. Check the DIFF LOCK SOLENOID integrity.
Remove the DIFF LOCK SOLENOID sensor.
A. If the resistance is an open circuit, replace the DIFF LOCK SOLENOID.

4. Check the integrity of connector X-TRANS.
Disconnect X-TRANS connector and visually check the integrity of pin 27.
A. If the pin is damaged, replace the harness of the connector.

5. Check the integrity of harness between connector X-TRANS and A-UCM.
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From To Value
Connector X-UCM3B pin 1 Connector X-TRANS pin 27 Short circuit
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746-04 - Short to Ground at Differential Lock Valve

Control Module: UCM
Context:
The A-UCM detects a grounding on pin 3 of connector X-UCM3B.
Cause:

Solution:


A. If the resistance is = 0, replace the DIFF LOCK SOLENOID.
B. If the resistance is > 0, continue with Step 4.


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From To Value
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746-05 - Open Circuit at Differential Lock Valve

Control Module: UCM
Context:
The A-UCM detects an open circuit or a low current on pin 3 of connector X-UCM3B.
Cause:

Solution:


A. If the resistance is an open circuit or too high, replace the DIFF LOCK SOLENOID.
B. If the resistance is > 0, continue with Step 4.


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From To Value
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1049-01 - Front Brake Accumulator Low Pressure

Control Module: UCM
Context:
The A-UCM detects a pressure value from Front Brake Accumulator lower than the expected one.
Cause:
Front Accumulator Pressure Mpa < 7.7 MPa.

2. The Front Brake Accumulator Pressure Sensor is not functioning.
3. The Front Brake Accumulator is not functioning.
Solution:
2. By performing the procedures 1049-03 – Short to Power at Front Brake Accumulator Pressure Sensor and
1049-04 – Short to Ground at Front Brake Accumulator Pressure Sensor, check the Front Brake Accumulator
Pressure Sensor is correctly functioning.
A. If the sensor is not functioning, replace sensor.
B. If the sensor is functioning, continue with Step 3.

3. Replace the Front Brake Accumulator.
A. If the functionality is restored, the procedure ends, replace the harness.
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1049-03 - Short to Power at Front Brake Accumulator Pressure

Sensor
Control Module: UCM
Context:
The A-UCM detects a value from RED_BRAKE_FRNT ( B-PRB1) out of higher limit.
Cause:

2. The RED_BRAKE_FRNT ( B-PRB1) is damaged.
Solution:
1. Set Front Accumulator Pressure to 0 bar

No Brake Pressure Warning available
2. Check the RED_BRAKE_FRNT ( B-PRB1) integrity.
Remove the RED_BRAKE_FRNT ( B-PRB1).
From To Value
Connector X-PRB1 pin B Connector X-PRB1 pin A Resistance
A. If the resistance is an open circuit, replace the RED_BRAKE_FRNT.

3. Move the cursor of the sensor and, by using a multimeter, perform the following check:
From To Value
Connector X-PRB1 pin B Connector X-PRB1 pin C Resistance changing
A. If the value is a short circuit, replace the RED_BRAKE_FRNT.
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1049-04 - Short to Ground at Front Brake Accumulator Pressure

Sensor
Control Module: UCM
Context:
The A-UCM detects a value from RED_BRAKE_FRNT ( B-PRB1) out of lower limit.
Cause:

2. The harness between A-UCM and B-PRB1 is damaged.
3. The RED_BRAKE_FRNT ( B-PRB1) is not correctly supplied
4. The RED_BRAKE_FRNT ( B-PRB1) is damaged.
5. The harness between RED_BRAKE_FRNT ( B-PRB1) and A-UCM is damaged.
Solution:
1. Set Front Accumulator Pressure to 0 bar

2. Check the integrity of the harness between A-UCM and RED_BRAKE_FRNT ( B-PRB1).

Disconnect the connector X-TRANS from connector X-CAB_TR.
From To Value
Connector X-CAB_TR pin 26 Connector X-CAB_TR pin 3 (ref) Voltage = 5 V
A. If the value is correct, reconnect the connectors and continue with Step 6.

4. Check the integrity of the X-CAB_TR connector.
Visually check the integrity of pins 26 and 3.
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5. Check the harness of connector X-CAB_TR for a proper condition.
From To Value
Connector X-CAB_TR pin 26 Connector X-UCM1A pin 2 Short circuit
A. If the value is not correct, replace the harness between the connector and the A-UCM.

6. Check the RED_BRAKE_FRNT sensor integrity.
Remove the RED_BRAKE_FRNT sensor.
From To Value
A. If the resistance is an open circuit, replace the RED_BRAKE_FRNT.

From To Value
A. If the resistance does not change, replace the RED_BRAKE_FRNT.

8. Check the integrity of the X-TRANS connector.
Disconnect the connector X-TRANS from the connector X-CAB_TR and visually check the integrity of the pins
1 on both connectors.

9. Check the X-PRB1 to X-TRANS harness for a proper condition.
From To Value
Connector X-PRB1 pin C Connector X-TRANS pin 1 Short circuit
A. If the value is not correct, replace the harness between the connector and the RED_BRAKE_FRNT.

10. Check the A-UCM to X-TRANS harness for a proper condition.
From To Value
Connector X-UCM1A pin 15 Connector X-CAB_TR pin 1 Short circuit
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1052-01 - Rear Brake Accumulator Low Pressure

Control Module: UCM
Context:
The A-UCM detects a pressure value from Rear Brake Accumulator lower than the expected one.
Cause:
Rear Accumulator Pressure Mpa < 7.7 MPa.

2. The Rear Brake Accumulator Pressure Sensor is not functioning.
3. The Rear Brake Accumulator is not functioning.
Solution:
2. By performing the procedures 1052-03 – Short to Power at Rear Brake Accumulator Pressure Sensor and
1052-04 – Short to Ground at Rear Brake Accumulator Pressure Sensor, check the Rear Brake Accumulator
Pressure Sensor is correctly functioning.

3. Replace the Rear Brake Accumulator.
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1052-03 - Short to Power at Rear Brake Accumulator Pressure

Sensor
Control Module: UCM
Context:
The A-UCM detects a value from the rear brake accumulator pressure sensor ( B-PRB2) out of higher limit. As
reaction, the accumulator pressure is set to 0 bar. No brake pressure warning available.
Cause:

2. The rear brake accumulator pressure sensor ( B-PRB2) is damaged.
3. The rear brake accumulator pressure sensor circuit wiring is defective (open circuit or short circuit).
Solution:
2. Check the integrity of the rear brake accumulator pressure sensor ( B-PRB2) integrity.
Disconnect the connector X-PRB2 and remove the sensor ( B-PRB2).
Use a multimeter to perform the following resistance check on the sensor side:
From To Value
B-PRB2 pin C B-PRB2 pin A 5 kΩ < R < ∞
A. If the resistance is infinite, there is an internal open circuit, replace the sensor.
B. If resistance value is within the range, leave the connector disconnected and continue follows with Step 3.
3. Check the integrity of the rear brake accumulator pressure sensor ( B-PRB2).
Use a multimeter to perform the following resistance check on the sensor side:
From To Value
B-PRB2 pin C B-PRB2 pin B R>0Ω
A. If the resistance is about 0 Ω, there is an internal short circuit. Replace the sensor.
B. If the resistance s grater than 0 Ω, continue with Step 4.

4. Check the rear brake accumulator pressure sensor circuit for a short to high source condition.
Put the key in the ON position.
Use a multimeter to check the voltage between the following points on the harness side:
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From To Value
Connector X-PRB2 pin B Chassis ground There should be about 5 V
Connector X-PRB2 pin C Chassis ground There should be less than 5 V
Connector X-UCM1A pin 17 Chassis ground There should be less than 5 V
Connector X-UCM1A pin 2 Chassis ground There should be about 5 V
A. If there is more than 5 V, there is a short to high source condition.

Locate the fault and repair the shorted conductor.
B. If the voltage is correct, continue with Step 5.

5. Check the rear brake accumulator pressure sensor circuit for an open circuit condition.
Put the key in the OFF position.
Disconnect the B-PRB2 connector X-PRB2 and the A-UCM connector X-UCM1A.
Use a multimeter to check the continuity between the following points on the harness side:
From To Value
Connector X-PRB2 pin A Connector X-UCM1A pin 1 There should be continuity
Connector X-PRB2 pin B Connector X-UCM1A pin 2 There should be continuity
Connector X-PRB2 pin C Connector X-UCM1AA pin 17 There should be continuity
A. If there is no continuity, there is an open circuit. Locate the fault and repair the broken conductor.
B. If there is continuity, leave the connectors disconnected and continue to Step 6.

6. Check the rear brake accumulator pressure sensor circuit for a short circuit condition.
From To Value
Connector X-PRB2 pin C Connector X-PRB2 pin B There should be no continuity
Connector X-PRB2 pin C Connector X-UCM1A pin 1 There should be no continuity
Connector X-UCM1A pin 17 Connector X-UCM1A pin 1 There should be no continuity
A. If there is continuity, there is a short circuit condition.

Locate the fault and repair the shorted conductor.
B. If there is no continuity, check the A-UCM for the appropriate software and re-flash, if necessary. If the fault
recurs, replace the A-UCM.
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1052-04 - Short to Ground at Rear Brake Accumulator Pressure

Sensor
Control Module: UCM
Context:
The A-UCM detects a value from RED_BRAKE_REAR ( B-PRB2) out of lower limit.
Cause:

2. The harness between A-UCM and B-PRB2 is damaged.
3. The RED_BRAKE_REAR ( B-PRB2) is not correctly supplied
4. The RED_BRAKE_ REAR ( B-PRB2) is damaged.
5. The harness between RED_BRAKE_FRNT ( B-PRB1) and A-UCM is damaged.
Solution:
1. Set Rear Accumulator Pressure to 0 bar

2. Check the integrity of the harness between A-UCM and RED_BRAKE_REAR ( B-PRB2).

Disconnect the connector X-TRANS from connector X-CAB_TR.
From To Value
Connector X-CAB_TR pin 26 Connector X-CAB_TR pin 3 (ref) Voltage = 5 V

4. Check the integrity of the X-CAB_TR connector.
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5. Check the harness of connector X-CAB_TR for a proper condition.
From To Value
B. If the value is correct, replace A-UCM.

6. Check the RED_BRAKE_REAR sensor integrity.
Remove the RED_BRAKE_REAR sensor.
From To Value
A. If the resistance is an open circuit, replace the RED_BRAKE_REAR.
B. If resistance value is correct, continue to Step 7.

From To Value
A. If the resistance does not change, replace the RED_BRAKE_REAR.

8. Check the integrity of the X-TRANS connector.
Disconnect the connector X-TRANS from the connector X-CAB_TR and visually check the integrity of the pins
24 on both connectors.

9. Check the X-PRB2 to X-TRANS harness for a proper condition.
From To Value
Connector X-PRB2 pin C Connector X-TRANS pin 24 Short circuit
A. If the value is not correct, replace the harness between the connector and the RED_BRAKE_REAR.

10. Check the A-UCM to X-TRANS harness for a proper condition.
From To Value
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1565-02 - Armrest Signals not plausible

Control Module: UCM
Context:
The A-UCM detects a value from LH ARMREST POSITION (UP and DWN) out of limits.
Cause:
The A-UCM detects one of the following conditions:

• voltage on pin 2B.12 > 15 V and 2B.20 > 15 V for T > 350 ms;
• voltage on pin 2B.12 < 10 V and 2B.20 < 10 V for T > 350 ms.

2. The harness between the A-UCM and the LH ARMREST POSITION (UP and DWN) is damaged.
3. The LH ARMREST POSITION (UP and DWN) is not supplied.
4. The harness between the connector X-CAB_L and the A-UCM is damaged.
5. The harness between the connector X-LFT_A and the LH ARMREST POSITION (UP and DWN) is damaged.
6. The LH ARMREST POSITION (UP and DWN) is damaged.
Solution:
1. If JSS is not Active:

- Prevent JSS Activation
If JSS is Active
- None (discuss if the fault shall be displayed) as soon as JSS get deactivated
- Set Joystick Position to Neutral
- Command PVED to cut Supply Pressure
A. f the fault is present and active, continue with Step 2.
2. Check the integrity of the harness between the A-UCM and the LH ARMREST POSITION (UP and DWN).

3. Check the LH ARMREST POSITION (UP and DWN) power supply.
Disconnect the connector X-LFT_A from the connector X-CAB_L.
From To Value
Connector X-CAB_L pin 10 + 24 V Ref. 24 V
A. If the value is not correct, connect the connector X-LFT_A to the connector X-CAB_L and continue with Step
4.
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4. Check the integrity of fuse F-5F8.
Remove the fuse F-5F8 from the LC5.
A. If the fuse is burned, replace the fuse.
B. If the fuse is not burned, check the harness between LC5 and the connector X-CAB_L.
5. Check the integrity of harness between the connector X-LFT_A and the LH ARMREST POSITION (UP and DWN).
Disconnect the connectors X-LH_ARM_UP and X-LH_ARM_DWN from the LH ARMREST POSITION (UP and
DWN).
From To Value
Connector X-LFT_A pin 10 Connector X-LH_ARM_UP pin 1 Short circuit
Connector X-LFT_A pin 10 Connector X-LH_ARM_DWN pin 1 Short circuit
A. If one measurement is not correct, replace the harness between the connector X-LFT_A and the LH-ARM-
REST POSITION (UP and DWN).

6. Check the integrity of harness between the connector X-CAB_L and the A-UCM.
Disconnect the connectors X-UCM2B from A-UCM. Use a multimeter to perform the following check:
From To Value
Connector X-UCM2B pin 12 Connector X-CAB_L pin 4 Short circuit
A. If one measurement is not correct, replace the harness between the connector X-CAB_L and the A-UCM.
B. If the measurements are correct, connect the connector X-UCM2B to the A-UCM and continue with Step 7.
7. Check the integrity of harness between the connector X-LFT_A and the LH ARMREST POSITION (UP and DWN).
Remove the connectors X-LH_ARM_UP and X-LH_ARM_DWN.
From To Value
Connector X-LFT_A pin 4 Connector X-LH_ARM_UP pin 3 Short circuit
Connector X-LFT_A pin 8 Connector X-LH_ARM_DWN pin 3 Short circuit
B. If all the measurements are correct, continue with Step 8.

8. Check the integrity of LH ARMREST POSITION (UP and DWN).
Replace the LH ARMREST POSITION UP and the LH ARMREST POSITION DWN.
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2580 - Low Brake Pressure

Context:
Low Brake Pressure.
Cause:

2. The brake pressure is low.
Solution:
2. Bring the machine to a safe stop, and turn the engine OFF immediately. Replace the brake pressure sensor.
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2661-14 - Roller X Hall cell plausibility error

Control Module: Keypad and Joystick
Context:
The right hand joystick SW-RH_JS is connected to the Universal Control Module (UCM) via CAN2 bus. This fault
occurs if the UCM detects a plausibility error on the joystick roller X hall.
Cause:
The UCM has detected a plausibility error on the joystick roller X hall.
1. Defective harness or connectors, damaged or not fully installed.

2. Defective right hand joystick SW-RH_JS, internal failure.
3. Defective right hand joystick SW-RH_JS wiring harness.
Solution:
Use the diagnostic tool to check the status of this fault.

been resolved.
B. If the fault has not been resolved, continue with Step 4.

4. Check the mechanical integrity of the right hand joystick SW-RH_JS.
Visually inspect the right hand joystick for damage or mechanical defects.
Control the joystick movement and check the integrity of the FNR switch.
Verify that the joystick harness is long enough to allow joystick movement without causing strain on the wires.
A. If the right hand joystick is defective, or the joystick harness is not long enough, replace the component.
B. If the right hand joystick works properly, continue with Step 5.

5. Check the electrical integrity of the right hand joystick SW-RH_JS.
Disconnect X-CAB_AR connector.
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Use a multimeter to perform the following continuity checks on the right hand joystick side:
From To Value
X-CAB_AR (Plug) pin 1 All the other pins of X-CAB_AR There should be no continuity
A. If there is continuity, there is an internal short circuit. Replace the component.
B. If there is no continuity, leave the connector disconnected and continue with Step 6.
6. Verify the integrity of the fuse F-5F6.
Verify that the fuse F-5F6 is properly installed.
Visually check the fuse F-5F6.
Disconnect the connector X-LC5 of the fuse box LC5.
Use a multimeter to perform the following continuity check:
From To Value
X-LC5 (Receptacle) pin 9B X-LC5 pin 6A There should be continuity
A. If the fuse is broken or damaged or there is no continuity, replace the fuse.
B. If the fuse is ok, continue with Step 7.

7. Verify that the CAN2 bus is properly shielded.
From To Value
CAN2 bus shield Chassis ground There should be continuity
A. If there is no continuity, the CAN2 bus is not properly shielded. Locate the fault and repair the conductor.

8. Check the CAN2 bus for an open circuit condition.
Disconnect X-UCM2B connector.
From To Value
X-CAB_AR (Plug) pin 3 X-UCM2B (Receptacle) pin 1 There should be continuity
B. If there is continuity, leave both connectors disconnected and continue with Step 9.
9. Check the CAN2 bus for a short to ground condition.
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From To Value
X-CAB_AR (Plug) pin 3 Chassis ground There should be no continuity
A. If there is continuity, there is a short to ground condition. Locate the fault and repair the conductor.

10. Check the right hand joystick SW-RH_JS ground connection.
From To Value
X-CAB_AR (Plug) pin 2 Chassis ground There should be continuity
A. If there is no continuity, there is an open circuit. Locate the fault and repair the conductor.

11. Check the right hand joystick SW-RH_JS power supply connection.
From To Value
X-CAB_AR (Plug) pin 1 X-LC5 pin 6A There should be continuity
B. If there is continuity, check the UCM and replace if necessary. Then erase the fault and continue operation.

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2662-03 - Hall cell X1/X2 voltage abnormally high

Context:
Hall cell X1/X2 voltage abnormally high.
Cause:
Solution:
A. If the fault is present and active, make calibration.
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2662-04 - Hall cell X1/X2 voltage abnormally low

Context:
Hall cell X1/X2 voltage abnormally low.
Cause:
Solution:
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2662-13 - Roller X out of neutral at power-up

Context:
Roller X out of neutral at power-up.
Cause:
Solution:
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2662-14 - Roller X Hall cell plausibility error

Context:
occurs if the UCM detects a plausibility error on the joystick roller X hall.
Cause:
The UCM has detected a plausibility error on the joystick roller X hall.

Solution:

been resolved.

A. If the right hand joystick is defect, replace the component.

Use a multimeter to perform the following continuity checks on the right-hand joystick side:
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From To Value
X-CAB_AR (Plug) pin 1 All the other pins of X-CAB_AR There should be no continuity.
From To Value
X-LC5 (Receptacle) pin 9B X-LC5 (Receptacle) pin 6A There should be continuity

From To Value

From To Value
From To Value
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From To Value

From To Value
X-CAB_AR (Plug) pin 1 X-LC5 (Receptacle) pin 6A There should be continuity

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2663-03 - Hall cell Y1/Y2 voltage abnormally high

Context:
Hall cell Y1/Y2 voltage abnormally high.
Cause:
Solution:
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2663-04 - Hall cell Y1/Y2 voltage abnormally low

Context:
Hall cell Y1/Y2 voltage abnormally low
Cause:
Solution:
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2663-13 - Roller Y out of neutral at power-up

Context:
Roller Y out of neutral at power-up.
Cause:
Solution:
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2663-14 - Roller Y Hall cell plausibility error

Context:
Roller Y Hall cell plausibility error.
Cause:
Solution:
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2664-03 - Hall cell Z1/Z2 voltage abnormally high

Context:
occurs if the UCM detects a voltage abnormally high from the joystick hall cell Z1/Z2.
Cause:
The UCM has detected a voltage abnormally high from the joystick hall cell Z1/Z2.

Solution:


been resolved.


Disconnect the X-CAB_AR connector.
From To Value
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From To Value
X-LC5 (Receptacle) pin 9B X-LC5 pin 6A There should be continuity.
B. If the fuse is ok and there is continuity, continue with Step 7.

From To Value
X-CAB_AR (Plug) pin 1 X-LC5 pin 6A There should be continuity.
B. If there is continuity, leave the connector disconnected and continue with Step 8.
From To Value
X-CAB_AR (Plug) pin 2 Chassis ground There should be continuity.
From To Value
CAN2 bus shield Chassis ground There should be continuity.

From To Value
X-CAB_AR (Plug) pin 3 X-UCM2B (Receptacle) pin 1 There should be continuity.
A. If there is no continuity, there is an open circuit condition. Locate the fault and repair the conductor
11. Check the CAN2 bus for a short to high source condition.
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From To Value
A. If there is continuity, there is a short circuit condition to the joystick power supply. Locate the fault and repair
the conductor.
B. If there is continuity, check the UCM and replace if necessary. Then erase the fault and continue operation..

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2664-04 - Hall cell Z1/Z2 voltage abnormally low

Context:
Hall cell Z1/Z2 voltage abnormally low.
Cause:
Solution:
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2664-13 - Roller Z out of neutral at power-up

Context:
Roller Z out of neutral at power-up.
Cause:
Solution:
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2664-14 - Roller Z Hall cell plausibility error

Context:
The right-hand joystick SW-RH_JS is connected to the Universal Control Module (UCM) via CAN2 bus. This fault
occurs if the UCM detects a plausibility error on the joystick roller Z hall.
Cause:
The UCM has detected a plausibility error on the joystick roller Z hall

2. Defective right-hand joystick SW-RH_JS, internal failure.
3. Defective right-hand joystick SW-RH_JS wiring harness.
Solution:


been resolved.


From To Value
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From To Value
X-LC5 (Receptacle) pin 9B X-LC5 pin 6A There should be continuity.

From To Value
CAN2 bus shield Chassis ground There should be continuity.

From To Value
From To Value

From To Value

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From To Value
X-CAB_AR (Plug) pin 1 X-LC5 (Receptacle) pin 6A There should be continuity.

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3509-02 - 5V internal fault

Context:
5 V internal fault.
Cause:

2. The wirings to CAN BUS are damaged.
3. The wirings to external connection are damaged.
Solution:
2. Verify the wirings to CAN BUS.
A. If one or more wirings are damaged, proceed with the replacement.
B. If the wirings are intact and functioning, continue with Step 3.

3. Verify the wirings to external connection.
B. If the wiring are not damaged, verify that the fault code is not active.
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3651-02 - Primary FNR Fault

Control Module: UCM
Context:
The A-UCM detects a fail on the Primary FNR outputs.
Cause:
3 channel Low OR 2 channel High.

2. The harness between A-UCM and the PRIMARY FNR is damaged.
3. The connectors X-CAB_P2 and X-PED_2 are damaged.
4. The harness between connector X-CAB_P2 and component A-UCM is damaged.
5. The harness between connector X-PED_2 and component PFNR is damaged.
Solution:
1. Set Primary FNR to N.

2. Check the integrity of the harness between A-UCM and the PRIMARY FNR.

3. Check the integrity of connectors X-CAB_P2 and X-PED_2.
Disconnect X-CAB_P2 connector from X-PED_2 connector and visually check the integrity of the pins from 1 to
and 6 of both connectors.

4. Check the integrity of harness between connector X-CAB_P2 and component A-UCM.
From To Value
Connector X-UCM2A pin 11 Connector X-CAB_P2 pin 1 Short circuit
Connector X-UCM2B pin 22 Connector X-CAB_P2 pin 4 Short circuit
Connector X-UCM2B pin 21 Connector X-CAB_P2 pin 5 Short circuit
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5. Check the integrity of harness between connector X-PED_2 and component PFNR.
From To Value
Connector X-TS1 pin A Connector X-PED_2 pin 6 Short circuit
Connector X-TS1 pin B Connector X-PED_2 pin 3 Short circuit
Connector X-TS1 pin C Connector X-PED_2 pin 1 Short circuit
Connector X-TS1 pin D Connector X-PED_2 pin 2 Short circuit
Connector X-TS2 pin B Connector X-PED_2 pin 5 Short circuit
Connector X-TS2 pin C Connector X-PED_2 pin 4 Short circuit
B. If the measurements are correct, replace the component A-PFNR.
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5123-19 - Display Source Address Cyclic Timeout

Control Module: UCM
Context:
The Universal Control Module A-UCM is connected to the Display A-DSP via both CAN 1 and CAN 2 bus. This fault
occurs if the A-UCM does not receive any message from the Display Source Address within the maximum interval
time (3 times of maximum defined cycle time). As consequence, the UCM uses the last GHMI CAN message received.
Cause:
The A-UCM has detected a cycle time interval, of the CAN display messages, greater than 3 times of maximum
defined cycle time.

Solution:




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5220-09 - Brakes timeout

Control Module: TCU
Context:
control.
The Transmission Control Unit A-TRANS keeps the last state of parking brake.
Cause:
The Unit Control Module A-UCM does not send CAN message B from the parking brake.

Solution:
been resolved.



6. Check the wires of the CAN harness connected to the Engine Control Unit A-ECU, connector X-ECU pin 46 and
pin 47.
A. If a problem is found, repair or replace the damaged wire.
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5230-09 - Zftc1 Timeout

Control Module: TCU
Context:
control.
The Transmission Control Unit A-TRANS shifts the transmission to neutral position.
Cause:
The Unit Control Module A-UCM does not send CAN message ZF-TransmissionControl from the transmission con-
troller on tranny A-TRC.

Solution:
been resolved.



6. Check the wire of the CAN harness connected to the Unit Control Module A-UCM, connector X-UCM1B pin 34
and pin 25.
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7. Check the wires of the CAN harness connected to the Unit Control Module A-UCM, connector X-UCM2B pin 1
and pin 10.

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5260-09 - Dct1 Timeout = Vehicle_1 Timeout

Control Module: TCU
Context:
control.
Cause:
There is a timeout of the CAN-message DTC1 from the display computer A-DSP.

4. The display computer A-DSP is defective.
Solution:
been resolved.

4. Check the harness to display computer and replace if necessary.


6. Check the wire of the CAN harness connected to the display computer A-DSP, connector X-DSP pins 1, 2, 5 and
6.
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B. If there are no problems, replace the display computer A-DSP.
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5270-09 - Jss Timeout =Vehicle_2 Timeout

Control Module: TCU
Context:
control.
The Transmission Control Unit A-TRANS shifts the transmission to neutral position while the joystick steering valve
Y-JSS_STRG_VLV is active.
Cause:
There is a timeout of the CAN-message JSS from the joystick steering valve Y-JSS_STRG_VLV.

4. The joystick steering valve Y-JSS_STRG_VLV is defective.
Solution:
been resolved.



6. Check the wire of the CAN harness connected to the joystick steering valve Y-JSS_STRG_VLV, connector X-JSV
pins 4, 5, 9 and 10.
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B. If there are no problems, replace the joystick steering valve Y-JSS_STRG_VLV.
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5271-09 - DISPID1 CAN message timeout

Control Module: TCU
Context:
The detected failure in the system has strong limitations to transmission control. The Transmission Control Unit
A-TRANS can engage only one gear in each direction. In some cases only one direction will be possible.
The Transmission Control Unit A-TRANS select the parameter set with ID0.
Cause:
There is a timeout of the CAN-message DISPID1 from the display computer A-DSP.

4. The display computer A-DSP is defective.
Solution:
been resolved.


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6. Check the wire of the CAN harness connected to the display computer A-DSP, connector X-DSP pins 1, 2, 5 and
6.
B. If there are no problems, replace the display computer A-DSP.
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5280-09 - Engine Conf timeout

Control Module: TCU
Context:
Cause:
There is a timeout of the CAN-message ENGINE CONF from the Engine Control Unit A-ECU.

4. The Engine Control Unit A-ECU is defective.
Solution:
been resolved.



6. Check the wire of the CAN harness connected to the Engine Control Unit A-ECU, connector X-ECU pin 46 and
pin 47.
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B. If there are no problems, replace the Engine Control Unit A-ECU.
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5290-09 - EEC1 Timeout

Control Module: TCU
Context:
Cause:
There is a timeout of the CAN-message EEC1 from the Engine Control Unit A-ECU.

Solution:
been resolved.



pin 47.
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Control Module: TCU
Context:
Cause:

Solution:
been resolved.



pin 47.
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5310-09 - Engine speed limit function during gearshifts does not

work properly
Control Module: TCU
Context:
control.
After the selection of the neutral position, only limited gears are available depending on applications.
Cause:
During gearshift, the engine speed limit function does not work properly.

Solution:
been resolved.

pin 47.

5. Check the efficiency of the Engine Control Unit A-ECU.
The Engine Control Unit A-ECU may ignore torque or speed limit command the Transmission Control Unit
A-TRANS via TSC1 message.
A. If a problem is found, replace the Engine Control Unit A-ECU.
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5370-02 - Shift lever signal defective

Control Module: TCU
Context:
control.
The Transmission Control Unit A-TRANS shifts the transmission to neutral position and uses informations from the
substitute shift lever.
Cause:
The CAN signal for the shift lever A-PFNR is defective

3. The I/O controller is defective.
Solution:
been resolved.

4. Check the harness of the I/O Controller.
A. If a problem is found, repair or replace the harness.
B. If there are no problems, replace the I/O Controller.
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5390-02 - Aeb request signal defective

Control Module: TCU
Context:
control.
The last selection of the transmission is kept from the Transmission Control Unit A-TRANS.
Cause:
The CAN signal for the Automatic Emergency Braking (AEB) request is defective.

Solution:
been resolved.

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5420-02 - Starting gear signal defective

Control Module: TCU
Context:
control.
The Transmission Control Unit A-TRANS uses the default starting gear.
Cause:
The CAN signal for the starting gear is defective.

Solution:
been resolved.

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5430-02 - Enginge torque signal defective

Control Module: TCU
Context:
Cause:
The CAN signal for the engine torque is defective.

Solution:
been resolved.

4. Check the harness of the Engine Control Unit A-ECU.

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5431-09 - Engine speed limit function does not work properly

during stall or output speed limit function
Control Module: TCU
Context:
control.
After the selection of the neutral position, only limited gears are available depending on applications.
Cause:
The engine speed limit function or output limit function do not work properly during stall.

Solution:
been resolved.

The Engine Control Unit A-ECU may ignore torque or speed limit command the Transmission Control Unit
A-TRANS via TSC1 message.

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5440-02 - Reference engine torque signal defective

Control Module: TCU
Context:
Cause:
The CAN signal for reference of the engine torque is defective.

Solution:
been resolved.


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5450-02 - Actual engine torque signal defective

Control Module: TCU
Context:
Cause:
The CAN signal for actual of the engine torque is defective.

Solution:
been resolved.


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5460-02 - Nom friction torque signal defective

Control Module: TCU
Context:
Cause:
The CAN signal for nominal friction torque is defective.

Solution:
been resolved.


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Control Module: TCU
Context:
control.
The Transmission Control Unit A-TRANS uses the default signal of the accelerator pedal in idle position.
Cause:

Solution:
been resolved.



pin 47.
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5480-03 - Short circuit to battery voltage at clutch K1

Control Module: TCU
Context:
If a failure at another clutch is pending, the Transmission Control Unit A-TRANS detects a severe failure that disables
control of system.
The Transmission Control Unit A-TRANS shuts off all solenoid valves and also both common power supplies ( VPS1,
VPS2). The park brake is operating, also all functions which use ADM 1 to ADM 8 are disabled.
Cause:
There is a short circuit to battery voltage at clutch K1 of the transmission controller of tranny A-TRC. The measured
resistance value of the valve is out of limit, the voltage at K1 valve is too high.

3. The harness between the transmission controller of tranny A-TRC and the Transmission Control Unit A-TRANS
is defective.
4. The transmission controller of tranny A-TRC is defective.
Solution:
2. Check if the connector X-TRC is connected to the transmission controller of tranny A-TRC.

3. Disconnect the connector X-TRC from the transmission controller of tranny A-TRC.
Check the integrity of the connector X-TRC and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-TRC.
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B. If there are no problems, connect the connector X-TRC to the transmission controller of tranny A-TRC and
and to the pin 18.
5.
Check the integrity of the connector X-TECM and visually check for any damage to the connector and to the pin
32.

6. heck the harness between the transmission controller of tranny A-TRC and the Transmission Control Unit
A-TRANS for a short circuit to battery voltage condition.
From To Value
B. If there is no voltage, connect X-TECM to the Transmission Control Unit A-TRANS and continue with Step 7.
Check if the transmission controller of tranny A-TRC is defective.
Check the resistance of the transmission controller of tranny A-TRC.
A. If a problem is found, replace the transmission controller of tranny A-TRC.
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5480-04 - Short circuit to ground at clutch K1

Control Module: TCU
Context:
control of system.
Cause:
There is a short circuit to ground at clutch K1 of the transmission controller of tranny A-TRC. The measured resistance
value of the valve is out of limit, the voltage at K1 valve is too low.

is defective.
4. The harness between the Transmission Control Unit A-TRANS and the lockup solenoid Y-YLS is defective.
5. The lockup solenoid Y-YLS is defective (only for 5-speed models).
Solution:
2. Check if the connector X-TRC is properly connected to the transmission controller of tranny A-TRC.
Check if the connector X-TRANS is properly connected to the connector X-CAB_TR.
Check if the connector X-TECM is properly connected to the Transmission Control Unit A-TRANS.
Check if the connector X-YLS is properly connected to the lockup solenoid Y-YLS (only for 5-speed models).

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and to the pin 18.
B. If there are no problems, connect the connector X-CAB_TR to the connector X-TRANS and continue with
Step 5.
5. Disconnect the connector X-TECM from the Transmission Control Unit A-TRANS. Check the integrity of the con-
nector X-TECM and visually check for any damage to the connector and to the pin 32.

6. Disconnect the connector X-YLS from the lockup solenoid Y-YLS (only for 5-speed models).
Check the integrity of the connector X-YLS and visually check for any damage to the connector and to the pins
1 and 2.
A. If a problem is found,.replace the connector X-YLS.

7. Check the cables 419 and 420 of the lockup solenoid option (only for 4-speed models). Verify that the cables are
properly insulated from the other connectors.
A. If a problem is found, fix or replace the cable.

8. Check the harness between the transmission controller of tranny A-TRC and the Transmission Control Unit
A-TRANS for a short circuit to ground condition.
From To Value
Connector X-TECM (Receptacle) Chassis ground There should be no continuity
pin 32
Connector X-CAB_TR (Receptacle) Chassis ground There should be no continuity
pin 18
Connector X-TRANS (Plug) pin 18 Chassis ground There should be no continuity
Connector X-TRC (Receptacle) pin Chassis ground There should be no continuity
3
A. If there is a continuity, find and replace the wire 837 and/or 837A.

9. Check the electric insulation of the harness between the transmission controller of tranny A-TRC and the Trans-
mission Control Unit A-TRANS.
Disconnect the connector X-TRC from the transmission controller of tranny A-TRC.
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From To Value
Connector X-TECM (Receptacle) Connector X-TRC pin 1 There should be no continuity
pin 32
pin 32
Connector X-TECM (Receptacle) Connector X-TRC pin 3 There should be continuity
pin 32
Connector X-TECM pin 32 Connector X-TRC pin 4 There should be no continuity
pin 32
pin 32

10. Replace the transmission controller of tranny A-TRC.
A. If the problem has been solved, repeat the Step 1.
B. If the problem has not been solved, replace the Transmission Control Unit A-TRANS.
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5480-05 - Open circuit at clutch K1

Control Module: TCU
Context:
control of system.
Cause:
There is an open circuit at clutch K1 of the transmission controller of tranny A-TRC. The measured resistance value
of the valve is out of limit.

is defective.
Solution:

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and to the pin 18.
5.
32.

A-TRANS for an open circuit condition.
From To Value
Connector X-TECM pin 32 Connector X-TRC pin 3 There should be continuity

7. Check if the transmission controller of tranny A-TRC is defective.
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Control Module: TCU
Context:
control of system.
Cause:

is defective.
Solution:

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and to the pin 19.
5.
55.

From To Value
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Control Module: TCU
Context:
control of system.
Cause:

is defective.
Solution:

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and to the pin 19.
5.
55.

From To Value

From To Value

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Control Module: TCU
Context:
control of system.
Cause:

is defective.
Solution:

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and to the pin 19.
5.
55.

From To Value

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Control Module: TCU
Context:
control of system.
Cause:

is defective.
Solution:

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and to the pin 16.
5.
56.

From To Value
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Control Module: TCU
Context:
control of system.
Cause:

is defective.
Solution:

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and to the pin 16.
5.
56.

From To Value

From To Value

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Control Module: TCU
Context:
control of system.
Cause:

is defective.
Solution:

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and to the pin 16.
5.
56.

From To Value

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5520-03 - Short circuit to battery voltage at clutch Kv

Control Module: TCU
Context:
control of system.
Cause:
There is a short circuit to battery voltage at clutch Kv of the transmission controller of tranny A-TRC. The measured
resistance value of the valve is out of limit, the voltage at Kv valve is too high.

is defective.
Solution:

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and to the pin 20.
5.
Check the integrity of the connector X-TECM and visually check for any damage to the connector and to the pin 9.

From To Value
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5520-04 - Short circuit to ground at clutch Kv

Control Module: TCU
Context:
control of system.
Cause:
There is a short circuit to ground at clutch Kv of the transmission controller of tranny A-TRC. The measured resistance
value of the valve is out of limit, the voltage at Kv valve is too low.

is defective.
Solution:

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and to the pin 20.
5.

From To Value

From To Value

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5520-05 - Open circuit at clutch Kv

Control Module: TCU
Context:
control of system.
Cause:
There is an open circuit at clutch Kv of the transmission controller of tranny A-TRC. The measured resistance value

is defective.
Solution:

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and to the pin 20.
5.

A-TRANSS for an open circuit condition.
From To Value

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5530-03 - Short circuit to battery voltage at clutch Kr

Control Module: TCU
Context:
control of system. The Transmission Control Unit A-TRANS shuts off all solenoid valves and also both common power
supplies ( VPS1, VPS2). The park brake is operating, also all functions which use ADM 1 to ADM 8 are disabled.
Cause:
There is a short circuit to battery voltage at clutch Kr of the transmission controller of tranny A-TRC. The measured
resistance value of the valve is out of limit, the voltage at Kr valve is too high.

is defective.
Solution:
B. f there are no problems, continue with Step 3.

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and to the pin 17.
5.
10.

From To Value
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5530-04 - Short circuit to ground at clutch Kr

Control Module: TCU
Context:
control of system.
Cause:
There is a short circuit to ground at clutch Kr of the transmission controller of tranny A-TRC. The measured resistance
value of the valve is out of limit, the voltage at Kr valve is too low.

is defective.
Solution:

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and to the pin 17.
5.
10.

From To Value

From To Value

8. Check if the transmission controller of tranny A-TRC is defective. Check the resistance of the transmission con-
troller of tranny A-TRC.
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5530-05 - Open circuit at clutch Kr

Control Module: TCU
Context:
neutral. The operator has to slow down the vehicle and must shift the gear selector into neutral position. If a failure
at another clutch is pending, the Transmission Control Unit A-TRANS detects a severe failure that disables control of
system.
Cause:
There is an open circuit at clutch Kr of the transmission controller of tranny A-TRC. The measured resistance value

is defective.
Solution:

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and to the pin 17.
5.
10.

From To Value

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5536-00 - Hydraulic oil temperature is very high

Context:
Hydraulic oil temperature is very high.
Cause:

2. The hydraulic oil temperature is over 125 °C.
Solution:
2. Bring the machine to a safe stop, and turn the engine OFF immediately. Replace the hydraulic oil temperature
sensor.
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5536-16 - Hydraulic oil temperature is high

Context:
Hydraulic oil temperature is high.
Cause:

2. The Hydraulic oil temperature is between 110 – 115 °C.
Solution:
2. Idle the machine and monitor the temperature. Wait until the hydraulic oil temperature reach the proper tempera-
ture and restart the machine.
A. If the hydraulic oil temperature rises again, idle the machine and continue with Step 3.
B. If the hydraulic oil temperature within proper range continue to work monitoring the temperature.
3. Clean the radiator or operate the fan reverser. Wait until the hydraulic oil temperature reach the proper temperature
A. If the hydraulic oil temperature rises again, idle the machine and continue with Step 4.
4. Check the hydraulic oil level. Wait until the hydraulic oil temperature reach the proper temperature and restart the
machine.
A. If the hydraulic oil temperature rises again, idle the machine and replace the hydraulic oil temperature sensor.
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5540-03 - Short circuit to battery voltage at converter clutch

(regulator valve)
Control Module: TCU
Context:
control.
Cause:
There is a short circuit to battery voltage at the converter clutch.

is defective.
Solution:

and to the pin 5.
5.
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39.

From To Value
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5540-04 - Short circuit to ground at converter clutch (regulator

valve)
Control Module: TCU
Context:
control.
Cause:
There is a short circuit to ground at the converter clutch.

is defective.
Solution:

and to the pin 5.
5.
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39.

From To Value
B. If there is no continuity, connect X-TECM to the Transmission Control Unit A-TRANS and continue with Step 7.
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5540-05 - Open circuit at converter clutch (regulator valve)

Control Module: TCU
Context:
control.
Cause:
There is an opened circuit at the converter clutch.

is defective.
Solution:

and to the pin 5.
5.
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39.

From To Value

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5560-03 - Short circuit to battery voltage at relay reverse warning

alarm
Control Module: TCU
Context:
control.
Cause:
There is a short circuit to battery voltage at relay reverse warning alarm. The Transmission Control Unit A-TRANS
detected a wrong voltage at the output pin, that looks like a short circuit to battery voltage.

3. The backup alarm device H-BU_ALARM is defective.
4. The Smart Fuse Box A-SFB is defective.
Solution:
2. Check of the cable that connect the backup alarm device H-BU_ALARM.
been resolved.
3. Check the harness between the Smart Fuse Box A-SFB and the backup alarm device H-BU_ALARM for a short
circuit to battery voltage condition.
Disconnect the connector X-X4 form the Smart Fuse Box A-SFB.
From To Value
Connector X-X4 pin 21 Chassis ground There should be no voltage

4. Check if the backup alarm device H-BU_ALARM is defective.
Check the resistance of the backup alarm device.
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A. If a problem is found, replace the tbackup alarm device.
B. If there are no problems, replace the Smart Fuse Box A-SFB.
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5560-05 - Open circuit at relay reverse warning alarm

Control Module: TCU
Context:
control.
Cause:
There is a short circuit to battery voltage at relay reverse warning alarm. The Transmission Control Unit A-TRANS
detected a wrong voltage at the output pin, that looks like a short circuit to battery voltage.

3. The backup alarm device H-BU_ALARM is defective.
4. The Smart Fuse Box A-SFB is defective.
Solution:
2. Check of the cable that connect the backup alarm device H-BU_ALARM.
been resolved.
3. Check the harness between the Smart Fuse Box A-SFB and the backup alarm device H-BU_ALARM for a short
circuit to battery voltage condition.
Disconnect the connector X-X4 form the Smart Fuse Box A-SFB.
From To Value
Connector X-X4 pin 21 Chassis ground There should be no voltage

4. Check if the backup alarm device H-BU_ALARM is defective.
Check the resistance of the backup alarm device.
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A. If a problem is found, replace the tbackup alarm device.
B. If there are no problems, replace the Smart Fuse Box A-SFB.
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5657-02 - Incorrect Anti-tamper checksum sent by Engine Controller

Control Module: UCM
Context:
The A-UCM detects an error on the ECU messages checksum; as a consequence Limitation of Torque and Speed.
Cause:
Incorrect Anti-tamper checksum sent by engine ECU.

2. The harness of busses CAN 1 is damaged.
Solution:


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5657-09 - Anti-tamper checksum not sent by Engine Controller

Control Module: UCM
Context:
The A-UCM detects an error on the ECU messages checksum; as a consequence Limitation of Torque and Speed.
Cause:
Anti-tamper checksum not sent by engine ECU.

2. The harness of busses CAN 1 is damaged.
Solution:


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5660-02 - Slippage at clutch K1

Control Module: TCU
Context:
control of system.
VPS2).
The park brake is operating, also all functions which use ADM 1 to ADM 8 are disabled. The Transmission Control
Unit A-TRANS shifts the transmission to neutral position.
Cause:
The Transmission Control Unit A-TRANS calculates a differential speed at closed clutch K1. If this calculated value
is out of range, the Transmission Control Unit A-TRANS interprets this as a slipping clutch.

2. The pressure at clutch K1 is low.
3. The main pressure is low.
4. The intermediate speed sensor B-IS_S or the harness to the Transmission Control Unit A-TRANS or the connec-
tors are defective.
5. The output speed sensor B-OSS or the harness to the Transmission Control Unit A-TRANS or the connectors are
defective.
6. The clutch is defective.
Solution:
2. Check the pressure at clutch K1.
A. If a problem is found, repair the transmission as needed.

3. Check the main pressure into the transmission system.
A. If a problem is found, repair the system as needed.

4. Check for the following related faults:
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5160-12 - Logical error at internal speed input (55.640)
5170-12 - Logical error at output speed input (55.640)
5160-03 - Short circuit to battery voltage or open circuit at internal speed input (55.640)
5160-04 - Short circuit to ground at internal speed input (55.640)
5170-03 - Short circuit to battery voltage or open circuit at output speed input (55.640)
5170-04 - Short circuit to ground at output speed input (55.640)
A. If any of the listed faults are active, diagnose them first and then return to this fault.
B. If none of the listed faults are active, replace the clutch.
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Control Module: TCU
Context:
control of system.
Cause:

tors are defective.
defective.
Solution:


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48083742_EN 31/07/2018
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Control Module: TCU
Context:
control of system.
Cause:

tors are defective.
defective.
Solution:


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48083742_EN 31/07/2018
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Control Module: TCU
Context:
Cause:

tors are defective.
5. The turbine speed sensor B-TS_S or the harness to the Transmission Control Unit A-TRANS or the connectors
are defective.
Solution:


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5150-12 - Logical error at turbine speed input (55.640)
5150-03 - Short circuit to battery voltage or open circuit at turbine speed input (55.640)
5150-04 - Short circuit to ground at turbine speed input (55.640)
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5680-02 - Slippage at clutch Kv

Control Module: TCU
Context:
Cause:
The Transmission Control Unit A-TRANS calculates a differential speed at closed clutch Kv. If this calculated value

2. The pressure at clutch Kv is low.
tors are defective.
are defective.
Solution:
2. Check the pressure at clutch Kv.


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5685-02 - Slippage at clutch Kr

Control Module: TCU
Context:
Cause:
The Transmission Control Unit A-TRANS calculates a differential speed at closed clutch Kr. If this calculated value

2. The pressure at clutch Kr is low.
tors are defective.
are defective.
Solution:
2. Check the pressure at clutch Kr.


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5700-00 - Overtemp Sump

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS measures a temperature in the oil sump that is over the allowed threshold.

2. Incorrect level of oil into the transmission.
Solution:
2. Cool down the machine.
Check the oil level of the transmission.
A. If a problem is found, restore the oil level of the transmission.

A. If a problem is found, replace the connector B-HOT.
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5710-00 - Overtemp Retarder

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS measures a temperature in the retarder oil that is over the allowed threshold.

Solution:

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5720-00 - Overspeed Engine

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS measures an engine speed above the defined threshold.

Solution:

Step 4.
5.
3 and 19.
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From To Value

7. Check the harness between the engine speed sensor B-ES_S and the Transmission Control Unit A-TRANS for
Disconnect the connector X-ESS from the engine speed sensor B-ES_S.
From To Value
Connector X-TECM pin 19 Connector X-ESS pin 1 There should be continuity

8. Check if the engine speed sensor B-ES_S is defective.
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5730-00 - Differential pressure oil filter

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS measures a voltage at the differential pressure switch that is out of the
allowed range.

2. The hydraulic oil filter is polluted.
4. The hydraulic filter pressure switch SW-PHF is defective.
Solution:
Check the efficiency of the hydraulic oil filter.
A. If a problem is found, replace the hydraulic oil filter.

3. Check if the connector X-PHF is connected to the hydraulic filter pressure switch SW-PHF.

4. Disconnect the connector X-PHF from the hydraulic filter pressure switch SW-PHF.
Check the integrity of the connector X-PHF and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-PHF.
B. If there are no problems, connect the connector X-PHF to the hydraulic filter pressure switch SW-PHF and
and to the pin 23.
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6.
17.

7. Check the harness between the hydraulic filter pressure switch SW-PHF and the Unit Control Module A-UCM for
From To Value
Connector X-UCM3A pin 17 Chassis ground There should be no continuity

8. Check the harness between the hydraulic filter pressure switch SW-PHF and the Unit Control Module A-UCM for
a short circuit to battery voltage condition.
From To Value
Connector X-UCM3A pin 17 Chassis ground There should be no voltage
B. If there is no voltage, connect the connector X-UCM3A to the Unit Control Module A-UCM and continue with
Step 9.
9. Disconnect the connector X-PHF from the hydraulic filter pressure switch SW-PHF.
Check if the hydraulic filter pressure switch SW-PHF is defective.
A. If a problem is found, replace the hydraulic filter pressure switch SW-PHF.
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5740-02 - Slippage at converter lockup clutch

Control Module: TCU
Context:
The lockup clutch is disabled immediately by the system. After fault code was displayed, while the transmission is in
neutral position, the lockup clutch will be enabled again.
Cause:
The Transmission Control Unit A-TRANS calculates a differential speed at closed converter lockup clutch. If this
calculated value is out of range, the Transmission Control Unit A-TRANS interprets this as a slipping clutch.

2. The pressure at converter lock up clutch is low.
4. The engine speed sensor B-ES_S or the harness to the Transmission Control Unit A-TRANS or the connectors
are defective.
are defective.
Solution:
2. Check the pressure at converter lockup clutch.


5140-12 - Logical error at engine speed input (55.640)
5140-03 - Short circuit to battery voltage or open circuit at engine speed input (55.640)
5140-04 - Short circuit to ground at engine speed input (55.640)
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5745-15 - Overspeed output

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS measures a transmission output speed above the defined threshold.

Solution:

Step 4.
Step 5.
4 and 62.
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From To Value

7. Check the harness between the output speed sensor B-OSS and the Transmission Control Unit A-TRANS for an
open circuit condition.
Disconnect the connector X-OSS from the output speed sensor B-OSS.
From To Value
Connector X-TECM pin 62 Connector X-OSS pin 2 There should be continuity

8. Check if the output speed sensor B-OSS is defective.
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5755-15 - Transmission input torque overload

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS calculates a transmission input torque above the defined threshold.

defective.
Solution:

tinue with Step 4.
5.
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46 and 49.

From To Value

Disconnect the connector X-TCOT from the gear oil temperature sensor B-GOT.
From To Value
Connector X-TECM pin 49 Connector X-TCOT pin 1 There should be continuity

8. Check if the gear oil temperature sensor B-GOT is defective.
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5760-00 - Overtemp converter output

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS measures an oil temperature at the gear oil temperature sensor B-GOT
output that is over the allowed threshold.

Solution:


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5810-03 - Short circuit to battery voltage at power supply for

sensors
Control Module: TCU
Cause:
There is a short circuit to battery voltage at the power supply for sensors. The Transmission Control Unit A-TRANS
measures more than 6 V at the pin AU1 (Sensor supply: 5 V).

2. The connector or the harness are damaged or the connectors are not installed.
Solution:
2. Check the integrity of harnesses and connectors of the sensors that are supplied from the power supply at pin
AU1.
been resolved.
3. Check the power supply at pin AU1 for a short circuit to battery voltage condition.
The voltage should be approximately 5 V.
A. If a problem is found, replace the defective component.
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5810-04 - Short circuit to ground at power supply for sensors

Control Module: TCU
Cause:
There is a short circuit to ground at the power supply for sensors. The Transmission Control Unit A-TRANS measures
less than 4 V at the pin AU1 (Sensor supply: 5 V).

Solution:
2. Check the integrity of harnesses and connectors of the sensors that are supplied from the power supply at pin
AU1.
been resolved.
3. Check the power supply at pin AU1 for a short circuit to ground condition.
The voltage should be approximately 5 V.
A. If a problem is found, replace the defective component.
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5820-03 - High voltage at battery

Control Module: TCU
Context:
The Transmission Control Unit A-TRANS detects a severe failure that disables control of system. The Transmission
Control Unit A-TRANS shuts off all solenoid valves and also both common power supplies ( VPS1, VPS2). The park
brake is operating, also all functions which use ADM 1 to ADM 8 are disabled.
Cause:
The Transmission Control Unit A-TRANS measures a voltage at power supply that is higher than 32.5 V (device
voltage: 24 V).

Solution:
2. Check the efficiency of the power supply batteries.
A. If a problem is found, replace the defective battery.

3. Check the integrity of harnesses and connectors that connect the batteries to the Transmission Control Unit
A-TRANS.
been resolved.
B. If you do not find damage and the display indicates only normal readings, replace the Transmission Control
Unit A-TRANS.
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5820-04 - Low voltage at battery

Control Module: TCU
Context:
Cause:
The Transmission Control Unit A-TRANS measures a voltage at power supply that is lower than 18 V (device voltage:
24 V).

Solution:
2. Check the efficiency of the power supply batteries.
A. If a problem is found, replace the defective battery.

3. Check the integrity of harnesses and connectors that connect the batteries to the Transmission Control Unit
A-TRANS.
been resolved.
B. If you do not find damage and the display indicates only normal readings, replace the Transmission Control
Unit A-TRANS.
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5830-02 - Error at valve power supply VPS1

Control Module: TCU
Context:
Cause:
The Transmission Control Unit A-TRANS switchs ON VPS1 and measures that VPS1 is OFF or Transmission Control
Unit A-TRANS switchs OFF VPS1 and measures that VPS1 is still ON.

3. The permanent power supply KL30 is missing.
Solution:
2. Check the integrity of harnesses and connectors that connect the gearbox to the Transmission Control Unit
A-TRANS.
been resolved.
3. Check the harnesses between the gearbox and the Transmission Control Unit A-TRANS for a short circuit to
battery voltage condition.
A. If a problem is found, find and replace the damaged component.

ground condition.
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5840-02 - Error valve power supply VPS2

Control Module: TCU
Context:
Cause:
The Transmission Control Unit A-TRANS switchs ON VPS2 and measures that VPS2 is OFF or Transmission Control
Unit A-TRANS switchs OFF VPS2 and measures that VPS2 is still ON.

3. The permanent power supply KL30 is missing.
Solution:
B. If the fault is no longer present or in an inactive state,the fault may be intermittent and not currently active.
2. Check the integrity of harnesses and connectors that connect the gearbox to the Transmission Control Unit
A-TRANS.
been resolved.

ground condition.
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5860-03 - Short circuit to battery voltage at display output

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS sends data to the display A-DSP and measures always a high voltage level
on the connector X-DSP. There is a short circuit to battery voltage at the display A-DSP output.

3. The display A-DSP is defective.
Solution:
2. Check if the connector X-DSP is connected to the display A-DSP.

3. Disconnect the connector X-DSP from the display A-DSP.
Check the integrity of the connector X-DSP and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-DSP.

25 and 26.
tinue with Step 5.
5. Check the harness between the display A-DSP and the Transmission Control Unit A-TRANS for a short circuit to
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From To Value
Connector X-DSP pin 1 Connector X-DSP pin 13 There should be no continuity
A. If there is continuity, find and replace the damaged wire.
B. If there is no continuity, replace the display A-DSP.

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5860-04 - Short circuit to ground at display output

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS sends data to the display A-DSP and measures always a high voltage level
on the connector X-DSP. There is a short circuit to ground at the display A-DSP output.

3. The display A-DSP is defective.
Solution:
2. Check if the connector X-DSP is connected to the display A-DSP.

3. Disconnect the connector X-DSP from the display A-DSP.
Check the integrity of the connector X-DSP and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-DSP.

25 and 26.
tinue with Step 5.
5. Check the harness between the display A-DSP and the Transmission Control Unit A-TRANS for a short circuit to
ground condition.
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From To Value
A. If there is continuity, find and replace the damaged wire.
B. If there is no continuity, replace the display A-DSP.

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5880-02 - Illegal ID request via Can

Control Module: TCU
Context:
The Transmission Control Unit A-TRANS detects a severe failure that disables control of system.
Cause:
Illegal ID Request via CAN.
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5890-02 - General EEPROM fault

Control Module: TCU
Context:
control.
Cause:
There is a general EEPROM fault. The Transmission Control Unit A-TRANS can not read the non volatile memory.

Solution:
A. If the fault is present and active, replace the Transmission Control Unit A-TRANS.
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5900-13 - Configuration lost

Control Module: TCU
Context:
Cause:
The Transmission Control Unit A-TRANS has lost the correct configuration and can not control the transmission.

2. Interference during the saving of the data on the non volatile memory.
3. The Transmission Control Unit A-TRANS is brand new.
4. The Transmission Control Unit A-TRANS is taken from another vehicle.
Solution:
A. If the fault is present and active, reprogram the correct configuration for the vehicle (e.g. with cluster controller,
...).
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5910-13 - Application error

Control Module: TCU
Context:
Cause:
There is an application error, something of the application is wrong.

Solution:
A. If the fault is present and active, replace the Transmission Control Unit A-TRANS.
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5930-07 - Clutch failure

Control Module: TCU
Context:
Cause:
The Automatic Emergency Braking (AEB) was not able to adjust the clutch filling parameters. One of the AEB-Values
is out of limit. The Transmission Control Unit A-TRANS shows also the affected clutch on the display.

Solution:
A. If the fault is present and active, check the clutch and repair or replace if necessary.
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5930-13 - Clutch adjustment data lost or inchpedal calibration data

lost
Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS is not able to read the correct clutch adjustment parameters.

2. Interference during the saving of the data on the non volatile memory.
3. The Transmission Control Unit A-TRANS is brand new.
Solution:
A. If the fault is present and active, execute the automatic calibration of shifting elements.
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5940-11 - Substitute clutch control

Control Module: TCU
Context:
Cause:
The transmission input torque is out of allowed range.

2. The engine retarder torque is wrong.
3. The engine torque is wrong.
4. The engine speed signal is defective.
Solution:
5120-03 - Short circuit to battery voltage or open circuit at retarder / torque converter temperature sensor
input (55.640)
5120-04 - Short circuit to ground at retarder / torque converter temperature sensor input (55.640)
5430-02 - Enginge torque signal defective (55.640)
5140-03 - Short circuit to battery voltage or open circuit at engine speed input (55.640)
5140-04 - Short circuit to ground at engine speed input (55.640)
5140-12 - Logical error at engine speed input (55.640)
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65562-03 - Terminal 50 - Always On

Control Module: ECU
Context:
The Engine Control Unit (ECU) has sensed that the raw battery voltage is greater than the high limit established in
the ECU for longer than 1 s. This fault should reset if battery voltage stays below threshold for longer than 0.5 s.
Cause:
Battery voltage at the ECU is too high.
1. Faulty wiring.
2. Faulty alternator / regulator.
Solution:
1. Verify the fault is still present and in an active state.
A. If fault is still present and active, continue with Step 2.
B. If the fault is not present, the fault may be intermittent. Check for an intermittent fault. If no faults are found,
clear fault code. Return machine to service.
2. Check ECU voltages. Verify the condition of the ECU wiring harness. The voltage reading should be between 22
– 26 V
A. If the voltage reading is greater than 26 V, there is a short to high source in the harness. Locate and repair
damage.
B. If the voltage reading is in range, continue with Step 3.

3. Start the combine engine. Use the Display Monitor diagnostics capability to view "Parameter" status, to check the
battery voltage range.
Increase the engine RPM to high idle (maximum) and check voltage range.
The acceptable voltage range for the module is 22 – 26 V volts when the engine is running.
A. If the voltage reading is greater than 26 V, the alternator and/or regulator has failed, and is producing excessive
voltage. Replace the alternator.
B. If the voltage reading is between 22 – 26 V, check for intermittent fault.
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65564-03 - Water detected in Fuel

Control Module: ECU
Context:
The fuel filter separates any water from the fuel and collects it in a special tank. This error path is set if this tank is
full and not emptied over a certain time.
Cause:
After preliminary debouncing, the fuel filter water level sensor signal is active.
1. Excess water in the fuel supply.

2. Faulty water in fuel sensor B-WIF, wiring or internal (mechanical and/or electrical) failure.
3. Faulty A-ECU, software.
Solution:
has been resolved.
3. Check fuel for water contamination.
A. If there is water contamination, continue with Step 4.
B. If there is no water contamination, continue with Step 5.

4. Verify proper water in fuel sensor B-WIF operation.
Purge fuel supply system, replace fuel filter(s) and refill with fuel that is free of water contamination.
Start and run engine for 5 min.
Check for code to return to active status.
A. If code returns in an active status, replace water in fuel sensor B-WIF.
B. If code remains inactive, return the machine to service.

5. Check for open, short and grounded circuit conditions in the water in fuel sensor B-WIF circuit.
Disconnect the connector X-WIF.
Disconnect the vehicle harness from the A-ECU at connector X-EDC7.
Disconnect the connector X-LC5 X- from the fuse box LC5.
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Use a multimeter to perform the following tests, on the vehicle harness:
From To Value
Connector X-WIF pin 1 Connector X-EDC7 (Plug) pin 42 There should be continuity
Connector X-WIF pin 2 Chassis ground There should be continuity
Connector X-WIF (Receptacle) pin Connector X-LC5 (Receptacle) pin There should be continuity
3 9A
Then use the multimeter to perform the following tests, on the vehicle harness:
From To Value
Connector X-WIF pin 1 Connector X-WIF pin 2 There should be no continuity
Connector X-WIF pin 1 Connector X-WIF (Receptacle) pin There should be no continuity
3
Connector X-WIF pin 2 Connector X-WIF (Receptacle) pin There should be no continuity
3
Then use the multimeter to perform the following tests, on the vehicle harness:
From To Value
Connector X-WIF pin 1 Chassis ground There should be no continuity
Connector X-WIF (Receptacle) pin Chassis ground There should be no continuity
3
A. If the results are not as expected for any of the wiring tests listed above, there is an open, short or grounded
circuit condition in the wiring. Locate the fault and repair the wiring.
B. If the results are as expected in all of the wiring tests listed above, the wiring is ok. Leave the connector X-WIF
disconnected and continue with Step 6.
6. Check for key switch voltage supply to water in fuel sensor B-WIF.
Put the key switch in the ON position.
Use a multimeter to perform the following test, on the vehicle harness side:
From To Value
Connector X-WIF (Receptacle) pin Chassis ground There should be key switch voltage
3
Connector X-WIF pin 1 Chassis ground There should be no key switch
voltage
A. If key switch voltage is not present in the first check or present in the second check, locate the fault and repair
the wiring.
B. If there is key switch voltage present in the first check and not present in the second check, continue with Step
7.
7. Replace the water in fuel sensor B-WIF.
Use the EST to verify the status of this fault.
B. If the fault has not been resolved, check the A-ECU for the appropriate software and re-flash, if necessary.
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65574-03 - Engine Controller battery voltage too High

Control Module: ECU
Context:
The Engine Control Unit ( A-ECU) receives the direct power supply from battery. If the A-ECU determines that battery
voltage is too high, this fault will occur.
Cause:
Battery voltage is too high.
1. Faulty battery
2. Faulty charging system
3. Faulty A-ECU supply wiring, open circuit
4. Faulty A-ECU, software
Solution:
has been resolved.
3. Check the battery voltage.
The engine must be running.
From To Value
Connector X-563 Connector X-566 There should be about 24 V
A. If there is more than 24 V, continue with Step 4
B. If there is about 24 V, continue with Step5.

4. Check the charging system for proper operation.
A. If the charging system is not functioning properly, repair the charging system as necessary.
B. If the charging system is functioning properly, check the A-ECU for the appropriate software and re-flash, if
necessary.
5. Verify the integrity of the F-LC6F1 fuse.
Verify that the fuse is properly installed.
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Visually check the fuse.
If necessary, use a multimeter to verify the continuity between the two poles of the fuse.
A. If the fuse is broken or damaged, replace the fuse.

6. Check the A-ECU supply wiring.
Disconnect the X-LC6 connector of the crank control.
Disconnect the X-EDC7 connector of the A-ECU.
From To Value
Connector X-LC6 (Receptacle) pin 5 Connector X-EDC7 (Plug) pin 2 There should be continuity
A. If there is no continuity on one or more checks, there is a failure in the A-ECU supply wiring. Locate and repair
the failed conductor.
B. If there is continuity on all checks, check the A-ECU for the appropriate software and re-flash, if necessary.

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65574-04 - Engine Controller battery voltage too Low

Control Module: ECU
Context:
The Engine Control Unit ( A-ECU) receives the direct power supply from battery. If the A-ECU determines that battery
voltage is too low, this fault will occur.
Cause:
Battery voltage is too low.
1. Faulty battery.
2. Engine cranked for extended period of time.
3. Faulty charging system.
4. Faulty A-ECU supply wiring.
Solution:
has been resolved.
From To Value
A. If there is less than 24 V, charge the battery and then perform a load test.
If the battery passes the load test, continue with Step 4.
If the battery fails the load test, continue with Step 7.
B. If there is about 24 V, continue with Step 4.

4. Check the voltage supply to the A-ECU.
Disconnect the connector X-EDC7.
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From To Value
Connector X-EDC7 (Plug) pin 2 Chassis ground There should be about 24 V
A. If there is less than 24 V on one or more checks, there is a failure in the A-ECU supply wiring. Locate and
repair the failed conductor.
B. If there is about 24 V on all checks, leave the connector X-EDC7 disconnected and continue with Step 5.
5. Check the ground connection of the A-ECU.
From To Value
Connector X-EDC7 (Plug) pin 5 Chassis ground There should be continuity
A. If there is no continuity on one or more the checks, there is a failure in the A-ECU ground wiring. Locate and
B. If there is continuity on all checks, continue with Step 6.

B. If the charging system is functioning properly, continue with Step 7.

7. Replace the battery.
A. If the fault has been resolved, perform a parasitic draw test to measure excessive current draw from the battery.
If an excessive draw is found, locate and repair as necessary and then return the machine to service.

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65576-03 - Engine Controller High side supply #2 to Grid heater -

Short to battery
Control Module: ECU
Context:
A short circuit to battery (SCB) of the main relay 1 can only be detected if it is switched off during after run (low side
actuators must also be deactivated). The monitoring of main relay 1 for an SCB error is stopped if a finalized short
circuit to ground of the main relay 1 is detected OR a low side actuator detects a 'no load' error (system ok, no SCB
possible) because both high and low side power stage are switched off.
Cause:
A 'short circuit to battery' longer than 100 ms is reported by the hardware.
1. Faulty of one of the component connected to main relay 1, internal failure.

2. Faulty main relay 1, internal failure.
Solution:
or shorts in the wiring concerned. Operate the machine while you monitor the display. Check all the components
connected to main relay 1.
has been resolved.
3. Check the ECU for the appropriate software and re-flash, if necessary.
B. If the fault has not been resolved, escalate an ASIST concern.
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65579-02 - Engine Controller Grid Heater relay circuit driver - No

Load
Control Module: ECU
Context:
The Engine Control Unit ( A-ECU) controls the grid heater relay activation on both high side and low side. If the
A-ECU detects an open circuit condition in the grid heater relay circuit, this fault will occur.
Cause:
The A-ECU has detected an open circuit condition in the grid heater relay circuit.
1. Faulty grid heater relay circuit wiring, open circuit.

2. Faulty grid heater relay, internal failure.
Solution:
has been resolved.
3. Verify the integrity of the inline GH fuse F-GH.

4. Check the grid heater relay K-GH circuit wiring for an open circuit condition.
Disconnect the A-ECU connector X-EDC7.
Disconnect the grid heater relay connector X-GHC.
Use a multimeter to perform the following continuity check on the vehicle harness:
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From To Value
Connector X-GHC pin 1 Connector X-EDC7 (Plug) pin 12 There should be continuity
Connector X-GHC pin 2 Connector X-EDC7 (Plug) pin 75 There should be continuity
A. If there is no continuity, there is an open circuit condition in the K-GH signal circuit. Locate the fault and repair
the shorted conductor.

5. Check the grid heater relay K-GH circuit wiring for an open circuit condition.
Disconnect the grid heater relay connectors GH4 and GH5 and the grid heater connector X-GH6.
Use a multimeter to perform the following continuity check on the vehicle harness:
From To Value
Connector GH5 Connector X-GH6 There should be continuity
Connector GH4 Battery + There should be continuity
A. If there is no continuity, there is an open circuit condition in the K-GH signal circuit. Locate the fault and repair

6. Replace the grid heater relay K-GH.

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65579-03 - Engine Controller Grid Heater relay circuit driver - Short

circuit to Battery
Control Module: ECU
Context:
A-ECU detects a short to high source condition in the high side supply of the grid heater relay, this fault will occur.
Cause:
The A-ECU has detected a short to high source condition in the grid heater relay high side control circuit.
1. Faulty grid heater relay circuit wiring, shorted to high source.

Solution:
has been resolved.
3. Check the grid heater relay K-GH circuit wiring for a short to high source condition.
Disconnect the A-ECU connector X-EDC7.
Disconnect the grid heater relay connector X-GHC.
Use a multimeter to perform the following voltage check on the vehicle harness:
From To Value
Connector X-GHC pin 1 Chassis ground There should be no voltage
A. If there is voltage, there is a short to high source condition in the K-GH signal circuit. Locate the fault and repair
B. If there is no voltage, leave the connectors disconnected and continue with Step 4.
4. Check the grid heater relay K-GH signal circuit at A-ECU side for a short to high source condition.
Use a multimeter to perform the following continuity check from the engine harness side:
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From To Value
Connector X-EDC7 (Plug) pin 12 Connector GH4 (pin 30) There should be no continuity
Connector X-EDC7 (Plug) pin 12 All the other pins of connector There should be no continuity
X-EDC7
A. If there is continuity, there is a short to high source condition. Locate and repair the shorted conductor.

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65579-04 - Engine Controller Grid Heater relay circuit driver - Short

circuit to Ground
Control Module: ECU
Context:
A-ECU detects a short to ground condition in the high side supply of the grid heater relay, this fault will occur.
Cause:
The A-ECU has detected a short to ground condition in the grid heater relay high side control circuit.
1. Faulty grid heater relay signal circuit, shorted to ground.

Solution:
has been resolved.
3. Check the integrity of the grid heater relay K-GH.
Remove the grid heater relay K-GH.
Use a multimeter to perform the following continuity check on the grid heater relay:
From To Value
GH5 (pin 87) Connector X-GHC (Plug) pin 2 (85) There should be no continuity
GH4 (pin 30) Connector X-GHC (Plug) pin 2 (85) There should be no continuity
A. If there is continuity, the grid heater relay is defective. Replace the component.
B. If there is no continuity, leave the grid heater relay removed and continue with Step 4.
4. Check the grid heater relay signal circuit for a short to ground condition.
Put the key switch in the OFF position.
Use a multimeter to perform the following continuity check on the engine harness side:
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From To Value
Connector X-GHC (Plug) pin 1 Chassis ground There should be no continuity
A. If there is continuity, there is a short circuit to ground in the signal circuit. Locate the fault and repair the shorted
conductor.

5. Check the grid heater relay signal circuit at ECU side for a short to ground condition.
Disconnect the X-EDC7 connector.
From To Value
Connector X-EDC7 (Plug) pin 12 Chassis ground There should be no continuity
Connector X-EDC7 (Plug) pin 12 All the other pins of connector There should be no continuity
X-EDC7
A. If there is continuity, there is a short to ground condition in the engine harness. Locate and repair the shorted
conductor.

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65585-03 - Engine Coolant Temperature Sensor - Signal Above

Range Max
Control Module: UCM
Context:
The Universal Control Module ( A-UCM) monitors the engine coolant temperature sensor B-RECTD circuit for a volt-
age higher than expected condition. If the A-UCM detects a voltage greater than 4.93 V in the B-RECTD circuit, this
fault will occur.
Cause:
The A-UCM has detected a voltage greater than 4.93 V in the engine coolant temperature sensor B-RECTD signal
circuit.
1. Faulty engine coolant temperature sensor B-RECTD circuit wiring, shorted to high source or open circuit.
2. Faulty engine coolant temperature sensor B-RECTD, internal failure.
3. Faulty A-UCM, software.
Solution:
has been resolved.
Use a multimeter to measure resistance on the coolant temperature sensor B-RECTD as follows:
From To Value
Connector X-RECT (Receptacle) Connector X-RECT (Receptacle) There should be measurable
pin 1 pin 2 resistance.
A. If the resistance is about 0 Ω or more than 1 MΩ, the coolant temperature sensor B-RECTD is defective. Re-
place the unit.
B. If there is measurable resistance, continue with Step 4.

4. Check the engine coolant temperature sensor B-RECTD signal circuit wiring for an open circuit condition.
Disconnect the connector X-RECT.
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From To Value
Connector X-RECT (Receptacle) Connector X-UCM4A (Receptacle) There should be continuity
pin 1 pin 12
pin 2 pin 1
A. If there is no continuity, there is an open circuit condition in the B-RECTD signal circuit. Locate the fault and
repair the broken conductor.
5. Check the engine coolant temperature sensor B-RECTD signal circuit for a short circuit condition.
From To Value
Connector X-UCM4A (Receptacle) All the other pins of connector There should be no continuity
pin 12 X-UCM4A
pin 1 X-UCM1A
A. If there is continuity, there is a short circuit condition in the B-RECTD signal circuit. Locate the fault and repair
B. If there is no continuity, leave both connectors disconnected and continue with Step 6.
6. Check the engine coolant temperature sensor B-RECTD signal circuit for a short key battery power condition.
From To Value
Connector X-UCM4A (Receptacle) Chassis ground There should be no voltage
pin 12
Connector X-UCM1A (Receptacle) Chassis ground There should be no voltage
pin 1
A. If there is voltage, there is a short to key batter power condition in the B-RECTD signal circuit. Locate the fault
and repair the shorted conductor.

7. Replace the engine coolant temperature sensor B-RECTD.
B. If the fault has not been resolved, check the A-UCM for the appropriate software and re-flash, if necessary.
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65585-04 - Engine Coolant Temperature Sensor - Signal Below

Range Min
Control Module: UCM
Context:
The Universal Control Module ( A-UCM) monitors the analog input value of the engine coolant temperature sensor
B-RECTD. If the coolant temperature sensor B-RECTD input signal is less than 200.39 mV, this fault will occur.
Cause:
The A-UCM is sensing an analog input signal less than 200.39 mV in the engine coolant temperature sensor B-RECTD
signal circuit.
1. Faulty engine coolant temperature sensor B-RECTD signal circuit, shorted to ground.
2. Faulty engine coolant temperature sensor B-RECTD, internal failure.
Solution:
has been resolved.
From To Value
pin 1 pin 2 resistance.
place the unit.

4. Check the coolant temperature sensor B-RECTD signal circuit for a short to ground condition.
From To Value
Connector X-RECT (Receptacle) Chassis ground There should be no continuity
pin 1
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A. If there is continuity, there is a short circuit to ground in the engine harness. Locate the fault and repair the
shorted conductor.

5. Check the coolant temperature sensor B-RECTD signal circuit at A-UCM side for a short to ground condition.
Disconnect the X-UCM4A connector.
From To Value
Connector X-UCM4A (Receptacle) Chassis ground There should be no continuity
pin 12
A. If there is continuity, there is a short to ground condition in the engine harness. Locate and repair the shorted
conductor.
B. If there is no continuity, check the A-UCM for the appropriate software and re-flash, if necessary.
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65585-12 - Engine Coolant Temperature Sensor - Signal Not

Plausible
Control Module: UCM
Context:
The Universal Control Module ( A-UCM) monitors the analog input value of the engine coolant temperature sensor
B-RECTD. If the coolant temperature sensor B-RECTD input signal is not plausible, this fault will occur.
Cause:
The A-UCM has detected an input signal of the coolant temperature sensor B-RECTD not plausible.
1. Faulty engine coolant temperature sensor B-RECTD signal circuit, shorted to ground, shorted to a high source or
open circuit.
2. Faulty engine coolant temperature sensor B-RECTD, failed internally.
Solution:
has been resolved.
From To Value
pin 1 pin 2 resistance
place the unit.

4. Check the engine coolant temperature sensor B-RECTD signal circuit wiring for a short to ground condition.
Use a multimeter to check for continuity on the engine harness as follows:
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From To Value
pin 1
A. If there is continuity, there is a short circuit to ground in the B-RECTD signal circuit. Locate the fault and repair
B. If there is no continuity, leave the connector X-RECT disconnected and continue with Step 5.
5. Check the engine coolant temperature sensor B-RECTD signal circuit for an open circuit condition.
Use a multimeter to check for continuity on the engine harness as follows:
From To Value
pin 1 pin 12
pin 2 pin 1
repair the conductor.
B. If there is continuity, leave the connector X-RECT disconnected and continue with Step 6.
6. Check the engine coolant temperature sensor B-RECTD signal circuit wiring for a voltage source condition.
Use a multimeter to check for voltage on the engine harness as follows:
From To Value
Connector X-RECT (Receptacle) Chassis ground There should be no voltage
pin 1
Connector X-RECT (Receptacle) Chassis ground There should be no voltage
pin 2
A. If there is voltage, there is a voltage source condition in the B-RECTD signal circuit. Locate the fault and repair
B. If there is no voltage, check the A-UCM for the appropriate software and re-flash, if necessary.
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65596-03 - Ambient Air Temperature Sensor failure - Signal too high

Control Module: UCM
Context:
The Engine Control Unit (ECU) monitors ambient air temperature by the humidity and ambient temperature sensor
B-HT. If the ECU detects a voltage greater than 4.90 V for more than 500 ms in the air temperature signal, this fault
will occur.
Cause:
The ECU has detected a voltage greater than 4.90 V for longer than 500 ms in the ambient air temperature signal of
the B-HT sensor.
1. Faulty ambient air temperature circuit wiring, short circuit, open circuit or shorted to external source.
2. Faulty humidity and ambient temperature sensor, internal failure.
3. Faulty ECU, software or internal failure.
Solution:
has been resolved.
3. Check the integrity of the humidity and ambient temperature sensor B-HT.
Put the key in the off position.
Disconnect the connector X-HTS and remove the B-HT sensor.
Use a multimeter to check the continuity between the following points on the component side:
From To Value
B-HT pin 4 B-HT pin 1 There should be no continuity
A. If there is continuity, there is an internal short circuit. Replace the sensor, then repeat the Step 1.
4. Check the humidity and ambient temperature sensor circuit wiring for an open circuit condition.
Disconnect the connector X-ECU.
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Use a multimeter to check the continuity between the following points on the engine harness side:
From To Value
Connector X-HTS (Receptacle) pin Connector X-ECU (Receptacle) pin There should be continuity
1 90
3 43
4 40
A. If there is no continuity, there is an open circuit condition in the B-HT circuit wiring. Locate the fault and repair
the broken conductor.
5. Check the humidity and ambient temperature sensor circuit wiring for a short circuit condition.
From To Value
Connector X-HTS (Receptacle) pin Connector X-ECU (Receptacle) pin There should be no continuity
1 40
4 90
Connector X-ECU (Receptacle) pin Connector X-ECU (Receptacle) pin There should be no continuity
40 90
Connector X-HTS (Receptacle) pin Connector X-HTS (Receptacle) pin There should be no continuity
1 4
A. If there is continuity, there is a short circuit condition in the B-HT circuit wiring. Locate the fault and repair the
shorted conductor.
6. Check the humidity and ambient temperature sensor circuit wiring for a short to key battery power condition.
Use a multimeter to check the voltage between the following points on the engine harness side:
From To Value
Connector X-HTS (Receptacle) pin Chassis ground There should be no voltage
4
Connector X-ECU (Receptacle) pin Chassis ground There should be no voltage
40
A. If there is voltage, there is a short to key batter power condition in the air temperature signal circuit. Locate the
fault and repair the shorted conductor.
B. If there is no voltage, check the ECU for the appropriate software and re-flash, if necessary.
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65596-04 - Ambient Air Temperature Sensor failure - Signal too low

Control Module: UCM
Context:
The Engine Control Unit (ECU) monitors ambient air temperature by the humidity and ambient temperature sensor
B-HT. If the ECU detects a voltage lower than 200.39 mV for more than 500 ms in the air temperature signal, this fault
will occur.
Cause:
The ECU has detected a voltage lower than 200.39 mV for longer than 500 ms in the ambient air temperature signal
of the B-HT sensor.
1. Faulty ambient air temperature circuit wiring, short circuit or shorted to ground.
Solution:
has been resolved.
3. Check the integrity of the humidity and ambient temperature sensor B-HT.
Put the key in the off position.
Disconnect the connector X-HTS and remove the B-HT sensor.
Use a multimeter to check the continuity between the following points on the component side:
From To Value
A. If there is continuity, there is an internal short circuit. Replace the sensor, then repeat the Step 1.
4. Check the humidity and ambient temperature sensor circuit wiring for an open circuit condition.
Disconnect the connector X-ECU.
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From To Value
1 90
3 43
4 40
A. If there is no continuity, there is an open circuit condition in the B-HT circuit wiring. Locate the fault and repair
the broken conductor.
5. Check the humidity and ambient temperature sensor circuit wiring for a short circuit condition.
From To Value
3 40
4 43
Connector X-ECU (Receptacle) pin Connector X-ECU (Receptacle) pin There should be no continuity
40 43
Connector X-HTS (Receptacle) pin Connector X-HTS (Receptacle) pin There should be no continuity
3 4
A. If there is continuity, there is a short circuit condition in the B-HT circuit wiring. Locate the fault and repair the
shorted conductor.
6. Check the humidity and ambient temperature sensor circuit wiring for a short to ground condition.
From To Value
Connector X-HTS (Receptacle) pin Chassis ground There should be no continuity
4
Connector X-HTS (Receptacle) pin Chassis ground There should be no continuity
1
A. If there is continuity, there is a short to key batter power condition in the air temperature signal circuit. Locate
the fault and repair the shorted conductor.
B. If there is no continuity, check the ECU for the appropriate software and re-flash, if necessary.
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65646-03 - Minimum Number of Injections Not Reached – Stop

Engine
Control Module: ECU
Context:
The injector shut-off function can switch off a single injector valve or an entire injection bank if a defect has been
detected in this component (monitoring is performed in other fault paths). If too many cylinders are shut down by the
shut-off function it is no longer possible to run the engine securely and it has to be shut down entirely. In this case
the fault path at hand is set.
Cause:
The number of cylinders with error or shut off exceeds 2 over 1 test cycles (injections).
1. Individual shut-off error of the injector/bank.

2. Faulty ECU, software.
Solution:
2. Check the presence of other related faults.
A. If one or more errors in injectors or banks is detected, resolve the fault. Then, repeat the Step 1.
B. If no other injector/bank fault is detected, continue with Step 3.

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65660-02 - Injection Processor (CY33X) Error – Injections Limited

By Software
Control Module: ECU
Context:
Fault path for errors in the power stage component of the common rail (or unit injection, for P342) system. The power
stage monitors itself and reports detected errors to the ECU. Monitoring is performed once per camshaft revolution.
Cause:
Power stage component is in 'TESTMODE' (used to test injection failures) longer than No 3 camshaft revolutions.

2. Faulty ECU, failed internally.
Solution:
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65660-03 - Injection Processor (CY33X) Error – Internal Reset /

Clock Loss / Voltage Too Low
Control Module: ECU
Context:
Cause:
An internal reset is present longer than No 3 camshaft revolutions.
1. Faulty ECU, clock error.

2. Faulty ECU, power supply voltage.
4. Faulty ECU, internal failure.
Solution:
has been resolved.

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From To Value
B. If there is about 24 V on all checks, leave the connector X-EDC7 disconnected and continue with step 5.

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65660-04 - Injection Processor (CY33X) Error – Unlocked /

Initialization Failure
Control Module: ECU
Context:
Cause:
After a reset the power stage component was not successfully initialized after No 3 camshaft revolutions.

Solution:
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65660-12 - Injection Processor (CY33X) Error – SPI Communication

Failure
Control Module: ECU
Context:
Cause:
Disturbed SPI communication, invalid command or a checksum error in the power stage message is present longer
than No 3 camshaft revolutions.

Solution:
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65683-03 - Turbine speed - Signal too high

Control Module: TCU
Context:
The Transmission Control Unit (TCU / A-TRANS) monitors the turbine speed sensor B-TS_S circuit for a voltage
higher than expected condition. If the A-TRANS detects a voltage too high of the turbine speed signal, this fault will
occur.
Cause:
The A-TRANS has detected a voltage too high of the turbine speed signal.
1. Faulty turbine speed sensor B-TS_S circuit wiring, shorted to high source or open circuit.
2. Faulty turbine speed sensor B-TS_S, internal failure.
3. Faulty A-TRANS, software.
Solution:
has been resolved.
3. Check the integrity of the turbine speed sensor B-TS_S.
Turn the key switch in the OFF position.
Disconnect the connector X-TSS and remove the turbine speed sensor.
Use a multimeter to measure resistance between the following points on the component side:
From To Value
B-TS_S pin 1 B-TS_S pin 2 There should be measurable
resistance
A. If the resistance is about 0 Ω or infinite, the turbine speed sensor B-TS_S is defective. Replace the component.
B. If there is measurable resistance, leave the connector disconnected and continue with Step 4.
4. Check the turbine speed sensor B-TS_S signal circuit wiring for an open circuit condition.
Disconnect the connector X-TECM.
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From To Value
Connector X-TSS (Receptacle) pin Connector X-TECM (Receptacle) There should be continuity
1 pin 41
Connector X-TSS (Receptacle) pin Connector X-TECM (Receptacle) There should be continuity
2 pin 3
A. If there is no continuity, there is an open circuit condition. Locate the fault and repair the broken conductor.
5. Check the turbine speed sensor B-TS_S signal circuit wiring for a short circuit condition.
From To Value
Connector X-TECM (Receptacle) All the other pins of connector There should be no continuity
pin 41 X-TECM
A. If there is continuity, there is a short circuit condition. Locate the fault and repair the shorted conductor.
6. Check the turbine speed sensor B-TS_S circuit wiring for a short key battery power condition.
Use a multimeter to check the voltage between the following points on the harness side:
From To Value
Connector X-TECM (Receptacle) Chassis ground There should be no voltage
pin 41
Connector X-TECM (Receptacle) Chassis ground There should be no voltage
pin 3
Connector X-TSS (Receptacle) pin Chassis ground There should be no voltage
1
Connector X-TSS (Receptacle) pin Chassis ground There should be no voltage
2
A. If there is voltage, there is a short to key batter power condition. Locate the fault and repair the shorted con-
ductor.

7. Replace the turbine speed sensor B-TS_S.
B. If the fault has not been resolved, check the A-TRANS for the appropriate software and re-flash, if necessary.
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65683-04 - Turbine speed - Signal too low

Control Module: TCU
Context:
The Transmission Control Unit (TCU / A-TRANS) monitors the analog input value of the turbine speed sensor B-TS_S.
If the turbine speed sensor B-TS_S input signal is too low, this fault will occur.
Cause:
The A-TRANS is sensing an analog input signal too low in the turbine speed sensor B-TS_S signal circuit.
1. Faulty turbine speed sensor B-TS_S signal circuit, shorted to ground.

2. Faulty turbine speed sensor B-TS_S, internal failure.
3. Faulty A-TRANS, software.
Solution:
has been resolved.
3. Check the integrity of the turbine speed sensor B-TS_S.
Disconnect the connector X-TSS and remove the turbine speed sensor.
Use a multimeter to measure resistance between the following points on the component side:
From To Value
B-TS_S pin 1 B-TS_S pin 2 There should be measurable
resistance
A. If the resistance is about 0 Ω or infinite, the turbine speed sensor B-TS_S is defective. Replace the component.
B. If there is measurable resistance, leave the connector disconnected and continue with Step 4.
4. Check the turbine speed sensor B-TS_S signal circuit for a short to ground condition.
Disconnect the connector X-TECM.
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From To Value
Connector X-TECM (Receptacle) Chassis ground There should be no continuity
pin 41
Connector X-TSS (Receptacle) pin Chassis ground There should be no continuity
1
A. If there is continuity, there is a short to ground condition. Locate the fault and repair the shorted conductor.
5. Check the turbine speed sensor B-TS_S signal circuit wiring for a short circuit condition.
From To Value
Connector X-TECM (Receptacle) Connector X-TSS (Receptacle) pin There should be no continuity
pin 41 2
Connector X-TECM (Receptacle) Connector X-TSS (Receptacle) pin There should be no continuity
pin 3 1
Connector X-TECM (Receptacle) All the other pins of connector There should be no continuity
pin 41 X-TECM
Connector X-TSS (Receptacle) pin Connector X-TSS (Receptacle) pin There should be no continuity
1 2
A. If there is continuity, there is a short circuit condition. Locate the fault and repair the shorted conductor.

6. Replace the turbine speed sensor B-TS_S.
B. If the fault has not been resolved, check the A-TRANS for the appropriate software and re-flash, if necessary.
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65694-04 - Torque Reduction due to Smoke Limitation

Context:
This fault path indicates that a power reduction due to smoke limitation is currently active which limits the engine
torque. In other words, this fault path is not used as an actual error status indicating a real defect but is used more for
information purposes for service personnel to determine the exact cause of the power limitation (in case a real defect
evokes a power reduction the triggering failure also has to be present in the failure memory).
Monitoring is only active if engine speed is above 500 RPM.
Cause:
A power reduction due to smoke limitation (via limiting torque) is active causing a torque limitation greater than 25%,
of the momentarily allowed maximum torque, or a high idle torque limitation greater than 5%.
1. Active power reduction due to smoke limitation.
Solution:
1. No actions necessary due to this failure alone. If power reduction occurred due to actual defect, the failure trig-
gering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
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65717-02 - Timeout of CAN Message VCM2EDC

Control Module: ECU
Context:
The Engine Control Unit (ECU) is capable of connecting to and communicating on two separate Controller Area Net-
works (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function of the
ECU. CAN Node 1 Bus is the main vehicle interface bus. The ECU provides a CAN termination resistor for the CAN
Node 1 Bus, internal to the ECU. The ECU receives and responds to proprietary idle speed, intermediate speed and
feedback information. If the ECU senses a message timeout, this fault will occur.
Cause:
The ECU has sensed a proprietary speed message timeout.
1. Faulty vehicle system, related CAN fault.

2. Faulty ECU supply voltage or ground, missing.
3. Faulty CAN 1 circuit wiring, open circuit, short to ground, or short circuit.
4. Faulty ECU, termination resistor or software.
Solution:
2. Check for other vehicle CAN faults.
Use the EST to determine if related vehicle CAN faults exist.
A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check if this fault is also resolved.
B. If other vehicle CAN faults do not exist, or this fault has not been resolved, continue with Step 3.
has been resolved.
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From To Value
Connector X-EDC7 (Plug) pin 3 Chassis ground Here should be about 24 V
A. If there is less than 24 V on one or more the checks, there is a failure in the A-ECU supply wiring.
Locate and repair the failed conductor.
From To Value
B. If there is continuity on all the checks, leave the connector X-EDC7 disconnected and continue with Step 7.
7. Check the ECU CAN 1 circuit for a short circuit condition.
Use a multimeter to perform the following continuity check on the engine harness:
From To Value
Connector X-EDC7 (Plug) pin 34 Connector X-EDC7 (Plug) pin 35 There should be no continuity
A. If there is continuity, there is a short circuit condition between the CAN H and CAN L wiring. Locate and repair
B. If there is no continuity, leave the connector X-EDC7 disconnected and continue with Step 8.
8. Check the ECU CAN 1 circuit for a short to ground condition.
From To Value
A. If there is continuity, there is a short circuit to ground condition in the CAN 1 circuit.
Locate and repair the shorted conductor.
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9. Check the ECU CAN 1 circuit for an open circuit condition.
Disconnect the diagnostic connector X-DIA.
Disconnect the UCM connector X-UCM1B.
From To Value
Connector X-EDC7 (Plug) pin 35 Connector X-DIA (Plug) pin C There should be continuity
Connector X-EDC7 (Plug) pin 34 Connector X-DIA (Plug) pin D There should be continuity
Connector X-EDC7 (Plug) pin 35 Connector X-UCM1B (Receptacle) There should be continuity
pin 34
pin 25
A. If there is no continuity, there is an open circuit condition in the CAN 1 circuit.

B. If there is continuity, check the ECU for the appropriate software and re-flash, if necessary.

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65734-03 - Timeout of CAN message TSC1-PE Torque (When Active)

Control Module: ECU
Context:
Node 1 Bus, internal to the ECU. The ECU receives and responds to Power take-off to Engine controller (PE) infor-
mation at two different rates (active and passive) dependent upon change request status. If the ECU is not sensing
the PE message at the active rate, this fault will occur.
Cause:
CAN controller of the EDC reports a reception timeout for the PTO message TSC1PEActIv while the override control
mode is active. Defect condition fulfilled continuously for more than 200.0 ms.

Solution:
has been resolved.
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From To Value
A. If there is less than 24 V on one or more the checks, there is a failure in the A-ECU supply wiring. Locate and
From To Value
From To Value
From To Value
A. If there is continuity, there is a short circuit to ground condition in the CAN 1 circuit. Locate and repair the
shorted conductor.
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From To Value
pin 34
pin 25


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65736-03 - Timeout of CAN message TSC1-VE Speed (When Active)

Control Module: ECU
Context:
works (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function of
the ECU. CAN Node 1 Bus is the main vehicle interface bus. The ECU provides a CAN termination resistor for the
CAN Node 1 Bus, internal to the ECU. The ECU receives and responds to Torque/Speed Control (TSC) information
at two different rates (active and passive) dependent upon change request status. If the ECU is not sensing the TSC
message at the active rate, this fault will occur.
Cause:
CAN controller of the EDC reports a reception timeout for the VCM/BC message TSC1VEActIv while the override
control mode is active. Defect condition fulfilled continuously for more than 200 ms.

Solution:
has been resolved.
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From To Value
Connector X-EDC7 (Plug) pin 3 Chassis ground here should be about 24 V
From To Value
From To Value
From To Value
A. If there is continuity, there is a short circuit to ground condition in the CAN 1 circuit.
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From To Value
pin 34
pin 25


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65745-03 - ECM Internal SPI Communication Error – CJ940

Control Module: ECU
Context:
This fault monitors the internal communication between the microcontroller and some peripheral integrated circuit and
is set if a disturbance occurs. The communication with each CJ 940 module via SPI bus is monitored cyclically every
100 ms by evaluating the corresponding communication error flag which is provided by the hardware encapsulation.
For every test an error counter is in-/decremented depending if the evaluated error flag indicates a defect or not.
Cause:
The error counter for defective SPI bus communication reaches or exceeds the value of 5. Counter increment at
default detection by 1 step per event.

2. Faulty ECU, electric disturbances.
3. Faulty ECU, internal failure leading to a SPI bus communication error.
Solution:
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65747-12 - ECM (Locked) Recovery Occurred

Control Module: ECU
Context:
There are various failures of the ECU which trigger a recovery (reset of the CPU). During a fresh ECU start up different
hardware tests are performed. If the error remains present even after reset, the software remains in the bootblock and
the driving software is not processed. If 3 recoveries are triggered within 4 s an irreversible shut off of the system is
carried out and the ECU is classified as permanently defective. In this case no error entry is possible. If, however, the
error leading to the recovery is not detected repeatedly and the system is allowed to start up, one of three recovery
error becomes active (Locked, suppressed or visible) depending on the visibility of the recovery.
Cause:
During system start up a hardware error or configuration problem was detected which leads to a ECU recovery that
is stored as protected.
1. Faulty ECU, electronic disturbances.

2. Faulty ECU, software configuration.
Solution:
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65748-12 - ECM Processor – Watchdog Not Plausible

Control Module: ECU
Context:
Next to a CPU the ECU also contains a monitoring module (watchdog). These two components communicate via
a SPI-Bus with each other. Both devices mutually monitor each other for correct functioning. On the one hand, the
watchdog initiates a query/response communication with the CPU. Once the CPU receives the query it starts a 'com-
mand test' (tests the correct functioning of important processor commands) and a 'program flow control' (monitors
the correct execution of code segments of the monitoring). From the results of these two procedures the response
to the watchdog is composed. If this response does not correspond to the expected value an error counter (WD-
Com_dErrorCountForCntler_u8) is incremented. On the other hand, the CPU periodically sends incorrect responses
(regarding response time and value respectively) upon a received query of the watchdog. The CPU then monitors if
the above mentioned error counter of the watchdog is in-/decremented according to an incorrect/correct response. If
the behavior of the counter is implausible a second error counter (WDCom_dErrorCountForWD_u8) is incremented.
Cause:
One of the two error counters (WDCom_dErrorCountForCntler_u8 or WDCom_dErrorCountForWD_u8) exceeds the
value of 5.
1. Faulty ECU, defective monitoring module or CPU (e.g. impaired functioning of the CPU clock) of the EDC.
2. Faulty ECU, Disturbed SPI-Bus.
Solution:
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65749-02 - Shutoff Paths During Initialization – Supply Voltage Too

High
Control Module: ECU
Context:
The ECU comprises so-called redundant shut-off paths (SOP) which deactivate all power stages relevant to injection if
certain internal ECU errors are detected. The defects which trigger such a redundant shut-off are an internal watchdog
error (Dfp_Mon) and an over- or undervoltage error of the ECU (Dfp_HWEMonU%Supply, %= Max, Min). In order to
test the correct functioning of the SOP procedure every path is shortly activated during ECU initialization and following
this the fuel injection power stage is activated. Since, however, the SOP is active no injection should occur as it is
blocked if the SOP procedure functions correctly. During a successful redundant shut-off test an open circuit (=no
current flow) should be detected.
The SOP test can only be carried out once, during ECU initialization if no errors such as short circuits of the injection
power stage has been detected previously.
Cause:
Injection occurred although internal shut-off path of the overvoltage monitoring was active.

Solution:
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65749-04 - Shutoff Paths During Initialization - Watchdog

Control Module: ECU
Context:
error (Dfp_Mon) and an over- or undervoltage error of the ECU (Dfp_HWEMonU%Supply, %= Max, Min). In order to
test the correct functioning of the SOP procedure every path is shortly activated during ECU initialization and following
this the fuel injection power stage is activated. Since, however, the SOP is active no injection should occur as it is
blocked if the SOP procedure functions correctly. During a successful redundant shut-off test an open circuit (=no
current flow) should be detected.
Cause:
Injection occurred although internal shut-off path of the ECU watchdog was active.
1. Faulty ECU, watchdog switch off path defect.

Solution:
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65749-12 - Shutoff Paths During Initialization – Supply Voltage Too

Low
Control Module: ECU
Context:
error (Dfp_Mon) and an over- or undervoltage error of the ECU.
In order to test the correct functioning of the SOP procedure every path is shortly activated during ECU initialization
and following this the fuel injection power stage is activated. Since, however, the SOP is active no injection should
occur as it is blocked if the SOP procedure functions correctly. During a successful redundant shut-off test an open
circuit (=no current flow) should be detected.
Cause:
Injection occurred although internal shut-off path of the undervoltage monitoring was active.

Solution:
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65750-12 - TPU Monitoring – Time Deviation between TPU and

System Not Plausible
Control Module: ECU
Context:
Faultpath for monitoring of the time processing unit (TPU). As the time base of the CPU is checked according to
a query/response communication with the monitoring module (watchdog) it should be correct if no error has been
detected and therefore can be used to check the time base of the TPU. For this purpose the time bases of the TPU
and CPU are compared every 10 ms. After 100 ms the maximum and the minimum value, together with the absolute
value of the sum of the time differences are evaluated.
Cause:
If the maximum time difference between the TPU and CPU time base exceeds the threshold 81.00 ms
Or the minimum time difference is below the limit 81.00 ms
Or the absolute value of the sum of time differences is above 81.00 ms an error counter is incremented. If this counter
exceeds the value of 4, this fault path is set.

2. Faulty ECU, wrong TPU timebase.
Solution:
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65752-12 - Controller Watchdog – SPI Communication Failure

Control Module: ECU
Context:
Next to a CPU the ECU also contains a monitoring module (watchdog). These two components communicate via
a Serial Peripheral Interface (SPI) Bus with each other. Both devices mutually monitor each other for correct func-
tioning. If, however, the SPI communication between them fails this monitoring is impaired and an error counter is
incremented. If the error counter exceeds a limit the fault path at hand is activated. Communication status is checked
autonomously by the SPI driver component every 20 ms and reports a detected error to the EDC.
Cause:
Error counter for failed SPI communication between CPU and monitoring module exceeds 2 over 2x 20 ms (two tests).
1. Faulty ECU, defective monitoring module or CPU (e.g. impaired functioning of the CPU clock) of the EDC.
2. Faulty ECU, Disturbed SPI-Bus.
Solution:
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65753-02 - ADC Monitoring – Test Impulse Error

Control Module: ECU
Context:
This function monitors the analog-digital converter (ADC) of the microcontroller. The test pulse for the signal error
consists of cyclically setting the ADC channel of the accelerator pedal (APP2) to zero. Monitoring for no-load test
pulse is switched off (only allowed for poti/switch accelerator pedal).
Cause:
The converted test pulse voltage exceeds 5.20 V for longer than 10.92 min more than 65535.00 consecutive times.

Solution:
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65753-03 - ADC Monitoring – Reference Voltage Too High

Control Module: ECU
Context:
consists of cyclically setting the ADC channel of the accelerator pedal (APP2) to zero.
Cause:
The reference voltage exceeds 5.20 V.
1. Faulty ECU, short circuit to external source inside ECU.

Solution:
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65753-04 - ADC Monitoring – Reference Voltage Too Low

Control Module: ECU
Context:
Cause:
The reference voltage falls below 0.00 mV.
1. Faulty ECU, short circuit to ground inside ECU.

Solution:
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65753-12 - ADC Monitoring – Queue Error

Control Module: ECU
Context:
Cause:
An error is detected if not all ADC queues are converted within a time window. Time and engine speed synchronous
queues are monitored.
1. Faulty ECU buffer overrun.

Solution:
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65763-03 - Overrun Monitoring – Injection Time Too Long

Control Module: ECU
Context:
When the engine is in overrun operation the monitoring becomes active and the current injection energizing time is
compared with a maximum permissible time limit. If the limit is exceeded a recovery or even a shut off of injection
relevant power stages is triggered. The basic idea is that the driver reacts to an unintentional torque increase, caused
by a malfunction of the control unit, by releasing the accelerator pedal which causes the engine to enter the overrun
operation mode. Overrun monitoring is only released if various conditions are met, such as no accelerator pedal
activation, no activated cruise control, no intervention of the vehicle dynamic control or gearbox control is present
etc. The overrun monitoring is executed in layer 2 of the ECU monitoring concept, i.e. function monitoring, in order
to monitor the safety-relevant signal paths of the operational layer (layer 1, application software).
Cause:
The sum of all torque-forming energizing times of an individual cylinder exceeds the limit (calculated from the map
depending on the engine speed and the time since the overrun monitoring is active) for more than 100.00 test events
(test frequency every 10 ms).
1. Faulty fuel injectors, leakage.

2. Requested torque increase via tester.
4. Faulty ECU, wrong application of injection relevant parameters.
Solution:
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65764-03 - Redundant Engine Speed in Overrun Monitoring – Speed

Signal Not Plausible
Control Module: ECU
Context:
In order to execute an overrun monitoring, which checks if the injection energizing time is below a certain limit during
overrun, the information of the current engine speed is required. As the overrun monitoring is executed in layer 2 of the
ECU monitoring concept, i.e. function monitoring, in order to monitor the safety-relevant signal paths of the operational
layer (layer 1, application software) a redundant engine speed is additionally calculated in layer 2 independent of the
engine speed information of layer 1. If the engine speed information of the two layers varies excessively an error is
reported.
Cause:
The absolute value of the deviation between engine speed and redundant segment speed (layer 2) exceeds
320.00 RPM over 800.00 ms (event checked each 40 ms) while the redundant segment speed is above
1000.00 RPM.

Solution:
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65765-03 - Engine regulated 12 Volt sensor supply - Voltage High

Control Module: ECU
Context:
The Engine Control Unit ( A-ECU) provides independent 12 V voltage supply for the sensors. If the A-ECU detects
that the voltage sensor supply is too high, this fault will occur.
Cause:
The A-ECU has detected a sensor supply voltage too high.
1. Faulty battery
2. Faulty charging system
3. Faulty A-ECU supply wiring, open circuit
4. Faulty A-ECU, software
Solution:
has been resolved.
From To Value
A. If there is more than 24 V, continue with Step 4.

necessary.
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From To Value
A. If there is no continuity on one or more the checks, there is a failure in the A-ECU supply wiring. Locate and
B. If there is continuity on all the checks, check the A-ECU for the appropriate software and re-flash, if necessary.

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65765-04 - Engine regulated 12 Volt sensor supply - Voltage Low

Control Module: ECU
Context:
The Engine Control Unit ( A-ECU) provides independent 12 V voltage supply for the sensors. If the A-ECU detects
that the voltage sensor supply is too low, this fault will occur.
Cause:
The A-ECU has detected a sensor supply voltage too low.
1. Faulty battery.
2. Engine cranked for extended period of time.
3. Faulty charging system.
4. Faulty A-ECU supply wiring.
Solution:
has been resolved.

From To Value
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A. If there is less than 24 V, charge the battery and then perform a load test. If the battery passes the load test,
continue with Step 4. If the battery fails the load test, continue with Step 7.
B. If there is about 24 V, continue with step 5.

From To Value
From To Value
B. If there is continuity on all the checks, continue with Step 7.



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65766-03 - Sensor Supply Voltage 1 - High

Control Module: ECU
Context:
For reasons of safety the ECU provides 3 independent 5 V voltage supplies for the sensors. These sensor supply
voltages are monitored to ensure they remain within a given range. This check for voltage limits is done autonomously
by the hardware (thresholds not applicable). The error status is then reported via SPI-bus to the diagnostic system
management (DSM) where the error status is time-debounced before setting/healing the fault path.
Currently following sensors are connected to supply circuit 1:
- oil pressure/temperature,
- boost pressure/temperature,
- low fuel circuit pressure/temperature.
Cause:
The hardware has detected the sensor voltage supply 1 to exceed an upper limit.
1. Faulty battery, voltage too high.

2. Faulty ECU power supply, voltage too high.
3. Faulty ECU supply voltage 1 output wiring, defect in one of the connected components.
Solution:
has been resolved.
3. Check defects in one of the connected components.
One at a time, disconnect each component connected to the sensor supply voltage 1 and use the EST to monitor
the status of this fault.
A. If the fault is eliminated after a component disconnection, the relevant component has failed. Replace the
relevant component.
B. If the fault has not been eliminated after components disconnection, continue with Step 4.
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From To Value

necessary.

From To Value
Connector X-LC6 pin 5 Connector X-EDC7 (Plug) pin 2 There should be continuity

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65766-04 - Sensor Supply Voltage 1 - Low

Control Module: ECU
Context:
Currently following sensors are connected to supply circuit 1:
- oil pressure/temperature,
- boost pressure/temperature,
- low fuel circuit pressure/temperature.
Cause:
The hardware has detected the sensor voltage supply 1 to be below a lower limit.
1. Faulty battery, voltage too low.

2. Faulty ECU power supply, voltage too low.
Solution:
has been resolved.
relevant component.
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From To Value
A. If there is less than 24 V, continue with Step 5.

necessary.

From To Value

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Control Module: ECU
Context:
Cause:

Solution:
has been resolved.
relevant component.
From To Value
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necessary.

From To Value

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Control Module: ECU
Context:
Cause:

Solution:
has been resolved.
relevant component.
From To Value
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necessary.

From To Value

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Control Module: ECU
Context:
Cause:

Solution:
has been resolved.
relevant component.
From To Value
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necessary.

From To Value

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Control Module: ECU
Context:
Cause:

Solution:
has been resolved.
relevant component.
From To Value
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necessary.

From To Value

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65769-03 - ECM Internal Supply Voltage Too High – CJ940 Above

Limit
Control Module: ECU
Context:
Every CJ940 component of the EDC is monitored for sufficient voltage supply. If the voltage supply is outside of
an admissible range the hardware encapsulation registers this and sets an according error flag. These flags are
evaluated by the Diagnostic System Management (DSM) and depending on their value corresponding fault paths are
set. The monitoring procedure for overvoltage errors also takes the engine speed into account.
Cause:
A CJ940 has detected its voltage supply to be above an upper limit.

Solution:
has been resolved.
From To Value

necessary.
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From To Value

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65770-04 - ECM Internal Supply Voltage Too Low – CJ940 Below

Limit
Control Module: ECU
Context:
Every CJ940 component of the EDC is monitored for sufficient voltage supply. If the voltage supply is outside of
an admissible range the hardware encapsulation registers this and sets an according error flag. These flags are
evaluated by the Diagnostic System Management (DSM) and depending on their value corresponding fault paths are
set.
Cause:
A CJ940 has detected its voltage supply to be below a lower limit.

Solution:
has been resolved.

From To Value
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A. If there is less than 24 V, charge the battery and then perform a load test. If the battery passes the load test,
continue with Step 4. If the battery fails the load test, continue with Step 7.
B. If there is about 24 V, continue with step 5.

From To Value
From To Value
B. If there is continuity on all the checks, continue with Step 7.



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131112-04 - Engine Controller High side supply #2 to Grid heater

- Short to ground
Context:
A short circuit to ground (SCG) of the main relay 1 is only detected if it is switched on. If SCG error is detected the
main relay 1 is switched off automatically but is reactivated after 500.00 ms to check if error is permanent. If the
number of these reactivations exceeds 5 times the error is finalized. Error state is reset during ECU reset as well as
during interrupted after run.
Cause:
A 'short circuit to ground' is reported by the hardware, power stage is switched off and reactivated for a maximum of
5. If after that short circuit is still detected, power stage is permanently shut off.
1. Faulty of one of the component connected to main relay 1, internal failure.

2. Faulty main relay 1, internal failure.
Solution:
or shorts in the wiring concerned. Operate the machine while you monitor the display. Check all the components
connected to main relay 1.
has been resolved.
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131122-12 - Coolant Temperature Test Failure

Control Module: UCM
Context:
The Universal Control Module (UCM) monitors for a sufficient rise in engine coolant temperature. The start coolant
temperature is acquired after 60.00 s since engine start (engine in normal operation). If this start temperature is below
39.96 °C timer runs as long as engine speed > 1400.00 RPM and injection quantity > 16.00 mg/hub (mg/cyc).
Cause:
The coolant temperature does not reach the minimum threshold when the timer exceeds the maximum test time.
1. Extreme ambient conditions.

2. Faulty thermostat, blocked in open position.
3. Faulty coolant temperature sensor B-RECTD circuit wiring, shorted to ground or open circuit.
4. Faulty coolant temperature sensor B-RECTD, internal failure.
5. Faulty UCM, software.
Solution:
1. Ensure that the engine is not running in extreme ambient conditions.
A. If the engine is running in extreme ambient condition, wait until the conditions are within the normal operative
range, then continue with Step 3.
B. If the engine is not running in extreme ambient conditions, continue with Step 2.
2. Check that the thermostat is not blocked in open position.
A. If the thermostat is blocked in open position, restore the correct functionality of the thermostat or replace the
component. Then continue with Step 3.
B. If the thermostat works properly, continue with Step 3.

has been resolved.
5. Verify the integrity of the coolant temperature sensor B-RECTD.
Use a multimeter to measure the resistance between the following pins:
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From To Value
Connector X-RECT (Receptacle) Connector X-RECT (Receptacle) There should be 332 – 10.149 kΩ
pin 1 pin 2 depending on coolant temperature.
A. If the measured resistance is minimal or zero, the coolant temperature sensor B-RECTD has failed, internally.
Replace the sensor.
B. If the measured resistance is within the specified range, leave the connector X-RECT disconnected and con-
tinue with Step 6.
6. Check the coolant temperature sensor B-RECTD signal circuit for a short to ground condition.
From To Value
pin 1
Connector X-UCM4A (Receptacle) Chassis ground There should be no continuity
pin 12
A. If there is continuity, there is a short circuit to ground in the engine harness. Locate the fault and repair the
shorted conductor.
B. If there is no continuity, leave both connector disconnected and continue with Step 7.
7. Check the coolant temperature sensor B-RECTD signal circuit wiring for an open circuit condition.
From To Value
pin 1 pin 12
pin 2 pin 1
repair the broken conductor.
B. If there is continuity, leave all the connectors disconnected and continue with Step 8.
8. Check the coolant temperature sensor B-RECTD signal circuit for a short circuit condition.
From To Value
pin 12 X-UCM4A
pin 1 X-UCM1A
A. If there is continuity, there is a short circuit condition in the B-RECTD signal circuit. Locate the fault and repair

9. Replace the coolant temperature sensor B-RECTD.
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B. If the fault has not been resolved, check the UCM for the appropriate software and re-flash, if necessary.
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131151-03 - Emergency start time expired and shutdown initiated

Context:
This failure is used as 'Info-Failure'. Although the vehicle has run through the whole inducement procedure an engine
start (with full power) is permitted at every time. But the engine will run only for a certain time. After this time the
inducement is activated again and this info failure is set.
Cause:
If the vehicle is in final inducement condition an engine start (with full power) is permitted at every time. But only for
a limited time. After 30 s this info failure is set an the inducement will start again.
1. Only an Info-Failure signaling that engine shut down inducement is active.
Solution:
1. Check and repair failures which are activating inducement procedure.
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131196-02 - Injection Processor Error – Test Mode

Context:
Cause:
The 'YSEL' signal was not inverted as requested during injection for over No 3 camshaft revolutions.

Solution:
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131196-03 - Injection Processor Error – Internal Reset / Clock Loss

/ Voltage Too Low
Control Module: ECU
Context:
Cause:
Internal parity error is present longer than No 3 camshaft revolutions.
1. Faulty ECU, clock error.

Solution:
has been resolved.

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From To Value

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131196-04 - Injection Processor Error – Unlocked / Initialization

Failure
Control Module: ECU
Context:
Cause:
Internal program flow error longer than No 3 camshaft revolutions.

Solution:
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131196-12 - Injection Processor Error – SPI Communication Failure

Control Module: ECU
Context:
Cause:
Power stage component on timeout is present for at least 1 cylinder longer than No 3 camshaft revolutions.

Solution:
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131246-03 - Humidity Sensor possibly saturated with water droplets

– Signal Ratio above Limit
Context:
Undelayed signal range check of the humidity and ambient temperature sensor B-HT. In case of a Max failure the
sensor could be saturated with water droplets. If this is the case the failure will disappear after some time when the
engine is running.
Cause:
The ECU has detected a voltage greater than 3.6 V for a period greater than 500 ms after engine start caused by
water droplets into the humidity and ambient temperature sensor B-HT.
1. Faulty humidity and ambient temperature sensor B-HT, possibly saturated with water droplets.
2. Faulty ambient air temperature circuit wiring, short circuit, open circuit or shorted to external source.
Solution:
or shorts in the wiring concerned. Operate the machine while you monitor the display. Check the components
connected to the main relay 4 output.
has been resolved.
3. Check the presence of the following related fault:
65596-03 - Ambient Air Temperature Sensor failure - Signal too high (55.640).
A. If the fault is active, resolve the fault. Then, repeat the Step 1.
B. If the fault is not active, the humidity and ambient temperature sensor B-HT is experiencing a temporary short
circuit condition due to water droplets into the sensor. This fault should resolve itself after approximately 8 –
10 min of engine operation. If the fault remains active after approximately 8 – 10 min, replace the humidity and
ambient temperature sensor B-HT. If the fault recurs, check the ECU for the appropriate software and re-flash,
if necessary.
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131246-04 - Humidity Sensor possibly saturated with water droplets

– Signal Ratio below Limit
Context:
Undelayed signal range check of the humidity and ambient temperature sensor B-HT. In case of a Max failure the
sensor could be saturated with water droplets. If this is the case the failure will disappear after some time when the
engine is running.
Cause:
The raw value of the humidity and ambient temperature sensor B-HT is below 200.39 mV.
The ECU has detected a voltage lower than 200.39 mV for a period greater than 500 ms after engine start caused by
water droplets into the humidity and ambient temperature sensor B-HT.
1. Faulty humidity and ambient temperature sensor B-HT, possibly saturated with water droplets.
2. Faulty ambient air temperature circuit wiring, short circuit or shorted to ground.
Solution:
or shorts in the wiring concerned. Operate the machine while you monitor the display. Check the components
connected to the main relay 4 output.
has been resolved.
3. Check the presence of the following related fault:
65596-04 - Ambient Air Temperature Sensor failure - Signal too low (55.640).
A. If the fault is active, resolve the fault. Then, repeat the Step 1.
B. If the fault is not active, the humidity and ambient temperature sensor B-HT is experiencing a temporary short
circuit condition due to water droplets into the sensor. This fault should resolve itself after approximately 8 –
10 min of engine operation. If the fault remains active after approximately 8 – 10 min, replace the humidity and
ambient temperature sensor B-HT. If the fault recurs, check the ECU for the appropriate software and re-flash,
if necessary.
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131252-02 - Timeout of CAN Message BC2EDC2

Control Module: ECU
Context:
Node 1 Bus, internal to the ECU. The ECU receives and responds to proprietary Body Computer (BC) information. If
the ECU senses a message timeout, this fault will occur.
Cause:
The ECU has sensed a BC message timeout.

Solution:
has been resolved.
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From To Value
From To Value
From To Value
From To Value
shorted conductor.
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From To Value
pin 34
pin 25
A. If there is no continuity, there is an open circuit condition in the CAN 1 circuit. Locate and repair the shorted
conductor.

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131270-02 - Timeout of CAN message TSC1-PE Torque (When

Inactive)
Context:
Node 1 Bus, internal to the ECU. The ECU receives and responds to Power take-off to Engine controller (PE) infor-
mation at two different rates (active and passive) dependent upon change request status. If the ECU is not sensing
the PE message at the passive rate, this fault will occur.
Cause:
CAN controller of the EDC reports a reception timeout for the PTO message TSC1PEPasIv over 200.00 ms including
an additional 800.00 ms due to a longer CAN receiving cycle time because of an inactive override control mode.
Defect condition fulfilled continuously for more than 800.00 ms.

Solution:
has been resolved.
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From To Value
From To Value
From To Value
From To Value
shorted conductor.
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From To Value
pin 34
pin 25
conductor.

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131272-03 - Timeout of CAN Message TSC1-VR (When Active)

Control Module: ECU
Context:
CAN Node 1 Bus, internal to the ECU. The ECU receives and responds to Vehicle Retarder (VR) information at two
different rates (active and passive) dependent upon change request status. If the ECU is not sensing the VR message
at the active rate, this fault will occur.
Cause:
The ECU is not properly sensing the VR message.

Solution:
has been resolved.
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From To Value
From To Value
From To Value
From To Value
shorted conductor.
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From To Value
pin 34
pin 25
conductor.

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131283-12 - ECM Recovery which is suppressed

Context:
Cause:
is not stored.

Solution:
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196685-04 - Speed limitation activates torque limitation

Context:
This fault path indicates that a power reduction due to engine mechanics protection by speed limitation is currently
active which limits the engine torque. In other words, this fault path is not used as an actual error status indicating a
real defect but is used more for information purposes for service personnel to determine the exact cause of the power
limitation (in case a real defect evokes a power reduction the triggering failure also has to be present in the failure
memory).
Cause:
A power reduction due to engine mechanics protection (by speed limitation) is active. Torque demand is greater than
limitation torque, for engine mechanics protection by speed limitation, or high idle torque demand is greater than
limitation torque, for engine mechanics protection by speed limitation.
1. Active power reduction due to engine mechanics protection by speed limitation.
Solution:
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196766-04 - Torque limitation due to turbo charger protection

Context:
This fault path indicates that a power reduction due to turbo charger protection is currently active which limits the
engine torque. In other words, this fault path is not used as an actual error status indicating a real defect but is used
more for information purposes for service personnel to determine the exact cause of the power limitation (in case a
real defect evokes a power reduction the triggering failure also has to be present in the failure memory).
Cause:
A power reduction due to turbo charger protection is active causing a torque limitation greater than 25%, of the mo-
mentarily allowed maximum torque, or a high idle torque limitation greater than 25%.
1. Active power reduction due to turbo charger protection.
Solution:
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196804-02 - CAN message not received from XXXX1 (TSC1-AE

passive)
Control Module: ECU
Context:
The Engine Control Unit (ECU) receives and responds to AE information at two different rates (active and passive)
dependent upon change request status. If the ECU is not sensing the AE message at the passive rate, this fault will
occur.
Cause:
The ECU is not properly sensing the AE passive message.

Solution:
has been resolved.

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From To Value
From To Value
A. If there is no continuity on one or more checks, there is a failure in the A-ECU ground wiring. Locate and repair
From To Value
From To Value
shorted conductor.
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From To Value
pin 34
pin 25
conductor.

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196808-02 - Timeout of CAN message TSC1-VE Speed (When

Inactive)
Context:
CAN Node 1 Bus, internal to the ECU. The ECU receives and responds to Torque/Speed Control (TSC) information
at two different rates (active and passive) dependent upon change request status. If the ECU is not sensing the TSC
message at the passive rate, this fault will occur.
Cause:
CAN controller of the EDC reports a reception timeout for the VCM/BC message TSC1VEPasIv over 200.00 ms in-
cluding an additional 800.00 ms due to a longer CAN receiving cycle time because of an inactive override control
mode. Defect condition fulfilled continuously for more than 800.00 ms.

Solution:
has been resolved.
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From To Value
From To Value
A. If there is no continuity on one or more checks, there is a failure in the A-ECU ground wiring. Locate and repair
From To Value
From To Value
shorted conductor.
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From To Value
pin 34
pin 25
conductor.

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196819-12 - ECU Recovery (Visible) - Recovery Occurred

Context:
Cause:
is visible in the error memory.

Solution:
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262302-04 - Torque Limitation due to Engine Protection (Against

Excessive Torque, Engine Overspeed and Overheat)
Context:
This fault path indicates that a power reduction due to engine mechanics protection is currently active which limits the
Cause:
A power reduction due to engine mechanics protection (by torque limitation) is active. Torque demand is greater
than limitation torque for engine mechanics protection or high idle torque demand is greater than limitation torque for
engine mechanics protection.
1. Active power reduction due to engine mechanics protection.
Solution:
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262344-02 - Timeout of CAN Message TSC1-VR (When Inactive)

Control Module: ECU
Context:
CAN Node 1 Bus, internal to the ECU. The ECU receives and responds to Vehicle Retarder (VR) information at two
different rates (active and passive) dependent upon change request status. If the ECU is not sensing the VR message
at the passive rate, this fault will occur.
Cause:
The ECU is not properly sensing the VR message.

Solution:
has been resolved.
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From To Value
From To Value
From To Value
B. If there is no continuity, leave the connector X-EDC7 disconnected and continue with step 8.
From To Value
shorted conductor.
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From To Value
pin 34
pin 25
conductor.

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393292-04 - Overheat protection activates torque limitation

Context:
This fault path indicates that a power reduction due to engine overheat protection is currently active which limits the
Cause:
A power reduction due to engine overheat protection (via limiting torque) is active. Torque demand is greater than
limitation torque, for over heat protection, or high idle torque demand is greater than limitation torque, for over heat
protection.
1. Active power reduction due to engine overheat protection.
Solution:
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393374-04 - Torque Limitation due to Fuel Quantity Limitation

because of Injection System Errors
Context:
This fault path indicates that a power reduction due to limiting fuel quantity is currently active which limits the engine
torque. In other words, this fault path is not used as an actual error status indicating a real defect but is used more for
information purposes for service personnel to determine the exact cause of the power limitation (in case a real defect
evokes a power reduction the triggering failure also has to be present in the failure memory).
Cause:
A power reduction due to limiting fuel quantity (via limiting torque) is active causing a torque limitation greater than
25%, of the momentarily allowed maximum torque, or a high idle torque limitation greater than 5%.
1. Active power reduction due to limiting fuel quantity.
Solution:
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517755-09 - EJM Message Timeout (AUX FNR, AUX I, AUX II)

Control Module: UCM
Context:
The Universal Control Module A-UCM receives, from the right-hand joystick (SW-RH_JS) via CAN 2 bus, the Ex-
tended Joystick Message (EJM), that includes the AUX FNR, AUX I and AUX II messages. This fault occurs if, after
5 s from the key ON, the A-UCM does not receive any message from the Extended Joystick Message (EJM) within
the maximum interval time (3 times of maximum defined cycle time). As consequence, the A-UCM turns the default
AUX FNR signal to Neutral and AUX I / AUX II signals to 0%.
Cause:
The A-UCM has detected a cycle time interval, of the EJM message, greater than 3 times of maximum defined cycle
time.

2. The harness of CAN 2 bus is damaged.
4. The right-hand joystick connector X-CAB_AR (Plug) is damaged.
5. The right-hand joystick is not properly connected to the power supply or ground.
6. The right-hand joystick is damaged.
Solution:

A. If one pin is damaged, replace the connector or the harness.
B. f pins are not damaged, continue with Step 4.

4. Check the integrity of connector X-CAB_AR (Plug) .
Disconnect the connector X-CAB_AR (Plug) from the right hand joystick and visually check the integrity of the
pins.

5. Verify the integrity of the fuse 5F6.
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6. Check the electrical continuity between the following points:
• X-CAB_AR (Plug) pin 3 of right hand joystick and X-UCM2B (Receptacle) pin 1 of A-UCM
• X-CAB_AR (Plug) pin 1 of right hand joystick and F-LC5-6A of fuse box LC5
• X-CAB_AR (Plug) pin 2 of right hand joystick and chassis ground.
A. If there is no continuity, repair or replace the harness.

7. Check the right hand joystick and replace, if necessary.
A. If the fault has been solved, return to Step 1 to confirm elimination of fault.
B. If the fault has not been solved, check the A-UCM.

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517755-19 - BJM Message Timeout (Boom, Bucket, Kick down)

Control Module: UCM
Context:
The A-UCM does not receive messages from the Basic Joystick Message (BJM) within the maximum interval
time; as a consequence:
• Default Joystick Signal to Neutral or 0%;
• Default kick down to not pressed.
Cause:
After 5 s from key on incoming cycle time message interval > 3 times of maximum defined cycle time.

2. The harness of CAN 2 bus is damaged.
4. The right hand joystick connector X-CAB_AR (Plug) is damaged.
5. The right hand joystick is not properly connected to the power supply or ground.
6. The right hand joystick is damaged.
Solution:

B. f pins are not damaged, continue with Step 4.

4. Check the integrity of connector X-CAB_AR (Plug) .
Disconnect the connector X-CAB_AR (Plug) from the right hand joystick and visually check the integrity of the
pins.

5. Verify the integrity of the fuse 5F6.
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6. Check the electrical continuity between the following points:
• X-CAB_AR (Plug) pin 1 of right hand joystick and F-LC5-6A of fuse box LC5
• X-CAB_AR (Plug) pin 2 of right hand joystick and chassis ground.
A. If there is no continuity, repair or replace the harness.

7. Check the right hand joystick and replace, if necessary.
A. If the fault has been solved, return to Step 1 to confirm elimination of fault.
B. If the fault has not been solved, check the A-UCM.

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518032-03 - Aux FNR Key Fault

Context:
Aux FNR Key Fault.
Cause:

2. The Aux FNR Key is damaged.
Solution:
A. If the fault is present and active, replace the Aux FNR Key.
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518036-03 - Beacon Light Switch Key Fault

Context:
Beacon Light Switch Key Fault.
Cause:

2. The connector’s pin X-BEA are damaged.
3. The harness between the connector X-BEA and the ground is damaged.
4. The harness between the connector X-BEA and the connector X-ROOF is damaged.
5. The connector’s pin X-ROOF are damaged.
6. The connector’s pin X-CAB_R are damaged.
7. The harness between the connector X-CAB_R and the connector X-X3 is damaged
8. The connector’s pin X-X3 are damaged.
9. The LMP-BEA_RT is damaged.
10. The A-SFB is damaged.
Solution:
2. Check the integrity of connector X-BEA.
Disconnect the connector X-BEA from the ROTATING BEACON and visually check the integrity of pin 1 and 2.
A. If the pin is damaged, replace the harness relevant to the connector.

3. Check the integrity of the harness between the connector X-BEA and the ground.
From To Value
Connector X-BEA pin 2 Ground Short circuit

4. Check the integrity of connectors X-ROOF and X-CAB_R.
Disconnect the connector X-ROOF from the harness and visually check the integrity of pin of both connectors.
A. If the pin in damaged, replace the harness relevant to the connector.

5. Check the integrity of the harness between the connector X-BEA and the connector X-ROOF.
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From To Value
Connector X-BEA pin 1 Connector X-ROOF pin 3 Short circuit

6. Check the integrity of connectors X-X3.
Disconnect the connector X-X3 from the harness and visually check the integrity of pin 3.

7. Check the integrity of the harness between the connector X-CAB_R and the connector X-X3.
From To Value
Connector X-ROOF pin 3 Connector X-X3 pin 3 Short circuit

8. Replace the Rotating beacon LMP-BEA_RT.
A. If the fault is present, replace the A-SFB.
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518047-03 - Declutch Key Fault

Context:
Declutch Key Fault.
Cause:

2. The Declutch Key is damaged.
Solution:
A. If the fault is present and active, replace the Declutch Key.
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518052-03 - Differential Lock Up Key Fault

Context:
Differential Lock Up Key Fault.
Cause:

2. The Differential Lock Up key is damaged.
Solution:
A. If the fault is present and active, replace the Differential Lock Up key.
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518056-03 - Fan Mode Key Fault

Context:
Fan Mode Key Fault.
Cause:

2. The Fan Mode Key is damaged.
Solution:
A. If the fault is present and active, replace the Fan Mode Key.
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518058-03 - Float Key Fault

Context:
Float Key Fault.
Cause:

2. The Float Key is damaged.
Solution:
A. If the fault is present and active, replace the Float Key.
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518063-03 - Implement Coupler Key Fault

Context:
Implement Coupler Key Fault.
Cause:

2. The Implement Coupler key is damaged.
Solution:
A. If the fault is present and active, replace the Implement Coupler key.
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518066-03 - Implement Enable Key Fault

Context:
Implement Enable Key Fault.
Cause:

2. The Implement Enable key is damaged.
Solution:
A. If the fault is present and active, replace the Implement Enable key.
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518069-02 - Joystick Steering Activation Button Signals not

plausible
Control Module: UCM
Context:
The A-UCM detects a value from SWITCH JSS ACTIVATION (SW-SW_JSS) out of limits.
Cause:
The A-UCM detects one of the following conditions:

• Voltage on pin 3B.16 > 15 V and 3B.23 > 15 V for T > 350 ms;
• Voltage on pin 3B.16 < 10 V and 3B.23 < 10 V for T > 350 ms.

2. The harness between the A-UCM and the SWITCH JSS ACTIVATION is damaged.
3. The SWITCH JSS ACTIVATION is not supplied.
5. The harness between the connector X-LFT_A and the SWITCH JSS ACTIVATION is damaged.
6. The SWITCH JSS ACTIVATION is damaged.
Solution:
1. If JSS is not Active:

- Prevent JSS Activation
If JSS is Active
- None (discuss if the fault shall be displayed) as soon as JSS get deactivated:
2. Check the integrity of the harness between the A-UCM and the SWITCH JSS ACTIVATION.

3. Check the SWITCH JSS ACTIVATION power supply.
From To Value
Connector X-CAB_L pin 10 + 24 V Ref. 24 V
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A. If the value is not correct, connect the connector X-LFT_A to the connector X-CAB_L and continue with Step
4.

4. Check the integrity of fuse F-5F8.
Remove the fuse F-5F8 from the LC5.
A. If the fuse is burned, replace the fuse.
B. If the fuse is not burned, check the harness between LC5 and the connector X-CAB_L.
5. Check the integrity of harness between the connector X-LFT_A and the SWITCH JSS ACTIVATION.
Disconnect the connector X-SW_JSS from the SWITCH JSS ACTIVATION.
From To Value
Connector X-LFT_A pin 10 Connector X-SW_JSS pin 2 Short circuit
A. If the measurement is not correct, replace the harness between the connector X-LFT_A and the SWITCH JSS
ACTIVATION.

Disconnect the connectors X-UCM3B from A-UCM.
From To Value
A. If one measurement is not correct, replace the harness between the connector X-CAB_L and the A-UCM.
B. If the measurements are correct, connect the connector X-UCM2B to the A-UCM and continue with Step 7.
7. Check the integrity of harness between the connector X-LFT_A and the SWITCH JSS ACTIVATION.
Remove the connector X-SW_JSS.
From To Value

8. Check the integrity of SWITCH JSS ACTIVATION.
Replace the SWITCH JSS ACTIVATION.
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518070-03 - Key_2 Key Fault

Context:
Key_2 Key Fault.
Cause:

2. The Key_2 Key is damaged.
Solution:
A. If the fault is present and active, replace the Key_2 Key.
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518074-03 - Key_18 Key Fault

Context:
Key_18 Key Fault.
Cause:

Solution:
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518078-03 - Key_20 Key Fault

Context:
Key_20 Key Fault.
Cause:

Solution:
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518083-03 - Park Brake Key Fault

Context:
Park Brake Key Fault.
Cause:

2. The park brake sensor is damaged.
3. The park brake key is damaged.
Solution:
2. Replace the parking brake sensor.
A. If the fault is present and active, replace the parking brake key.
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518089-03 - Short to Power at Ride Control Valve High Side Driver

Control Module: UCM
Context:
The A-UCM detects a high voltage from ride control solenoid ( Y-YRC).
Cause:
The A-UCM detects on pin 6 of connector X-UCM3B a short circuit to power risen by BSP.

2. The harness between A-UCM and the ride control solenoid ( Y-YRC) is damaged.
3. The YRC RIDE CONTROL SOL is damaged.
4. The harness between the connector X-FRNT and the connector X-YRC is damaged.
5. The harness between the connector X-BTM and the connector X-BTM_F is damaged.
Solution:
1. Ride Control Function Disabled (function forced active).
2. Check the integrity of the harness between the A-UCM and the ride control solenoid ( Y-YRC).

3. Check the UCM monitor voltage of the ride control solenoid.
Deactivate the ride control.
Disconnect the solenoid connector X-YRC.
From To Value
Connector X-YRC pin 1 Chassis ground 6V
A. If the measurement is not correct, continue with Step 6.
B. If the measurement is correct, leave the connector disconnected and continue with Step 4.
4. Check the and the ride control solenoid ( Y-YRC) ground circuit.
From To Value
Connector X-YRC pin 2 Chassis ground Short circuit
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5. Check the and the ride control solenoid ( Y-YRC) integrity.
Remove the and the ride control solenoid ( Y-YRC).
A. If the resistance is an open circuit, replace the and the ride control solenoid ( Y-YRC).

6. Check the integrity of connectors X-FRNT and X-BTM_F.
Disconnect the connector X-BTM_F from the connector X-FRNT and visually check the integrity of pins P of both
connectors.

7. Check the integrity of harness between the connector X-FRNT and the connector X-YRC.
Remove the connector X-YRC from the and the ride control solenoid ( Y-YRC).
From To Value
Connector X-FRNT pin P Connector X-YRC pin 1 Short circuit

8. Check the integrity of connectors X-CAB_B and X-BTM.
Disconnect the connector X-BTM from the connector X-CAB_B and visually check the integrity of pin 5 of both
connectors.

9. Check the integrity of harness between connectors X-BTM and X-BTM_F.
From To Value
Connector X-BTM pin 5 Connector X-BTM_F pin P Short circuit

10. Check the integrity of harness between connector X-CAB_B and A-UCM.
Disconnect the connector X-UCM3B from A-UCM and visually check the integrity of pin 6 of X-UCM3B.
From To Value
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518089-04 - Short to Ground at Ride Control Valve High Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding from YRC RIDE CONTROL SOL ( Y-YRC).
Cause:
The A-UCM detects on pin 6 of connector X-UCM3B a short circuit to ground risen by BSP.

2. The harness between A-UCM and the YRC RIDE CONTROL SOL is damaged.
Solution:
1. Ride Control Function Disabled.
2. Check the integrity of the harness between the A-UCM and the YRC RIDE CONTROL SOL.

3. Check the YRC RIDE CONTROL SOL integrity.
Remove the YRC RIDE CONTROL SOL sensor.
A. If the resistance is a short circuit, replace the YRC RIDE CONTROL SOL.

Disconnect the connector X-BTM_F from the connector X-FRNT and visually check the integrity of pin P of both
connectors.

Remove the connector X-YRC from YRC RIDE CONTROL SOL.
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From To Value

connectors.

From To Value

From To Value
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518089-05 - Open Circuit at Ride Control Valve High Side Driver

Control Module: UCM
Context:
The A-UCM detects an unexpected value of current from YRC RIDE CONTROL SOL ( Y-YRC).
Cause:
The A-UCM detects on pin 6 of connector X-UCM3B an Open Circuit or Low Current Error risen by BSP.

2. The harness between A-UCM and the YRC RIDE CONTROL SOL is damaged.
4. The YRC RIDE CONTROL SOL is not grounded.
Solution:
1. Ride Control Function Disabled.
2. Check the integrity of the harness between the A-UCM and the YRC RIDE CONTROL SOL.

3. Check the YRC RIDE CONTROL SOL integrity.
Remove the YRC RIDE CONTROL SOL sensor.
A. If the resistance is an open circuit or a value out of limit, replace the YRC RIDE CONTROL SOL.

4. Check the integrity of connectors X-YRC.
Disconnect the connector X-YRC from the YRC RIDE CONTROL SOL and visually check the integrity of pin
2.Disconnect the connector X-YRC from the YRC RIDE CONTROL SOL and visually check the integrity of pin 2.

5. Check the integrity of harness between the connector X-YRC and ground.
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From To Value
Connector X-YRC pin 2 Connector SP-624D Short circuit

Disconnect the connector X-BTM_F from the connector X-FRNT and visually check the integrity of pin P of both
connectors.

Remove the connector X-YRC from YRC RIDE CONTROL SOL.
From To Value

connectors.

From To Value

From To Value

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518093-03 - Return ToTravel Key Fault

Context:
Return ToTravel Key Fault
Cause:

2. The Return ToTravel Key is damaged.
Solution:
A. If the fault is present and active, replace the Return ToTravel Key.
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518101-03 - Torque Converter Lock Up Key Fault

Context:
Torque Converter Lock Up Key Fault.
Cause:

2. The Torque Converter Lock Up Key is damaged.
Solution:
A. If the fault is present and active, replace the Torque Converter Lock Up Key.
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518103-03 - Transmission Auto Mode Key Fault

Context:
Transmission Auto Mode Key Fault.
Cause:

2. The Transmission Auto Mode key is damaged.
Solution:
A. If the fault is present and active, replace the Transmission Auto Mode key.
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518106-03 - WorkLight 1 Key Fault

Context:
WorkLight 1 Key Fault.
Cause:

3. The harness between the connector X-X3 and the X-CAB_R is damaged.
6. The harness between the connector X-ROOF and the connector X-LFWL is damaged.
7. The connector’s pin X-LFWL are damaged.
8. The harness between the connector X-LFWL and SP-949A is damaged.
9. The LMP-LF_WL is damaged.
11. The harness between the connector X-ROOF and the connector X-RFWL is damaged.
12. The connector’s pin X-RFWL are damaged.
13. The harness between the connector X-RFWL and SP-949A is damaged.
14. The LMP-RF_WL is damaged.
15. The harness between SP-949A and the connector X-ROOF is damaged.
16. The harness between the connector X-CAB_R and CG1 is damaged.
Solution:
2. Check the integrity of connector X-X3.
Disconnect the connector X-X3 from the A-SFB (SMART FUSE BOX) and visually check the integrity of pin 1
and 2.

3. Check the integrity of the harness between the connector X-X3 and the X-CAB_R.
From To Value
Connector X-X3 pin 2 Connector X-CAB_R pin 1 Short circuit
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Disconnect the connectors X-ROOF and X-CAB_R from the harness and visually check the integrity of pin of
both connectors.

5. Check the integrity of the harness between the connector X-ROOF and the connector X-LFWL.
From To Value
Connector X-ROOF pin 1 Connector X-LFWL pin 1 Short circuit

6. Check the integrity of connectors X-LFWL.
Disconnect the connector X-LFWL from the LMP-LF_WL (LEFT FRONT WORK LIGHT) and visually check the
integrity of pin 1 and 2.

7. Check the integrity of the harness between the connector X-LFWL and SP-949A.
From To Value
Connector X-LFWL pin 2 Connector SP-949A Short circuit

8. Replace the LMP-LF_WL (LEFT FRONT WORK LIGHT).
A. If the fault is present, continue with Step 9.

From To Value

10. Check the integrity of the harness between the connector X-ROOF and the connector X-RFWL.
From To Value
Connector X-ROOF pin 2 Connector X-RFWL pin 1 Short circuit

11. Check the integrity of connectors X-RFWL.
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Disconnect the connector X-RFWL from the LMP-RF_WL (RIGHT FRONT WORK LIGHT) and visually check the

12. Check the integrity of the harness between the connector X-RFWL and SP-949A.
From To Value
Connector X-RFWL pin 2 Connector SP-949A Short circuit

13. Check the integrity of the harness between SP-949A and the connector X-ROOF.
From To Value
Connector SP-949A Connector X-ROOF pin 6 Short circuit

14. Replace the LMP-RF_WL (RIGHT FRONT WORK LIGHT).

15. Check the integrity of the harness between X-CAB_R and CG1.
From To Value
Connector X-CAB_R pin 6 Connector CG1 Short circuit
B. If the measurement is correct, replace the A-SFB (SMART FUSE BOX).

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518108-03 - WorkLight 2 Key Fault

Context:
WorkLight 2 Key Fault.
Cause:

6. The harness between the connector X-ROOF and SP-859A is damaged.
7. The harness between SP-859A and the connector X-LRWL is damaged.
8. The connector’s pin X-LRWL are damaged.
9. The harness between the connector X-LRWL and SP-953A is damaged.
10. The LMP-LR_WL is damaged.
11. The harness between SP-859A and the connector X-RRWL is damaged.
12. The connector’s pin X-RRWL are damaged.
13. The harness between the connector X-RRWL and SP-953A is damaged.
14. The LMP-RR_WL is damaged.
15. The harness between SP-953A and the connector X-ROOF is damaged.
16. The harness between the connector X-CAB_R and CG1 is damaged.
Solution:
2. Check the integrity of connector X-X4.
Disconnect the connector X-X4 from the A-SFB (SMART FUSE BOX) and visually check the integrity of pin 1
and 2.

From To Value
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Disconnect the connectors X-ROOF and X-CAB_R from the harness and visually check the integrity of pin of
both connectors.

5. Check the integrity of the harness between the connector X-ROOF and SP-859A.
From To Value
Connector X-ROOF pin 5 Connector SP-859A Short circuit

6. Check the integrity of the harness between SP-859A and the connector X-LRWL.
From To Value
Connector SP-859A Connector X-LRWL pin 1 Short circuit

7. Check the integrity of connectors X-LRWL.
Disconnect the connector X-LRWL from the LMP-LR_WL (LEFT REAR WORK LIGHT) and visually check the

8. Check the integrity of the harness between the connector X-LRWL and SP-953A.
From To Value
Connector X-LRWL pin 2 Connector SP-953A Short circuit

9. Replace the LMP-LR_WL (LEFT REAR WORK LIGHT).

10. Check the integrity of the harness between SP-859A and the connector X-RRWL.
From To Value
Connector SP-859A Connector X-RRWL pin 1 Short circuit

11. Check the integrity of connectors X-RRWL.
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Disconnect the connector X-RRWL from the LMP-RR_WL (RIGHT REAR WORK LIGHT) and visually check the

12. Check the integrity of the harness between the connector X-RRWL and SP-953A.
From To Value
Connector X-RRWL pin 2 Connector SP-953A Short circuit

13. Replace the LMP-RR_WL (RIGHT REAR WORK LIGHT).

14. Check the integrity of the harness between SP-953A and the connector X-ROOF.
From To Value
Connector SP-953A Connector X-ROOF pin 7 Short circuit

15. Check the integrity of the harness between X-CAB_R and CG1.
From To Value
Connector X-CAB_R pin 7 Connector CG1 Short circuit
B. If the measurement is correct, see procedure of 518106-03 fault.

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518110-02 - Boom Angle Sensor signals not plausible

Control Module: UCM
Context:
The A-UCM detects not plausible values from the BOOM ANGLE sensor; as a consequence, the advanced EH BOOM
features (RTT/Float and HC) is disabled.
Cause:
The A-UCM detects, on pins 19 and 22 of connector X-UCM1B, two not plausible signals (│5-(Sig1+Sig2)│ > 0.5 V).

2. The harness between the A-UCM and the BOOM ANGLE is visually damaged.
3. The output ANGLE 1 of the BOOM ANGLE is not correct.
4. The output ANGLE 2 of the BOOM ANGLE is not correct.
5. The A-UCM is not functioning.
Solution:
2. Visually check the integrity of the harness between the A-UCM and the BOOM ANGLE for any damage.

3. The output BOOM ANGLE 1 of the sensor is not functioning.
Be sure the voltage on pin 19 of connector X-UCM1B is 0.25 V < Voltage < 4.75 V.
A. If one value is not correct, check the correct functioning of the circuit by performing:
- the procedure 518110-04 – Boom Angle Sensor Channel 1 Under Voltage if the voltage is < 0.25 V;
- the procedure 518110-03 – Boom Angle Sensor Channel 1 Over Voltage if the voltage is > 4.75 V.
B. If both value are correct, continue with Step 4.

4. The output BOOM ANGLE 2 of the sensor is not functioning.
- the procedure 518135-04 – Boom Angle Sensor Channel 2 Under Voltage if the voltage is < 0.25 V;
- the procedure 518135-03 – Boom Angle Sensor Channel 2 Over Voltage if the voltage is > 4.75 V.
B. If both values are correct, continue with Step 5.

Replace the A-UCM.
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518110-03 - Boom Angle Sensor Channel 1 Over Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the channel 1 of the BOOM ANGLE ( B-BKT_ANG) greater than the upper limit.
Cause:
The A-UCM detects, on pin 19 of connector X-UCM1B, a voltage > 4.75 V; as a consequence, the advanced EH
BOOM features (RTT/Float and HC) is disabled.

2. The harness between the A-UCM and the BOOM ANGLE is damaged.
3. The connectors X-BOA or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B are damaged.
4. The BOOM ANGLE is damaged.
5. The harness relevant to the BOOM ANGLE is damaged.
Solution:
2. Check the integrity of the harness between the A-UCM and the BOOM ANGLE.

3. Check the BOOM ANGLE sensor integrity.
Remove the BOOM ANGLE sensor.
From To Value
BOOM ANGLE pin P1 BOOM ANGLE pin N1 The sensor resistance
A. If the resistance is an open circuit, replace the BOOM ANGLE.
B. If the resistance value is correct, continue with Step 4.

4. Use a multimeter to perform the following check:
From To Value
BOOM ANGLE pin P1 BOOM ANGLE pin OUT1 A resistance value
A. If the measurement is a short circuit, replace the BOOM ANGLE.

5. Check the integrity of the connectors X-UCM1B.
Disconnect the connector X-UCM1B from the A-UCM.
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Visually check the integrity of pin 19.

6. Check the integrity of the harness between the connector X-UCM1B and the power supply.
Mount the BOOM ANGLE sensor.
From To Value
Connector X-UCM1B pin 19 Ground < + 5V

7. Check the integrity of the connectors X-BTM_EH and X-CAB_EH.
Disconnect the connector X-BTM_EH from the connector X-CAB_EH.
Visually check the integrity of pin S of both connectors.

8. Check the harness between the connector X-BTM_EH and the power supply.
From To Value
Connector X-BTM_EH pin 5 Ground < + 5V
A. If the value is not correct, replace the harness between the connectors X-CAB_EH and X-UCM1B.

9. Check the integrity of the connectors X-FRNT_EH and X-BTM_FEH.
Disconnect the connector X-FRNT_EH from the connector X-BTM_FEH.
Visually check the integrity of pins S and V of both connectors.

10. Check the harness of the connector X-FRNT_EH.
From To Value
Connector X-FRNT_EH pin S Connector X-FRNT_EH pin V Open circuit
A. If the value is not correct, replace the harness between the connectors X-BOA and X-FRNT_EH.
B. If the value is correct, replace the harness between the connectors X-BTM_FEH and X-BTM_EH.
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518110-04 - Boom Angle Sensor Channel 1 Under Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the channel 1 of the BOOM ANGLE ( B-BM_ANG) lower than the lower limit.
Cause:
The A-UCM detects, on pin 19 of connector X-UCM1B, a voltage < 0.25 V; as a consequence, the advanced EH

4. The BOOM ANGLE is not correctly supplied.
5. The BOOM ANGLE sensor is damaged.
6. The harness between the connectors X-BOA and X-FRNT_EH is damaged.
7. The harness between the connectors X-BTM_FEH and X-BTM_EH is damaged.
8. The harness between the connectors X-CAB_EH and X-UCM1B is damaged.
Solution:

3. Check the integrity of the connector X-BOA.
Disconnect the connector X-BOA from the BOOM ANGLE.
Visually check the integrity of pins A, B and C of the connector.

4. Check the BOOM ANGLE power supply.
From To Value
Connector X-BOA pin B Connector X-BOA pin A (Ref) + 5V
A. If the value is not correct, check the harness between the connectors X-BOA, X-FRNT_EH and X-FRNT.
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5. Replace the BOOM ANGLE sensor.


7. Check the harness between the connectors X-BOA and X-FRNT_EH.
From To Value
Connector X-BOA pin C Connector X-FRNT_EH pin S Short circuit


9. Check the harness between the connectors X-BTM_FEH and X-BTM_EH.
From To Value
Connector X-BTM_FEH pin S Connector X-BTM_EH pin S Short circuit
A. If the value is not correct, replace the harness between the connectors X-BTM_FEH and X-BTM_EH.

10. Check the integrity of the connector X-UCM1B.

11. Check the integrity of the harness between the connectors X-CAB_EH and X-UCM1B.
From To Value
Connector X-CAB_EH pin S Connector X-UCM1B pin 19 Short circuit
A. If the measurement is not correct, replace the harness between the connectors X-CAB_EH and X-UCM1B.
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518111-02 - Bucket Angle Sensor signals not plausible

Control Module: UCM
Context:
The A-UCM detects not plausible values from the BUCKET ANGLE sensor; as a consequence, the advanced EH
bucket features ( RTD) is disabled.
Cause:
The A-UCM detects, on pins 21 and 23 of connector X-UCM1B, two not plausible signals (│5-(Sig1+Sig2)│ > 0.5 V).

2. The harness between the A-UCM and the BUCKET ANGLE is visually damaged.
3. The output ANGLE 1 of the BUCKET ANGLE is not correct.
4. The output ANGLE 2 of the BUCKET ANGLE is not correct.
Solution:
2. Visually check the integrity of the harness between the A-UCM and the BUCKET ANGLE for any damage.

3. The output BUCKET ANGLE 1 of the sensor is not functioning.
- the procedure 518111-04 – Bucket Angle Sensor Channel 1 Under Voltage if the voltage is < 0.25 V;
- the procedure 518111-03 – Bucket Angle Sensor Channel 1 Over Voltage if the voltage is > 4.75 V.

4. The output BUCKET ANGLE 2 of the sensor is not functioning.
- the procedure 518136-04 – Bucket Angle Sensor Channel 2 Under Voltage if the voltage is < 0.25 V;
- the procedure 518136-03 – Bucket Angle Sensor Channel 2 Over Voltage if the voltage is > 4.75 V.

Replace the A-UCM.
B. If the functionality is not restored, replace the harness.
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518111-03 - Bucket Angle Sensor Channel 1 Over Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the channel 1 of the BUCKET ANGLE ( B-BKT_ANG) greater than the upper limit.
Cause:

2. The harness between the A-UCM and the BUCKET ANGLE is damaged.
3. The connectors X-BUA or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B are damaged.
4. The BUCKET ANGLE is damaged.
5. The harness relevant to the BUCKET ANGLE is damaged.
Solution:
2. Check the integrity of the harness between the A-UCM and the BUCKET ANGLE.

3. Check the BUCKET ANGLE sensor integrity.
Remove the BUCKET ANGLE sensor.
From To Value
BUCKET ANGLE pin P1 BUCKET ANGLE pin N1 The sensor resistance
A. If the resistance is an open circuit, replace the BUCKET ANGLE.

From To Value
BUCKET ANGLE pin P1 BUCKET ANGLE pin OUT1 A resistance value
A. If the measurement is a short circuit, replace the BUCKET ANGLE.

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Mount the BUCKET ANGLE sensor.
From To Value

Visually check the integrity of pin W of both connectors.

From To Value
Connector X-BTM_EH pin W Ground < + 5V

Visually check the integrity of pins W and V of both connectors.

From To Value
Connector X-FRNT_EH pin W Connector X-FRNT_EH pin V Open circuit
A. If the value is not correct, replace the harness between the connectors X-BUA and X-FRNT_EH.
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518111-04 - Bucket Angle Sensor Channel 1 Under Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the channel 1 of the BUCKET ANGLE ( B-BKT_ANG) lower than the lower limit.
Cause:

4. The BUCKET ANGLE is not correctly supplied.
5. The BUCKET ANGLE sensor is damaged.
6. The harness between the connectors X-BUA and X-FRNT_EH is damaged.
Solution:

3. Check the integrity of the connector X-BUA.
Disconnect the connector X-BUA from the BUCKET ANGLE.

4. Check the BUCKET ANGLE power supply.
From To Value
Connector X-BUA pin B Connector X-BUA pin A (Ref) + 5V
A. If the value is not correct, check the harness between the connectors X-BUA, X-FRNT_EH and X-FRNT.
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5. Replace the BUCKET ANGLE sensor.


7. Check the harness between the connectors X-BUA and X-FRNT_EH.
From To Value
Connector X-BUA pin C Connector X-FRNT_EH pin W (Ref) Short circuit


From To Value
Connector X-BTM_FEH pin W Connector X-BTM_EH pin W Short circuit


From To Value
Connector X-CAB_EH pin W Connector X-UCM1B pin 21 Short circuit
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518112-01 - Radiator Coolant Temperature Sensor under resistance

Short to Ground
Control Module: UCM
Context:
The resistance of the Radiator Coolant Temperature Sensor is < 500 Ω.
Cause:
On pin 12 of connector X-UCM4 of component A-UCM, the detected resistance is < 500 Ω.
Set the fan speed to max.

2. The harness between A-UCM and the B-RECTD COOLANT TEMP sensor is damaged.
3. The B-RECTD COOLANT TEMP sensor is damaged.
4. The connector X-ENG is damaged.
5. The B-RECTD COOLANT TEMP sensor hardness is damaged
6. The harness between connector X-ENG and component A-UCM is damaged.
Solution:
1. Set the fan speed to max.

2. Check the integrity of the harness between A-UCM and the B-RECTD COOLANT TEMP sensor.

3. Check the B-RECTD COOLANT TEMP sensor integrity.
Remove the B-RECTD COOLANT TEMP sensor.
A. If the resistance is < 500 Ω, replace the B-RECTD COOLANT TEMP sensor.

4. Check the integrity of the X-ENG connector.
Disconnect X-ENG connector and visually check the integrity of the pins 5 and 9.
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5. Check the B-RECTD COOLANT TEMP sensor harness for a proper condition.
From To Value
Connector X-ENG pin 5 Connector X-ENG pin 9 Resistance > 500 Ω
A. If the value is not correct, replace the harness between the connector and the sensor.
B. If the value is correct, continue to Step 6.

6. Check the integrity of harness between connector X-ENG and component A-UCM.
From To Value
Connector X-UCM4A pin 12 Connector X-ENG pin 5 Short circuit
Connector X-UCM4A pin 12 Connector X-ENG pin 9 Open circuit
B. If both measurements is are correct, replace the A-UCM component.
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518112.00 - Radiator Coolant Temperature Sensor over resistance

Open Circuit/Short to Power
Control Module: UCM
Context:
The resistance of the Radiator Coolant Temperature Sensor is > 2000 Ω.
Cause:
On pin 12 of connector X-UCM4 of component A-UCM, the detected resistance is > 2000 Ω.

2. The harness between A-UCM and the B-RECTD COOLANT TEMP ( B-RECTD) sensor is damaged.
3. The B-RECTD COOLANT TEMP ( B-RECTD) sensor is damaged.
4. The connector X-ENG is damaged.
5. The B-RECTD COOLANT TEMP ( B-RECTD) sensor hardness is damaged
6. The harness between connector X-ENG and component A-UCM is damaged.
Solution:
1. Set the fan speed to max.

2. Check the integrity of the harness between A-UCM and the B-RECTD COOLANT TEMP sensor.

3. Check the B-RECTD COOLANT TEMP sensor integrity.
Remove the B-RECTD COOLANT TEMP sensor.
A. If Resistance > 2000 Ω, replace the B-RECTD COOLANT TEMP sensor.

Disconnect X-ENG connector and visually check the integrity of the pins 5 and 9.

5. Check the B-RECTD COOLANT TEMP sensor harness for a proper condition.
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From To Value
Connector X-ENG pin 5 Connector X-ENG pin 9 Resistance < 2000 Ω
A. If the value is not correct, replace the harness between the connector and the sensor.
B. If the value is correct, continue to Step 6.

6. Check the integrity of harness between connector X-ENG and component A-UCM.
From To Value
Connector X-ENG pin 5 Connector X-UCM4A pin 12 Short circuit
A. If there is not a short circuit, replace the harness.
B. If there is a short circuit, replace the A-UCM component.
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518113-02 - Low Brake Pressure

Control Module: UCM
Context:
The A-UCM detects a value from Brake lower than the expected one; as a consequence:
• UCM: none
• GHMI:
- Low Brake Pressure Indicator = ON
- Red Master Indicator = ON
- Error Pop Up Message Displayed
- Buzzer = ON (Consistent with other RED warnings)
Cause:
• Key Switch = ON;

• Engine Running for 4 s;
• Brake Pressure < 12.2 for 3.0 s continuous.

2. The Brake Supply Line Pressure Sensor is not functioning.
3. The Brake Supply Line is not functioning.
Solution:
2. By performing the procedures 518113-03 – Short to Power at Brake Supply Line Pressure Sensor and
518113-04 – Short to Ground at Brake Supply Line Pressure Sensor, check the Brake Supply Line Pressure
Sensor is correctly functioning.

3. Replace the Brake Supply Line.
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518113-03 - Short to Power at Brake Supply Line Pressure Sensor

Control Module: UCM
Context:
The A-UCM detects a value from BRAKE SUPPLY PRESS ( B-PBW) out of higher limit.
Cause:

2. The BRAKE SUPPLY PRESS ( B-PBW) is damaged.
Solution:
1. Set Brake Supply Pressure to 0 bar

No Break Pressure Warning available
2. Check the BRAKE SUPPLY PRESS ( B-PBW) integrity.
Remove the BRAKE SUPPLY PRESS ( B-PBW). Use a multimeter to perform the PBW check:
From To Value
Connector X-PBW pin B Connector X-PBW pin A Resistance
A. If the resistance is an open circuit, replace the BRAKE SUPPLY PRESS.

3. Move the cursor of the sensor and, by using a multimeter, perform the PBW check:
From To Value
Connector X-PBW pin B Connector X-PBW pin C Resistance changing
A. If the value is a short circuit, replace the BRAKE SUPPLY PRESS.
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518113-04 - Short to Ground at Brake Supply Line Pressure Sensor

Control Module: UCM
Context:
The A-UCM detects a value from BRAKE SUPPLY PRESS ( B-PBW) out of lower limit.
Cause:

2. The harness between A-UCM and B-PBW is damaged.
3. The BRAKE SUPPLY PRESS ( B-PBW) is not correctly supplied
4. The BRAKE SUPPLY PRESS ( B-PBW) is damaged.
5. The harness between BRAKE SUPPLY PRESS ( B-PBW) and A-UCM is damaged.
Solution:
1. Set Brake Supply Pressure to 0 bar

2. Check the integrity of the harness between A-UCM and BRAKE SUPPLY PRESS ( B-PBW).

From To Value
Connector X-CAB_B pin 8 Connector X-CAB_B pin 10 Voltage = 5 V


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From To Value

6. Check the BRAKE SUPPLY PRESS sensor integrity.
Remove the BRAKE SUPPLY PRESS sensor.
Use a multimeter to perform the PBW check:
From To Value
Connector X-PBW pin B Connector X-PBW pin A Resistance
A. If the resistance is an open circuit, replace the BRAKE SUPPLY PRESS.

7. Move the cursor of the sensor and, by using a multimeter, perform the PBW check:
From To Value
Connector X-PBW pin B Connector X-PBW pin C Resistance changing
A. If the resistance does not change, replace the BRAKE SUPPLY PRESS.

8. Check the integrity of the connector X-BTM.
Disconnect the connector X-BTM from the connector X-CAB_B and visually check the integrity of the pins 6 on
both connectors.

9. Check the B-PBW to X-BTM harness for a proper condition.
From To Value
Connector X-PBW pin C Connector X-BTM pin 6 Short circuit
A. If the value is not correct, replace the harness between the connector and the BRAKE SUPPLY PRESS.

From To Value
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518114-03 - Short to Power at Brake Line (declutch) Pressure

Sensor
Control Module: UCM
Context:
The A-UCM detects a value from PEDAL/DECLTCH ( B-PBL) out of higher limit.
Cause:
On pin 20 of connector X-UCM1B of A-UCM, the detected value is > 4.75 V.

2. The PEDAL/DECLTCH ( B-PBL) is damaged.
Solution:
1. Set Brake Line Pressure to 0 bar

CCO disabled (clutches will be immediately engaged if declutch was active)
Brake Light disabled (set error to SFB ) Default position sensor to minimum value (0%)
2. Check the PEDAL/DECLTCH ( B-PBL) integrity.
Remove the PEDAL/DECLTCH ( B-PBL).
Use a multimeter to perform the PBL check:
From To Value
Connector X-PLB-PBD pin B Connector X-PLB-PBD pin A Resistance
A. If the resistance is an open circuit, replace the PEDAL/DECLTCH.

3. Move the cursor of the sensor and, by using a multimeter, perform the PBL check:
From To Value
Connector X-PLB-PBD pin B Connector X-PLB-PBD pin C Resistance changing
A. If the value is a short circuit, replace the PEDAL/DECLTCH.
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518114-04 - Short to Ground at Brake Line (declutch) Pressure

Sensor
Control Module: UCM
Context:
The A-UCM detects a value from PEDAL/DECLTCH (B-PBL) out of lower limit.
Cause:
On pin 20 of connector X-UCM1B of A-UCM , the detected value is < 0.25 V.

2. The harness between A-UCM and B-PBL/PEDAL/DECLTCH is damaged.
3. The B-PBL/PEDAL/DECLTCH is not correctly supplied
4. The B-PBL/PEDAL/DECLTCH is damaged.
5. The harness between B-PBL/PEDAL/DECLTCH and A-UCM is damaged.
Solution:
1. Set Brake Line Pressure to 0 bar

CCO disabled (clutches will be immediately engaged if declutch was active)
Brake Light disabled (set error to SFB ) Default position sensor to minimum value (0%)
2. Check the integrity of the harness between A-UCM and B-PBL/PEDAL/DECLTCH.

From To Value
Connector X-CAB_B pin 8 Connector X-CAB_B pin 10 Voltage = 5 V

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From To Value

6. Check the PEDAL/DECLTCH sensor integrity.
Remove the PEDAL/DECLTCH sensor.
Use a multimeter to perform the PBL check:
From To Value
Connector X-PLB-PBD pin B Connector X-PLB-PBD pin A Resistance
A. If the resistance is an open circuit, replace the PEDAL/DECLTCH.

7. Move the cursor of the sensor and, by using a multimeter, perform the PBL check:
From To Value
Connector X-PLB-PBD pin B Connector X-PLB-PBD pin C Resistance changing
A. If the resistance does not change, replace the PEDAL/DECLTCH.

8. Check the integrity of the X-BTM connector.
Disconnect the connector X-BTM from the connector X-CAB_B and visually check the integrity of the pins 7 on
both connectors.

9. Check the B-PBL/PEDAL/DECLTCH to X-BTM harness for a proper condition.
From To Value
Connector X-PLB-PBD pin C Connector X-BTM pin 7 Short circuit
A. If the value is not correct, replace the harness between the connector and the PEDAL/DECLTCH.

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From To Value
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518115-01 - Auxiliary Steering lack of pressure

Control Module: UCM
Context:
The A-UCM detects a lack of pressure for the Auxiliary Steering.
Cause:
Engine Running is TRUE AND Steering Pressure < 240 kPa.

2. The Aux Steering Pressure Sensor is not functioning.
3. The Aux Steering is not functioning.
Solution:
2. By performing the procedures 518115-03 – Aux Steering Pressure Sensor Over Voltage and 518115-04 – Aux
Steering Pressure Sensor Over Voltage, check the Aux Steering Pressure Sensor is correctly functioning.

3. Replace the Aux Steering.
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518115-03 - Aux Steering Pressure Sensor Over Voltage

Control Module: UCM
Context:
The A-UCM detects a value from AUX STEERING PRESSURE ( B-PSS) greater than the upper limit.
Cause:
The A-UCM detects, on pin 8 of connector X-UCM1A, a voltage > 4.75 V.

2. The harness between the A-UCM and the AUX STEERING PRESSURE is damaged.
3. The AUX STEERING PRESSURE is damaged.
4. The harness relevant to the AUX STEERING PRESSURE is damaged.
Solution:
1. Disable Aux Steering Function.
2. Check the integrity of the harness between the A-UCM and the AUX STEERING PRESSURE.
The key must be in OFF position.

3. Check the AUX STEERING PRESSURE sensor integrity.
Remove the AUX STEERING PRESSURE sensor.
Use a multimeter to perform the AUX STEERING PRESSURE check:
From To Value
Connector X-PSS pin B Connector X-BPP pin A The sensor resistance
A. If the resistance is an open circuit, replace the AUX STEERING PRESSURE.

4. Move the cursor of the sensor and, by using a multimeter, perform the AUX STEERING PRESSURE check:
From To Value
Connector X-PSS pin B Connector X-PSS pin C Resistance changing
A. If the resistance does not change, replace the AUX STEERING PRESSURE.
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5. Check the integrity of the connectors X-SST and X-BTS.
Disconnect the connector X-SST from the connector X-BTS.
Visually check the integrity of pins 2, 3 and 4 of both connectors.

6. Check the integrity of the harness between the connector X-SST and the AUX STEERING PRESSURE.
From To Value
Connector X-PSS pin A Connector X-SST pin 3 Short circuit
Connector X-PSS pin C Connector X-SST pin 4 Short circuit
A. If one measurement is not correct, replace the harness between the connector X-SST and the AUX STEERING
PRESSURE.

7. Check the integrity of harness between the connector X-BTS and ground.
From To Value
Connector X-BTS pin 3 Ground Short circuit
A. If the measurement is not correct, replace the harness between the connector X-BTS and ground.

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518115-04 - Aux Steering Pressure Sensor Over Voltage

Control Module: UCM
Context:
The A-UCM detects a value from AUX STEERING PRESSURE ( B-PSS) lower than the upper limit.
Cause:
The A-UCM detects, on pin 8 of connector X-UCM1A, a voltage < 0.25 V.

2. The harness between the A-UCM and the AUX STEERING PRESSURE is damaged.
3. The AUX STEERING PRESSURE is not correctly supplied.
4. The harness relevant to the AUX STEERING PRESSURE is damaged.
5. The AUX STEERING PRESSURE is damaged.
Solution:
1. Disable Aux Steering Function.
2. Check the integrity of the harness between the A-UCM and the AUX STEERING PRESSURE.

3. Check the integrity of the connectors X-SST and X-BTS.
Disconnect the connector X-SST from the connector X-BTS.
Visually check the integrity of pins 2, 3 and 4 of both connectors.

4. Check the AUX STEERING PRESSURE power supply.
From To Value
Connector X-BTS pin 2 Connector X-BTS pin 3 (Ref) + 5V
A. If the value is not correct, replace the harness between the connector X-BTS and the connector X-BTM.

5. Check the harness between the AUX STEERING PRESSURE and the connector X-SST.
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Connect the connector X-BTS to the connector X-SST.
Remove the AUX STEERING PRESSURE sensor.
From To Value
Connector X-PSS pin B Connector X-PSS pin A + 5V
A. If the value is not correct, replace the harness between the connector X-SST and the connector X-PSS.

6. Check the integrity of the connectors X-BTM and X-CAB_B.
Disconnect the connector X-BTM from the connector X-CAB_B.
Visually check the integrity of the pin 11 of both connectors.

7. Check the integrity of the harness between the connector X-BTS and the connector X-BTM.
Disconnect the connector X-BTS from the connector X-SST.
From To Value
Connector X-BTS pin 4 Connector X-BTM pin 11 Short circuit
A. If the value is not correct, replace the harness between the connector X-BTS and the connector X-BTM.

8. Check the integrity of the connectors X-UCM1A.
Disconnect the connector X-UCM1A from the A-UCM.

9. Check the integrity of the harness between the connectors X-CAB_B and X-UCM1A.
From To Value
A. If the measurement is not correct, replace the harness between the connector X-CAB_B and the connector
X-UCM1A.

10. Check the AUX STEERING PRESSURE sensor integrity.
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Replace the AUX STEERING PRESSURE sensor.

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518116-09 - Hydraulic Filter is Clogged

Context:
Hydraulic Filter is Clogged.
Cause:

2. The hydraulic filter is clogged.
Solution:
2. Verify that the hydraulic filter is clean.
A. If the hydraulic filter is clean, replace the hydraulic filter sensor.
B. If the hydraulic filter is clogged, continue with Step 3.

3. Clean the hydraulic filter.
A. If the fault disappier after the cleaning, continue to work monitoring the fault.
B. If the fault is still present after the cleaning, bring the machine to a safe stop, and turn the engine OFF imme-
diately. Replace the air filter.
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518119-03 - Short to Power at Implement Coupler High Side Driver

Control Module: UCM
Context:
The A-UCM detects a malfunctioning from the COUPLER VALVE SOL. ( Y-YPE); as a consequence disable
implement coupler function (pin always engaged):
• Open Implement Coupler valve LSD
• Command Implement Coupler valve HSD to OFF
Cause:
The A-UCM detects on pin 7 of connector X-UCM3B a short circuit to power risen by BSP.

2. The harness between A-UCM and the COUPLER VALVE SOL. is damaged.
3. The connectors X-CAB_B or X-BTM or X-BTM_F or X-FRNT or X-UCM3B are damaged.
4. The harness between connectors X-BTM and X-FRNT is damaged.
5. The harness between connectors X-CAB_B and X-UCM3B is damaged.
6. The harness between connectors X-FRNT and X-YRC is damaged.
7. The COUPLER VALVE SOL. is damaged.
Solution:
2. Visually check the integrity of the harness between the connector X-UCM3B and the connector X-YPE for any
damage.

of both connectors.

4. Check the integrity of connectors X-BTM_F and X-FRNT.
Disconnect the connector X-BTM_F from the connector X-FRNT and visually check the integrity of pins R and S
of both connectors.

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6. Check the integrity of harness between the connector X-FRNT and the COUPLER VALVE SOL.
Remove the COUPLER VALVE SOL.
From To Value
Connector X-FRNT pin R Connector X-YPE pin 1 Short circuit
Connector X-FRNT pin S Connector X-YPE pin 2 Short circuit
Connector X-FRNT pin R Connector X-FRNT pin S Open circuit
Connector X-YPE pin 1 Connector X-YPE pin 2 Open circuit

7. Check the integrity of harness between the connectors X-BTM and X-BTM_F.
From To Value
Connector X-BTM pin 14 Connector X-BTM_F pin R Short circuit
Connector X-BTM pin 9 Connector X-BTM_F pin S Short circuit
Connector X-BTM pin 14 Connector X-BTM pin 9 Open circuit
Connector X-BTM_F pin R Connector X-BTM_F pin S Open circuit

8. Check the integrity of harness between the connectors X-UCM3B and X-CAB_B.
From To Value
Connector X-UCM3B pin 7 Connector X-UCM3B pin 4 Open circuit
Connector X-CAB_B pin 9 Connector X-CAB_B pin 14 Open circuit

9. Check the integrity of the COUPLER VALVE SOL.
Replace the COUPLER VALVE SOL.
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518119-04 - Short to Ground at Implement Coupler High Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding from the COUPLER VALVE SOL. ( Y-YPE); as a consequence disable implement
coupler function (pin always engaged):
Cause:

Solution:
damage.

3. Replace the COUPLER VALVE SOL.

of both connectors.

of both connectors.
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Remove the COUPLER VALVE SOL. Use a multimeter to perform the following check:
From To Value

From To Value

From To Value
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518119-05 - Open Circuit at Implement Coupler High Side Driver

Control Module: UCM
Context:
The A-UCM detects an open circuit or a low current absorption from the COUPLER VALVE SOL. ( Y-YPE); as a
consequence disable implement coupler function (pin always engaged):
Cause:
The A-UCM detects on pin 7 of connector X-UCM3B an Open Circuit or a Low Current Error risen by BSP.

Solution:
damage.

3. Replace the COUPLER VALVE SOL.

of both connectors.

of both connectors.
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From To Value

From To Value

From To Value
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518122-00 - Axle oil temperature is very high

Context:
Axle oil temperature is very high.
Cause:

2. The transmission oil temperature is very high.
Solution:
2. Bring the machine to a safe stop, and turn the engine OFF immediately. Replace the axle oil temperature sensor.
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518122-00 - Front Axle Oil Temp Sensor Over Resistance

Control Module: UCM
Context:
The A-UCM detects a value of resistance of the FRONT AXLE OIL TEMP ( B-FAX) higher than the upper limit;
as a consequence FAX Temperature not available:
• FAX warning disabled;
• Set PV_VC_STS.FAxOilTempWarn = 0x3 (out of range).
Cause:
The A-UCM detects on pin 17 of connector X-UCM4A a resistance value > 400 Ω.

2. The harness between A-UCM and the FRONT AXLE OIL TEMP is damaged.
3. The connectors X-CAB_B or X-BTM or X-BTM_F or X-FRNT or X-FAX or X-UCM4A are damaged.
4. The harness between connectors X-FAX and ground is damaged.
5. The harness between connectors X-FRNT and FRONT AXLE OIL TEMP is damaged.
6. The harness between connectors X-BTM and X-BTM_F is damaged.
7. The harness between connectors X-CAB_B and X-UCM4A is damaged.
8. The FRONT AXLE OIL TEMP is damaged.
Solution:
2. Visually check the integrity of the harness between the connector X-UCM4A and the connector X-FAX for any
damage.

3. Check the integrity of connector X-FAX.
Disconnect the connector X-FAX from the FRONT AXLE OIL TEMP and visually check the integrity of pins 1 and
2 of the connector.

4. Check the integrity of harness between the connector X-FAX and ground.
Remove the FRONT AXLE OIL TEMP.
From To Value
Connector X-FAX pin 2 Ground Short circuit
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connectors.

Disconnect the connector X-BTM_F from the connector X-FRNT and visually check the integrity of pin A of both
connectors.


8. Check the integrity of harness between the connector X-FRNT and the FRONT AXLE OIL TEMP.
From To Value
Connector X-FRNT pin A Connector X-FAX pin 1 Short circuit

From To Value
Connector X-BTM pin 17 Connector X-BTM_F pin A Short circuit

10. Check the integrity of harness between the connectors X-UCM4A and X-CAB_B.
From To Value

11. Replace the FRONT AXLE OIL TEMP.
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518122-01 - Front Axle Oil Temp Sensor Under Resistance

Control Module: UCM
Context:
The A-UCM detects a value of resistance of the FRONT AXLE OIL TEMP ( B-FAX) lower than the low limit;
as a consequence FAX Temperature not available:
• FAX warning disabled;
• Set PV_VC_STS.FAxOilTempWarn = 0x3 (out of range).
Cause:
The A-UCM detects on pin 17 of connector X-UCM4A a resistance value < 25 Ω.

2. The harness between A-UCM and the FRONT AXLE OIL TEMP is damaged.
3. The FRONT AXLE OIL TEMP is damaged.
4. The connectors X-CAB_B or X-BTM or X-BTM_F or X-FRNT or X-FAX or X-UCM4A are damaged.
5. The harness of FRONT AXLE OIL TEMP is damaged.
6. The harness between connectors X-FRNT and X-FAX is damaged.
7. The harness between connectors X-BTM and X-BTM_F is damaged.
8. The hardness between connectors X-CAB_B and X-UCM4A is damaged.
Solution:
2. Visually check the integrity of the harness between the connector X-UCM4A and the connector X-FAX for any
damage.

3. Replace the FRONT AXLE OIL TEMP.

4. Check the integrity of connector X-FAX.
Disconnect the connector X-FAX from the FRONT AXLE OIL TEMP and visually check the integrity of pins 1 and
2.

5. Check the integrity of harness of the FRONT AXLE OIL TEMP.
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From To Value
Connector X-FAX pin 1 Ground Open circuit

Disconnect the connector X-BTM_F from the connector X-FRNT and visually check the integrity of pin A of both
connectors.

7. Check the integrity of harness between the connector X-FRNT and the FRONT AXLE OIL TEMP.
Connect the FRONT AXLE OIL TEMP.
From To Value
Connector X-FRNT pin A Ground > 25 Ω

connectors.

9. Check the integrity of harness between the connector X-BTM_F and the connector X-BTM.
Connect the connector X-FRNT to the connector X-BTM_F.
From To Value
Connector X-BTM pin 17 Ground > 25 Ω


11. Check the integrity of harness between the connectors X-UCM4A and X-CAB_B.
Connect the connector X-BTM to the connector X-CAB_B.
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From To Value
Connector X-UCM4A pin 17 Ground > 25 Ω
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518122-16 - Axle oil temperature high

Context:
Axle oil temperature high.
Cause:

2. The axle oil temperature is high.
Solution:
2. Idle the machine and monitor the temperature. Wait until the oil temperature reach the proper temperature and
restart the machine.
B. If the oil temperature within the proper range continue to work monitoring the temperature.
3. Clean the cooler or operate the fan reverser. Wait until the oil temperature reach the proper temperature and
restart the machine.
4. Wait until the oil temperature reach the proper temperature and restart the machine and use a lower gear.
A. If the oil temperature rises again, idle the machine and replace the axle oil temperature sensor.
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518122-31 - Axle oil temperature sensor out of range

Context:
Axle oil temperature sensor out of range.
Cause:

2. The axle oil temperature sensor out of range.
Solution:
2. Idle the machine and monitor the temperature. Wait until the axle oil temperature reach the proper temperature
3. Wait until the axle oil temperature reach the proper temperature and restart the machine and use a lower gear.
4. Bring the machine to a safe stop, and turn the engine OFF immediately. Replace the axle oil temperature sensor.
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518129-03 - Short to Power at Boom Raise Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the boom rise, detects a short circuit to power; as a consequence:
• Boom Function disabled;
• Open Boom LSD;
• Command Boom HSD PWM to 0%;
• Disabled advanced EH features (RTT/Float, HC).
Cause:
The A-UCM detects, on pin 7 of connector X-UCM4A, a short circuit to power risen by BSP.

2. The harness between A-UCM and the connector X-BOOM_RAISE is damaged.
3. The connectors X-BOOM_RAISE or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B or
X-UCM4A are damaged.
5. The harness between connectors X-BTM_EH and X-BOOM_RAISE is damaged.
6. The harness between connectors X-FRNT_EH and X-BOOM_RAISE is damaged.
7. The BOOM_RAISE SOLENOID is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM4A, X-UCM1B and X-BOOM_RAISE
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BOOM_RAISE.
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From To Value
Connector X-UCM4A pin 7 Connector X-UCM1B pin 2 < + 24 V

6. Check the integrity of connectors X-CAB_EH and X-BTM_EH.
Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins B
and C of both connectors.

7. Check the integrity of harness between the connectors X-BTM_EH and X-BOOM_RAISE.
From To Value
Connector X-BTM_EH pin B Connector X-BTM_EH pin C < + 24 V
A. If the measurement is correct, replace the harness between connector X-CAB_EH and the A-UCM.

8. Check the integrity of connectors X-BTM_FEH and X-FRNT_EH.
Disconnect the connector X-BTM_FEH from the connector X-FRNT_EH and visually check the integrity of pins
B and C of both connectors.

9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BOOM_RAISE.
From To Value
Connector X-FRNT_EH pin B Connector X-FRNT_EH pin C < + 24 V
A. If the measurement is correct, replace the harness between connectors X-BTM_EH and X-BTM_FEH.

10. Check the integrity of connector X-BOOM_RAISE.
Disconnect the connector X-BOOM_RAISE from the ELECTROHYDRAULIC VALVE ( A-EH_VLV) and visually
check the integrity of pins 1 and 2 of the connector.
B. If the pins are not damaged, replace the BOOM RAISE SOLENOID.
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518129-04 - Short to Ground at Boom Raise Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the boom rise, detects a short circuit to power; as a consequence:
• Open Boom LSD;
Cause:
The A-UCM detects, on pin 7 of connector X-UCM4A, a short circuit to ground risen by BSP.

5. The harness between connectors X-BTM_EH and X-BOOM_RAISE is damaged.
6. The harness between connectors X-FRNT_EH and X-BOOM_RAISE is damaged.
Solution:
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BOOM_RAISE.
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From To Value
Connector X-UCM4A pin 7 Ground Open circuit
Connector X-UCM1B pin 2 Ground Open circuit


7. Check the integrity of harness between the connectors X-BTM_EH and X-BOOM_RAISE.
From To Value
Connector X-BTM_EH pin B Ground Open circuit
Connector X-BTM_EH pin C Ground Open circuit


9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BOOM_RAISE.
From To Value
Connector X-FRNT_EH pin B Ground Open circuit
Connector X-FRNT_EH pin C Ground Open circuit
A. If the measurements are correct, replace the harness between connectors X-BTM_EH and X-BTM_FEH.
B. If one measurement is correct, continue with Step 10.

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518129-05 - Open Circuit at Boom Raise Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the boom rise, detects an open circuit or a low current; as a consequence:
• Open Boom LSD;
Cause:
The A-UCM detects, on pin 7 of connector X-UCM4A, an open circuit or a low current risen by BSP.

4. The harness between connectors X-FRNT_EH and X-BTM_FEH is damaged.
5. The harness between connectors X-BTM_EH and X-BTM_FEH is damaged.
6. The harness between connectors A-UCM and the connector X-CAB_EH is damaged.
Solution:
for any damage.


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5. 5. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BOOM_RAISE.
Disconnect the connector X-BOOM_RAISE from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin B Connector X-BOOM_RAISE pin 1 Short circuit
Connector X-FRNT_EH pin C Connector X-BOOM_RAISE pin 2 Short circuit


7. Check the integrity of harness between the connectors X-BTM_FEH and X-BTM_EH.
From To Value
Connector X-BTM_FEH pin B Connector X-BTM_EH pin B Short circuit
Connector X-BTM_FEH pin C Connector X-BTM_EH pin C Short circuit



10. Check the integrity of harness between the A-UCM and the connector X-CAB_EH.
From To Value
Connector X-UCM4A pin 7 Connector X-CAB_EH pin B Short circuit
Connector X-UCM1B pin 2 Connector X-CAB_EH pin C Short circuit

11. Replace the BOOM RAISE SOLENOID.
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518130-03 - Short to Power at Boom Lower Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the boom lower, detects a short circuit to power; as a consequence:
• Open Boom LSD;
Cause:

2. The harness between A-UCM and the connector X-BOOM_LOWER is damaged.
3. The connectors X-BOOM_LOWER or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B or
5. The harness between connectors X-BTM_EH and X-BOOM_LOWER is damaged.
6. The harness between connectors X-FRNT_EH and X-BOOM_LOWER is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM4A, X-UCM1B and X-BOOM_LOWER
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BOOM_LOWER.
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From To Value
Connector X-UCM4A pin 6 Connector X-UCM1B pin 2 < + 24 V

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins D

7. Check the integrity of harness between the connectors X-BTM_EH and X-BOOM_LOWER.
From To Value
Connector X-BTM_EH pin D Connector X-BTM_EH pin C < + 24 V

D and C of both connectors.

9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BOOM_LOWER.
From To Value
Connector X-FRNT_EH pin D Connector X-FRNT_EH pin C < + 24 V

10. Check the integrity of connector X-BOOM_LOWER.
Disconnect the connector X-BOOM_LOWER from the ELECTROHYDRAULIC VALVE ( A-EH_VLV) and visually
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518130-04 - Short to Ground at Boom Lower Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the boom lower, detects a grounding connection; as a consequence:
• Open Boom LSD;
Cause:

5. The harness between connectors X-BTM_EH and X-BOOM_LOWER is damaged.
6. The harness between connectors X-FRNT_EH and X-BOOM_LOWER is damaged.
Solution:
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BOOM_LOWER.
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From To Value
A. If the measurements are correct, replace the A-UCM.
B. If one measurement is not correct, continue with Step 6.

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins D

7. Check the integrity of harness between the connectors X-BTM_EH and X-BOOM_LOWER.
From To Value
Connector X-BTM_EH pin D Ground Open circuit
Connector X-BTM_EH pin C Ground Open circuit


From To Value
Connector X-FRNT_EH pin D Ground Open circuit
Connector X-FRNT_EH pin C Ground Open circuit

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518130-05 - Open Circuit at Boom Lower Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the boom lower, detects an open circuit; as a consequence:
• Open Boom LSD;
Cause:
The A-UCM detects, on pin 6 of connector X-UCM4A, an open circuit risen by BSP.

4. The harness between X-FRNT_EH and X-BOOM_LOWER is damaged.
6. The harness between A-UCM and the connector X-CAB_EH is damaged.
Solution:
for any damage.


48083742_EN 31/07/2018
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Disconnect the connector X-BOOM_LOWER from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin D Connector X-BOOM_LOWER pin 1 Short circuit
Connector X-FRNT_EH pin C Connector X-BOOM_LOWER pin 2 Short circuit

Disconnect the connector X-CAB_EH from the connector X-BTM_EHand visually check the integrity of pins D

From To Value
Connector X-BTM_FEH pin D Connector X-BTM_EH pin D Short circuit
Connector X-BTM_FEH pin C Connector X-BTM_EH pin C Short circuit


Disconnect the connector X-UCM1B from the A-UCMand visually check the integrity of pin 2.

From To Value
Connector X-UCM4A pin 6 Connector X-CAB_EH pin D Short circuit
Connector X-UCM1B pin 2 Connector X-CAB_EH pin C Short circuit

11. Replace the BOOM LOWER SOLENOID.
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55.9 [55.DTC] / 458
48083742_EN 31/07/2018
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518131-03 - Short to Power/Open Circuit at Boom Valve Low Side

Driver
Control Module: UCM
Context:
The A-UCM detects a short circuit to power or an open circuit or a low current when drives a Boom Valve; as a
consequence:
• Open Boom LSD;
Cause:
The A-UCM detects, on pin 2 of connector X-UCM1B, a short circuit to power or an open circuit or a low current risen
by BSP.

2. The harness between the A-UCM and the connectors X-BOOM_RAISE and X-BOOM_LOWER is visually dam-
aged.
4. The harness between A-UCM and the connectors X-BOOM_RAISE and X-BOOM_LOWER is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1B, X-BOOM_RAISE and
X-BOOM_LOWER for any damage.


4. Check the integrity of harness between the A-UCM and the connectors X-BOOM_RAISE and X-BOOM_LOWER.
From To Value
Connector X-UCM1B pin 2 Ground 0V
48083742_EN 31/07/2018
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B. If the measurement is not correct, check the correct functioning of the circuits relevant to:
- the Boom Raise Valve High Side Driver (see procedure 518129-03 – Short to Power at Boom Raise Valve
High Side Driver).
- the Boom Lower Valve High Side Driver (see procedure 518130-03 – Short to Power at Boom Lower Valve
High Side Driver).
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518131-04 - Short to Ground at Boom Valve Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding connection when drives a Boom Valve; as a consequence:
• Open Boom LSD;
Cause:

2. The harness between the A-UCM and the connectors X-BOOM_RAISE and X-BOOM_LOWER is visually dam-
aged.
4. The harness between A-UCM and the connectors X-BOOM_RAISE and X-BOOM_LOWER is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1B, X-BOOM_RAISE and
X-BOOM_LOWER for any damage.


4. Check the integrity of harness between the A-UCM and the connectors X-BOOM_RAISE and X-BOOM_LOWER.
From To Value
- the Boom Raise Valve High Side Driver (see procedure 518129-04 – Short to Ground at Boom Raise Valve
High Side Driver).
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- the Boom Lower Valve High Side Driver (see procedure 518130-04 – Short to Ground at Boom Lower
Valve High Side Driver).
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518132-03 - Short to Power at Bucket Roll Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the bucket roll valve, detects a short circuit to power; as a consequence:
• Bucket Function disabled
• Open Bucket LSD
• Command Bucket HSD PWM to 0%
• Disabled advanced EH features ( RTD)
Cause:

2. The harness between A-UCM and the connector X-BUCKET_ROLL is damaged.
3. The connectors X-BUCKET_ROLL or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B or
X-UCM3B are damaged.
5. The harness between connectors X-BTM_EH and X-BUCKET_ROLL is damaged.
6. The harness between connectors X-FRNT_EH and X-BUCKET_ROLL is damaged.
7. The BUCKET ROLL SOLENOID is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM3B, X-UCM1B and X-BUCKET_ROLL
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BUCKET_ROLL.
48083742_EN 31/07/2018
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From To Value
Connector X-UCM3B pin 17 Connector X-UCM1B pin 30 < + 24 V

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins E
and F of both connectors.

7. Check the integrity of harness between the connectors X-BTM_EH and X-BUCKET_ROLL.
From To Value
Connector X-BTM_EH pin E Connector X-BTM_EH pin F < + 24 V

E and F of both connectors.

9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BUCKET_ROLL.
From To Value
Connector X-FRNT_EH pin E Connector X-FRNT_EH pin F < + 24 V

10. Check the integrity of connector X-BUCKET_ROLL.
Disconnect the connector X-BUCKET_ROLL from the ELECTROHYDRAULIC VALVE ( A-EH_VLV) and visually
B. If the pins are not damaged, replace the BUCKET ROLL SOLENOID.
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518132-04 - Short to Ground at Bucket Roll Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the bucket roll valve, detects a grounding connection; as a consequence:
• Open Bucket LSD
• Command Bucket HSD PWM to 0%
• Disabled advanced EH features ( RTD)
Cause:

5. The harness between connectors X-BTM_EH and X-BUCKET_ROLL is damaged.
Solution:
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BUCKET_ROLL.
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From To Value

Disconnect the connector X-CAB_EH from the connector X-CAB_EH and visually check the integrity of pins E

7. Check the integrity of harness between the connectors X-BTM_EH and X-BUCKET_ROLL.
From To Value
Connector X-BTM_EH pin E Ground Open circuit
Connector X-BTM_EH pin F Ground Open circuit
A. If the measurements are correct, replace the harness between connector X-CAB_EH and the A-UCM.


9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BUCKET_ROLL.
From To Value
Connector X-FRNT_EH pin E Ground Open circuit
Connector X-FRNT_EH pin F Ground Open circuit

B. If the pins are not damaged, replace the BUCKET ROLL SOLENOID.
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518132-05 - Open Circuit at Bucket Roll Valve High Side Driver

Control Module: UCM
Context:
• Open Boom LSD;
• Command Bucket HSD PWM to 0%;
• Disabled advanced EH features ( RTD).
Cause:

Solution:
for any damage.


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5. Check the integrity of harness between the connectors X-FRNT_EH and X-BUCKET_ROLL.
Disconnect the connector X-BUCKET_ROLL from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin E Connector X-BUCKET_ROLL pin 1 Short circuit
Connector X-FRNT_EH pin F Connector X-BUCKET_ROLL pin 2 Short circuit

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins E

From To Value
Connector X-BTM_FEH pin E Connector X-BTM_EH pin E Short circuit
Connector X-BTM_FEH pin F Connector X-BTM_EH pin F Short circuit


A. If the pin is damaged, replace the harness..

From To Value
Connector X-UCM3B pin 17 Connector X-CAB_EH pin E Short circuit
Connector X-UCM1B pin 30 Connector X-CAB_EH pin F Short circuit

11. Replace the BUCKET ROLL SOLENOID.
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55.9 [55.DTC] / 469
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55.9 [55.DTC] / 470
518133-03 - Short to Power at Bucket Dump Valve High Side Driver

Control Module: UCM
Context:
• Bucket Function disabled;
• Open Bucket LSD;
Cause:

2. The harness between A-UCM and the connector X-BUCKET_DUMP is damaged.
3. The connectors X-BUCKET_DUMP or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B
or X-UCM3B are damaged.
5. The harness between connectors X-BTM_EH and X-BUCKET_DUMP is damaged.
6. The harness between connectors X-FRNT_EH and X-BUCKET_DUMP is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM3B, X-UCM1B and X-BUCKET_DUMP
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BUCKET_DUMP.
48083742_EN 31/07/2018
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From To Value

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins G

7. Check the integrity of harness between the connectors X-BTM_EH and X-BUCKET_DUMP.
From To Value
Connector X-BTM_EH pin G Connector X-BTM_EH pin F < + 24 V

G and F of both connectors.

9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BUCKET_DUMP.
From To Value
Connector X-FRNT_EH pin G Connector X-FRNT_EH pin F < + 24 V

10. Check the integrity of connector X-BUCKET_DUMP.
Disconnect the connector X-BUCKET_DUMP from the ELECTROHYDRAULIC VALVE ( A-EH_VLV) and visually
B. If the pins are not damaged, replace the BUCKET DUMP SOLENOID.
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518133-04 - Short to Ground at Bucket Dump Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the bucket dump valve, detects a grounding connection; as a consequence:
Cause:

5. The harness between connectors X-BTM_EH and X-BUCKET_DUMP is damaged.
Solution:
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BUCKET_DUMP.
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From To Value


7. Check the integrity of harness between the connectors X-BTM_EH and X-BUCKET_DUMP.
From To Value
Connector X-BTM_EH pin G Ground Open circuit
Connector X-BTM_EH pin F Ground Open circuit


9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BUCKET_DUMP.
From To Value
Connector X-FRNT_EH pin G Ground Open circuit
Connector X-FRNT_EH pin F Ground Open circuit

B. If the pins are not damaged, replace the BUCKET DUMP SOLENOID.
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518133-05 - Open Circuit at Bucket Dump Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the bucket dump valve, detects an open circuit or a low current; as a consequence:
Cause:

7. The BUCKET DUMP SOLENOID is damaged.
Solution:
for any damage.


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5. Check the integrity of harness between the connectors X-FRNT_EH and X-BUCKET_DUMP.
Disconnect the connector X-BUCKET_DUMP from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin G Connector X-BUCKET_DUMP pin 1 Short circuit
Connector X-FRNT_EH pin F Connector X-BUCKET_DUMP pin 2 Short circuit


From To Value
Connector X-BTM_FEH pin G Connector X-BTM_EH pin G Short circuit
Connector X-BTM_FEH pin F Connector X-BTM_EH pin F Short circuit



From To Value
Connector X-UCM3B pin 25 Connector X-CAB_EH pin G Short circuit
Connector X-UCM1B pin 30 Connector X-CAB_EH pin F Short circuit

11. Replace the BUCKET DUMP SOLENOID.
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55.9 [55.DTC] / 476
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55.9 [55.DTC] / 477
518134-03 - Short to Power/Open Circuit at Bucket Valve Low Side

Driver
Control Module: UCM
Context:
The A-UCM detects a short circuit to power or an open circuit or a low current when drives a Bucket Valve; as a
consequence:
Cause:
The A-UCM detects, on pin 30 of connector X-UCM1B, a short circuit to power or an open circuit or a low current
risen by BSP.

2. The harness between the A-UCM and the connectors X-BUCKET_ROLL and X-BUCKET_DUMP is visually dam-
aged.
4. The harness between A-UCM and the connectors X-BOOM_ROLL and X-BOOM_DUMP is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1B, X-BUCKET_ROLL and
X-BUCKET_DUMP for any damage.


4. Check the integrity of harness between the A-UCM and the connectors X-BUCKET_ROLL and
X-BUCKET_DUMP.
From To Value
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- the Bucket Roll Valve High Side Driver (see procedure 518132-03 – Short to Power at Bucket Roll Valve
High Side Driver).
- the Bucket Dump Valve High Side Driver (see procedure 518133-03 – Short to Power at Bucket Dump
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518134-04 - Short to Ground at Bucket Valve Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding connection when drives a Bucket Valve; as a consequence:
Cause:

2. The harness between the A-UCM and the connectors X-BUCKET_ROLL and X-BUCKET_DUMP is visually dam-
aged.
4. The harness between A-UCM and the connectors X-BOOM_ROLL and X-BOOM_DUMP is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1B, X-BUCKET_ROLL and
X-BUCKET_DUMP for any damage.


4. Check the integrity of harness between the A-UCM and the connectors X-BUCKET_ROLL and
X-BUCKET_DUMP.
From To Value
- the Bucket Roll Valve High Side Driver (see procedure 518132-04 – Short to Ground at Bucket Roll Valve
High Side Driver).
48083742_EN 31/07/2018
55.9 [55.DTC] / 480
- the Bucket Dump Valve High Side Driver (see procedure 518133-04 – Short to Ground at Bucket Dump
48083742_EN 31/07/2018
55.9 [55.DTC] / 481
518135-03 - Boom Angle Sensor Channel 2 Over Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the Channel 2 of the BOOM ANGLE ( B-BKT_ANG) greater than the upper limit.
Cause:
The A-UCM detects, on pin 22 of connector X-UCM1B, a voltage > 4.75 V; as a consequence, the advanced CASE
CONSTRUCTION BOOM features (RTT/Float and HC) is disabled.

4. The BOOM ANGLE is damaged.
5. The harness relevant to the BOOM ANGLE is damaged.
Solution:

3. Check the BOOM ANGLE sensor integrity.
Remove the BOOM ANGLE sensor. Use a multimeter to perform the following check:
From To Value
BOOM ANGLE pin P2 BOOM ANGLE pin N2 The sensor resistance
A. If the resistance is an open circuit, replace the BOOM ANGLE.

From To Value
BOOM ANGLE pin P2 BOOM ANGLE pin OUT2 A resistance value
A. If the measurement is a short circuit, replace the BOOM ANGLE.

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Mount the BOOM ANGLE sensor.
From To Value

Visually check the integrity of pin T of both connectors.

From To Value
Connector X-BTM_EH pin T Ground < + 5V

Visually check the integrity of pins T and V of both connectors.

From To Value
Connector X-FRNT_EH pin T Connector X-FRNT_EH pin V Open circuit
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518135-04 - Boom Angle Sensor Channel 2 Under Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the Channel 2 of the BOOM ANGLE ( B-BM_ANG) lower than the lower limit.
Cause:

4. The BOOM ANGLE is not correctly supplied.
5. The BOOM ANGLE sensor is damaged.
6. The harness between the connectors X-BOA and X-FRNT_EH is damaged.
Solution:

3. Check the integrity of the connector X-BOA.
Disconnect the connector X-BOA from the BOOM ANGLE.

4. Check the BOOM ANGLE power supply.
From To Value
Connector X-BOA pin F Connector X-BOA pin E (Ref) + 5V
A. If the value is not correct, check the harness between the connectors X-BOA, X-FRNT_EH and X-FRNT.
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5. Replace the BOOM ANGLE sensor.


7. Check the harness between the connectors X-BOA and X-FRNT_EH.
From To Value
Connector X-BOA pin D Connector X-FRNT_EH pin T Short circuit


From To Value
Connector X-BTM_FEH pin T Connector X-BTM_EH pin T Short circuit


From To Value
Connector X-CAB_EH pin T Connector X-UCM1B pin 22 Short circuit
48083742_EN 31/07/2018
55.9 [55.DTC] / 485
48083742_EN 31/07/2018
55.9 [55.DTC] / 486
518136-03 - Bucket Angle Sensor Channel 2 Over Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the Channel 2 of the BUCKET ANGLE ( B-BKT_ANG) greater than the upper limit.
Cause:

4. The BUCKET ANGLE is damaged.
5. The harness relevant to the BUCKET ANGLE is damaged.
Solution:

3. Check the BUCKET ANGLE sensor integrity.
Remove the BUCKET ANGLE sensor.
From To Value
BUCKET ANGLE pin P2 BUCKET ANGLE pin N2 The sensor resistance
A. If the resistance is an open circuit, replace the BUCKET ANGLE.

From To Value
BUCKET ANGLE pin P2 BUCKET ANGLE pin OUT2 A resistance value
A. If the measurement is a short circuit, replace the BUCKET ANGLE.

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Mount the BUCKET ANGLE sensor.
From To Value

Visually check the integrity of pin X of both connectors.

From To Value
Connector X-BTM_EH pin X Ground < + 5V

Visually check the integrity of pins W and V of both connectors.

From To Value
Connector X-FRNT_EH pin X Connector X-FRNT_EH pin V Open circuit
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518136-04 - Bucket Angle Sensor Channel 2 Under Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the Channel 2 of the BUCKET ANGLE ( B-BKT_ANG) greater than the lower limit.
Cause:

4. The BUCKET ANGLE is not correctly supplied.
5. The BUCKET ANGLE sensor is damaged.
6. The harness between the connectors X-BUA and X-FRNT_EH is damaged.
8. The harness between the connectors X-CAB_EH and X-UCM1B is damaged
Solution:

3. Check the integrity of the connector X-BUA.
Disconnect the connector X-BUA from the BUCKET ANGLE.
Visually check the integrity of pins F, E and D of the connector.

4. Check the BUCKET ANGLE power supply.
From To Value
Connector X-BUA pin F Connector X-BUA pin E + 5V
A. If the value is not correct, check the harness between the connectors X-BUA, X-FRNT_EH and X-FRNT.
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5. Replace the BUCKET ANGLE sensor.


7. Check the harness between the connectors X-BUA and X-FRNT_EH.
From To Value
Connector X-BUA pin D Connector X-FRNT_EH pin X Short circuit


From To Value
Connector X-BTM_FEH pin X Connector X-BTM_EH pin X Short circuit

A. If the pin is damaged, replace the relevant harness..

11. 11. Check the integrity of the harness between the connectors X-CAB_EH and X-UCM1B.
From To Value
Connector X-CAB_EH pin X Connector X-UCM1B pin 23 Short circuit
48083742_EN 31/07/2018
55.9 [55.DTC] / 490
48083742_EN 31/07/2018
55.9 [55.DTC] / 491
518137-03 - Short to Power at AUX 1 Left High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 1 Left, detects a short circuit to power; as a consequence:
• AUX I Function disabled;
• Open AUX 1 LSD ;
• Command AUX I HSD PWMs to 0% Bucket Function disabled.
Cause:

2. The harness between A-UCM and the connector X-AUX_1_LEFT is damaged.
3. The connectors X-AUX_1_LEFT or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B or
5. The harness between connectors X-BTM_EH and X-AUX_1_LEFT is damaged.
6. The harness between connectors X-FRNT_EH and X-AUX_1_LEFT is damaged.
7. The AUX 1 LEFT SOLENOID is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM3B, X-UCM1B and X-AUX_1_LEFT
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-AUX_1_LEFT.
48083742_EN 31/07/2018
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From To Value

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins H
and J of both connectors.

7. Check the integrity of harness between the connectors X-BTM_EH and X-AUX_1_LEFT.
From To Value
Connector X-BTM_EH pin H Connector X-BTM_EH pin J < + 24 V

H and J of both connectors.

9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-AUX_1_LEFT.
From To Value
Connector X-FRNT_EH pin H Connector X-FRNT_EH pin J < + 24 V

10. Check the integrity of connector X-AUX_1_LEFT.
Disconnect the connector X-AUX_1_LEFT from the ELECTROHYDRAULIC VALVE ( A-EH_VLV) and visually
B. If the pins are not damaged, replace the AUX 1 LEFT SOLENOID.
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518137-04 - Short to Ground at AUX 1 Left High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 1 Left, detects a grounding connection; as a consequence:
Cause:

Solution:
for any damage.



48083742_EN 31/07/2018
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From To Value


From To Value
Connector X-BTM_EH pin H Ground Open circuit
Connector X-BTM_EH pin J Ground Open circuit


From To Value
Connector X-FRNT_EH pin H Ground Open circuit
Connector X-FRNT_EH pin J Ground Open circuit

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518137-05 - Open Circuit at AUX 1 Left High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 1 Left, detects an open circuit or a low current; as a consequence:
Cause:

Solution:
for any damage.


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5. Check the integrity of harness between the connectors X-FRNT_EH and X-AUX_1_LEFT.
Disconnect the connector X-AUX_1_LEFT from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin H Connector X-AUX_1_LEFT pin 1 Short circuit
Connector X-FRNT_EH pin J Connector X-AUX_1_LEFT pin 2 Short circuit


From To Value
Connector X-BTM_FEH pin H Connector X-BTM_EH pin H Short circuit
Connector X-BTM_FEH pin J Connector X-BTM_EH pin H Short circuit



From To Value
Connector X-UCM3B pin 32 Connector X-CAB_EH pin H Short circuit
Connector X-UCM1B pin 10 Connector X-CAB_EH pin J Short circuit

11. Replace the AUX 1 LEFT SOLENOID.
48083742_EN 31/07/2018
55.9 [55.DTC] / 497
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55.9 [55.DTC] / 498
518138-03 - Short to Power at AUX 1 Right High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 1 Right, detects a short circuit to power; as a consequence:
Cause:

2. The harness between A-UCM and the connector X-AUX_1_RIGHT is damaged.
3. The connectors X-AUX_1_RIGHT or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B or
5. The harness between connectors X-BTM_EH and X-AUX_1_RIGHT is damaged.
6. The harness between connectors X-FRNT_EH and X-AUX_1_RIGHT is damaged.
7. The AUX 1 RIGHT SOLENOID is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM3B, X-UCM1B and X-AUX_1_RIGHT
for any damage.


4. Check the integrity of connector X-UCM1B

5. Check the integrity of harness between the A-UCM and the connector X-AUX_1_RIGHT.
48083742_EN 31/07/2018
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From To Value

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins K

7. Check the integrity of harness between the connectors X-BTM_EH and X-AUX_1_RIGHT.
From To Value
Connector X-BTM_EH pin K Connector X-BTM_EH pin J < + 24 V

K and J of both connectors.

9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-AUX_1_RIGHT.
From To Value
Connector X-FRNT_EH pin K Connector X-FRNT_EH pin J < + 24 V

10. Check the integrity of connector X-AUX_1_RIGHT.
Disconnect the connector X-AUX_1_RIGHT from the ELECTROHYDRAULIC VALVE ( A-EH_VLV) and visually
B. If the pins are not damaged, replace the AUX 1 RIGHT SOLENOID.
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518138-04 - Short to Ground at AUX 1 Right High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 1 Right, detects a grounding connection; as a consequence:
Cause:

5. The hardness between connectors X-BTM_EH and X-AUX_1_RIGHT is damaged.
Solution:
for any damage.


4. Check the integrity of connector X-UCM1B

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From To Value


From To Value
Connector X-BTM_EH pin K Ground Open circuit
Connector X-BTM_EH pin J Ground Open circuit


From To Value
Connector X-FRNT_EH pin K Ground Open circuit
Connector X-FRNT_EH pin J Ground Open circuit

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518138-05 - Open Circuit at AUX 1 Right High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 1 Right, detects an open circuit or a low current; as a consequence:
Cause:

Solution:
for any damage.


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5. Check the integrity of harness between the connectors X-FRNT_EH and X-AUX_1_RIGHT.
Disconnect the connector X-AUX_1_RIGHT from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin K Connector X-AUX_1_RIGHT pin 1 Short circuit
Connector X-FRNT_EH pin J Connector X-AUX_1_RIGHT pin 2 Short circuit

A. If one pin is damaged, rreplace the harness relevant to the damaged connector.

From To Value
Connector X-BTM_FEH pin K Connector X-BTM_EH pin K Short circuit
Connector X-BTM_FEH pin J Connector X-BTM_EH pin J Short circuit



From To Value
Connector X-UCM3B pin 33 Connector X-CAB_EH pin K Short circuit
Connector X-UCM1B pin 10 Connector X-CAB_EH pin J Short circuit

11. Replace the AUX 1 RIGHT SOLENOID.
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55.9 [55.DTC] / 504
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518139-03 - Short to Power/Open Circuit at AUX 1 Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a short circuit to power or an open circuit or a low current when drives an AUX 1 Solenoid;
as a consequence:
• AUX I Function disabled
• Open AUX 1 LSD
• Command AUX I HSD PWMs to 0%
Cause:
The A-UCM detects, on pin 10 of connector X-UCM1B, a short circuit to power or an open circuit or a low current
risen by BSP.

2. The harness between the A-UCM and the connectors X-AUX_1_LEFT and X-AUX_1_RIGHT is visually damaged.
4. The harness between A-UCM and the connectors X-AUX_1_LEFT and X-AUX_1_RIGHT is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1B, X-AUX_1_LEFT and
X-AUX_1_RIGHT for any damage.


4. Check the integrity of harness between the A-UCM and the connectors X-AUX_1_LEFT and X-AUX_1_RIGHT.
From To Value
- the AUX 1 Left High Side Driver (see procedure 518137-03 – Short to Power at AUX 1 Left High Side
Driver).
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- the AUX 1 Right High Side Driver (see procedure 518138-03 – Short to Power at AUX 1 Right High Side
Driver).
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518139-04 - Short to Ground at AUX 1 Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding connection when drives an AUX 1 Solenoid; as a consequence:
• Open AUX 1 LSD
Cause:

Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1B, X-AUX_1_LEFT and


From To Value
- the AUX 1 Left High Side Driver (see procedure 518137-04 – Short to Ground at AUX 1 Left High Side
Driver).
- the AUX 1 Right High Side Driver (see procedure 518138-04 – Short to Ground at AUX 1 Right High Side
Driver).
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55.9 [55.DTC] / 508
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518140-03 - Short to Power at AUX 2 Left High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 2 Left, detects a short circuit to power; as a consequence:
• AUX II Function disabled;
• Open AUX II LSD;
• Command AUX II HSD PWMs to 0 °/s Bucket Function disabled.
Cause:

3. The connectors X-AUX_2_LEFT or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1A or
6. The harness between X-FRNT_EH and X-AUX_2_LEFT is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM4A, X-UCM1A and X-AUX_2_LEFT
for any damage.



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From To Value
Connector X-UCM4A pin 19 Connector X-UCM1A pin 21 < + 24 V

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins L
and M of both connectors.

From To Value
Connector X-BTM_EH pin L Connector X-BTM_EH pin M < + 24 V

L and M of both connectors.

From To Value
Connector X-FRNT_EH pin L Connector X-FRNT_EH pin M < + 24 V

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518140-04 - Short to Ground at AUX 2 Left High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 2 Left, detects a grounding connection; as a consequence:
Cause:

6. The harness between X-FRNT_EH and X-AUX_2_LEFT is damaged.
Solution:
for any damage.



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From To Value


From To Value
Connector X-BTM_EH pin L Ground Open circuit
Connector X-BTM_EH pin M Ground Open circuit


From To Value
Connector X-FRNT_EH pin L Ground Open circuit
Connector X-FRNT_EH pin M Ground Open circuit

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518140-05 - Open Circuit at AUX 2 Left High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 2 Left, detects an open circuit or a low current; as a consequence:
Cause:

Solution:
for any damage.


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5. Check the integrity of harness between the connectors X-FRNT_EH and X-AUX_2_LEFT.
Disconnect the connector X-AUX_2_LEFT from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin L Connector X-AUX_2_LEFT pin 1 Short circuit
Connector X-FRNT_EH pin M Connector X-AUX_2_LEFT pin 2 Short circuit


From To Value
Connector X-BTM_FEH pin L Connector X-BTM_EH pin L Short circuit
Connector X-BTM_FEH pin M Connector X-BTM_EH pin M Short circuit



From To Value
Connector X-UCM4A pin 19 Connector X-CAB_EH pin L Short circuit
Connector X-UCM1A pin 21 Connector X-CAB_EH pin M Short circuit

11. Replace the AUX 2 LEFT SOLENOID.
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518141-03 - Short to Power at AUX 2 Right High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 2 Right, detects a short circuit to power; as a consequence:
Cause:

3. The connectors X-AUX_2_RIGHT or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1A or
6. The harness between X-FRNT_EH and X-AUX_2_RIGHT is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM4A, X-UCM1A and X-AUX_2_RIGHT
for any damage.



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From To Value
Connector X-UCM4A pin 13 Connector X-UCM1A pin 21 < + 24 V

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins N

From To Value
Connector X-BTM_EH pin N Connector X-BTM_EH pin M < + 24 V

N and M of both connectors.

From To Value
Connector X-FRNT_EH pin N Connector X-FRNT_EH pin M < + 24 V

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518141-04 - Short to Ground at AUX 2 Right High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 2 Right, detects a grounding connection; as a consequence:
Cause:

Solution:
for any damage.



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From To Value


From To Value
Connector X-BTM_EH pin N Ground Open circuit
Connector X-BTM_EH pin M Ground Open circuit


From To Value
Connector X-FRNT_EH pin N Ground Open circuit
Connector X-FRNT_EH pin M Ground Open circuit

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518141-05 - Open Circuit at AUX 2 Right High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 2 Right, detects an open circuit or a low current; as a consequence:
Cause:

6. The harness between A-UCM and X-CAB_EH is damaged.
Solution:
for any damage.


4. Check the integrity of connector X-BTM_FEH and X-FRNT_EH.
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5. Check the integrity of harness between the connectors X-FRNT_EH and X-AUX_2_RIGHT.
Disconnect the connector X-AUX_2_RIGHT from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin N Connector X-AUX_2_RIGHT pin 1 Short circuit
Connector X-FRNT_EH pin M Connector X-AUX_2_RIGHT pin 2 Short circuit


From To Value
Connector X-BTM_FEH pin N Connector X-BTM_EH pin N Short circuit
Connector X-BTM_FEH pin M Connector X-BTM_EH pin M Short circuit



From To Value
Connector X-UCM4A pin 13 Connector X-CAB_EH pin N Short circuit
Connector X-UCM1A pin 21 Connector X-CAB_EH pin M Short circuit

11. Replace the AUX 2 RIGHT SOLENOID.
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55.9 [55.DTC] / 522
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518142-03 - Short to Power/Open Circuit at AUX 2 Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a short circuit to power or an open circuit or a low current when drives an AUX 2 Solenoid;
as a consequence:
• AUX II Function disabled
• Open AUX II LSD
• Command AUX II HSD PWMs to 0%
Cause:
The A-UCM detects, on pin 21 of connector X-UCM1A, a short circuit to power or an open circuit or a low current
risen by BSP.

3. The connector X-UCM1A is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1A, X-AUX_2_LEFT and


From To Value
Connector X-UCM1A pin 21 Ground 0V
- the AUX 2 Left High Side Driver (see procedure 518140-03 – Short to Power at AUX 2 Left High Side
Driver).
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- the AUX 2 Right High Side Driver (see procedure 518141-03 – Short to Power at AUX 2 Right High Side
Driver).
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518142-04 - Short to Ground at AUX 2 Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding connection when drives an AUX 2 Solenoid; as a consequence:
• AUX II Function disabled
• Open AUX II LSD
• Command AUX II HSD PWMs to 0%
Cause:

3. The connector X-UCM1A is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1A, X-AUX_2_LEFT and


From To Value
- the AUX 2 Left High Side Driver (see procedure 518140-04 – Short to Ground at AUX 2 Left High Side
Driver).
- the AUX 2 Right High Side Driver (see procedure 518141-04 – Short to Ground at AUX 2 Right High Side
Driver).
48083742_EN 31/07/2018
55.9 [55.DTC] / 526
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55.9 [55.DTC] / 527
518143-03 - Short to Power/Open Circuit at Implement Coupler Low

Side Driver
Control Module: UCM
Context:
The A-UCM detects a malfunctioning from the COUPLER VALVE SOL. ( Y-YPE); as a consequence disable
implement coupler function (pin always engaged):
Cause:
The A-UCM detects on pin 4 of connector X-UCM3B a Short circuit to power or an Open Circuit or a Low Current
risen by BSP.

4. The connectors X-CAB_B or X-BTM or X-BTM_F or X-FRNT are damaged.
Solution:
A. f the fault is present and active, continue with Step 2.
damage.

By means of a multimeter, measure the resistance between pin 1 and pin 2 of the COUPLER VALVE SOL. con-
nector.
A. If the resistance is an open circuit, replace COUPLER VALVE SOL.

of both connectors.
48083742_EN 31/07/2018
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of both connectors.

From To Value


From To Value

From To Value
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518143-04 - Short to Ground at Implement Coupler Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding from the COUPLER VALVE SOL. ( Y-YPE); as a consequence disable implement
coupler function (pin always engaged):
Cause:

3. The connectors X-CAB_B or X-BTM or X-BTM_F or X-FRNT are damaged.
Solution:
damage.

of both connectors.

of both connectors.

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From To Value


From To Value

From To Value

Replace the COUPLER VALVE SOL.
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518144-03 - Short to Power at Aux Steering Enable High Side Driver

Control Module: UCM
Context:
The A-UCM detects a value from X-LC3 greater than the upper limit, as a consequence:
• Disable Aux Steering function;
• Aux steering function forced to activate.
Cause:

2. The harness between the connector X-UCM4B and the connector X-LC3 is damaged.
3. The relay SEC STEERING ( K-3R2) of LC3 is damaged.
Solution:
2. Visually check the integrity of the harness between the connector X-UCM4B and the connector X-LC3 for any
damage.

3. Replace the relay SEC STEERING ( K-3R2) of LC3.

Disconnect the connector X-UCM4B from A-UCM.
Visually check the integrity of pin 8 of the connector.

5. Check the integrity of the connector X-LC3.
Disconnect the connector X-LC3 from the LC3.
Visually check the integrity of pins R2_30, R2_85, R2_86 and R2_87 of the connector.
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6. Check the integrity of the harness between the connector X-UCM4B and the connector X-LC3.
From To Value
Connector X-UCM4B pin 8 Connector X-LC3 pin R2_86 Short circuit
A. If the measurement is not correct, replace the harness between the connector X-UCM4B and the connector
X-LC3.

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518144-04 - Short to Ground at Aux Steering Enable High Side

Driver
Control Module: UCM
Context:
The A-UCM detects a grounding from X-LC3, as a consequence:

• Disable Aux Steering function.
Cause:

Solution:
damage.



5. Check the integrity of the harness relevant to the connector X-LC3.
From To Value
Connector X-LC3 pin R2_86 Connector X-LC3 pin R2_85 Open circuit
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X-LC3.

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518144-05 - Open Circuit at Aux Steering Enable High Side Driver

Control Module: UCM
Context:
The A-UCM detects an open circuit with respect to X-LC3, as a consequence:

• Disable Aux Steering function.
Cause:
The A-UCM detects, on pin 8 of connector X-UCM4B, an open circuit or a low current error risen by BSP.

Solution:
damage.


4. Check the integrity of the harness between the connector X-UCM4B and the connector X-LC3.
From To Value
Connector X-LC3 pin R2_86 Connector X-UCM4B pin 8 Short circuit
X-LC3.

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55.9 [55.DTC] / 536

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55.9 [55.DTC] / 537
518145-03 - Short to Power/Open Circuit at Park Brake Low Side

Driver
Control Module: UCM
Context:
The A-UCM detects a value from PARKING BRAKE SOLENOID ( Y-Y_BP) out of higher limit.
Cause:
The A-UCM detects on pin 22 of connector X-UCM1A a short circuit to power.

2. The harness between A-UCM and the PARKING BRAKE SOLENOID is damaged.
4. The connectors X-BTM and X-CAB_B are damaged.
Solution:
1. Park Brake Function disabled (PB always active)

- Open PB LSD
- Set B.PBrakeAct = 01 (Park Brake Actuator Active)

A. If the resistance is a short circuit, replace the PARKING BRAKE SOLENOID.
B. If the resistance is not short circuit, continue with Step 4.

of both connectors.
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5. Check the integrity of harness of connector X-BTM.
From To Value

6. Check the integrity of harness of connector X-CAB_B.
Disconnect the connectors X-UCM3B and X-UCM1A from A-UCM
From To Value
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518145-04 - Short to Ground at Park Brake Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding from PARKING BRAKE SOLENOID ( Y-Y_BP).
Cause:
The A-UCM detects on pin 22 of connector X-UCM1A a short circuit to ground.

2. The harness between A-UCM and the PARKING BRAKE SOLENOID is damaged.
4. The connectors X-BTM and X-CAB_B are damaged.
5. The harness of connector X-BTM is damaged.
6. The harness of connector X-CAB_B is damaged.
Solution:
1. Set the key in OFF position.

A. If the resistance is a short circuit, replace the PARKING BRAKE SOLENOID.
B. If the resistance is not short circuit, continue with Step 4.

of both connectors.

5. Check the integrity of harness of connector X-BTM.
48083742_EN 31/07/2018
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From To Value
Connector X-BTM pin 19 Ground Open circuit

6. Check the integrity of harness of connector X-CAB_B.
From To Value
Connector X-CAB_B pin 19 Ground Open circuit
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55.9 [55.DTC] / 541
518146-03 - Short to Power at FAN Control High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the PWM FAN CONTROL ( Y-Y_FC), detects a short circuit to power; as a consequence the FAN
Functions are disabled.
Cause:

2. The harness between A-UCM and the connector X-YFN is damaged.
3. The connectors X-CAB_E-2 or X-ENG-2 or X-YFN or X-UCM2A are damaged.
4. The harness between A-UCM and the power supply is damaged.
5. The harness between connector X-BTM_EH and the power supply is damaged.
6. The harness between connector X-YFN and the power supply is damaged.
7. The PWM FAN CONTROL is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM2A and X-YFN for any damage.


4. Check the integrity of harness between the A-UCM and the power supply.
From To Value
Connector X-UCM2A pin 25 Ground < + 24 V

5. Check the integrity of connectors X-CAB_E-2 and X-ENG-2.
Disconnect the connector X-CAB_E-2 from the connector X-ENG-2 and visually check the integrity of pin P of
both connectors.
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6. Check the integrity of harness between the connectors X-ENG-2 and the power supply.
From To Value
Connector X-ENG-2 pin P Ground < + 24 V
A. If the measurement is correct, replace the harness between connector X-CAB_E-2 and the A-UCM.

7. Check the integrity of connector X-YFN.
Disconnect the connector X-YFN from the PWM FAN CONTROL and visually check the integrity of pins A and B
of the connector.

8. Check the integrity of harness between the connector X-YFN and the power supply.
From To Value
Connector X-YFN pin A Ground < + 24 V
A. If the measurement is not correct, replace the harness of connector X-YFN.
B. If the measurement is correct, replace the PWM FAN CONTROL.
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518146-04 - Short to Ground at FAN Control High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the PWM FAN CONTROL ( Y-Y_FC), detects a grounding connection; as a consequence the
FAN Functions are disabled.
Cause:

4. The harness between A-UCM and ground is damaged.
5. The harness between connector X-ENG-2 and ground is damaged.
6. The harness between connector X-ENG-2 and X-YFN is damaged.
Solution:


4. Check the integrity of harness between the A-UCM and the ground.
From To Value
Connector X-UCM2A pin 25 Ground The PWM FAN CONTROL resistance

both connectors.
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6. Check the integrity of harness between the connectors X-ENG-2 and ground.
From To Value
Connector X-ENG-2 pin P Ground The PWM FAN CONTROL resistance
B. If one measurement is not correct,continue with Step 7.

of the connector.

8. Check the integrity of harness between the connectors X-ENG-2 and X-YFN.
From To Value
Connector X-ENG-2 pin P Connector X-YFN pin B Open circuit
A. If the measurement is not correct, replace the harness of connector X-YFN.
B. If the measurement is correct, replace the PWM FAN CONTROL.
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518146-05 - Open Circuit at FAN Control High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the PWM FAN CONTROL ( Y-Y_FC), detects an open circuit or a low current; as a consequence
the FAN Functions are disabled.
Cause:
The A-UCM detects, on pin 25 of connector X-UCM2A, an open circuit or a low current error risen by BSP.

4. The harness between connector X-YFN and ground is damaged.
5. The harness between connector X-ENG-2 and X-YFN is damaged.
6. The harness between the A-UCM and the connector X-CAB_E-2 is damaged.
Solution:

of the connector.

4. Check the integrity of harness between the X-YFN and the ground.
Disconnect the connector X-YFN from the PWM FAN CONTROL.
From To Value
Connector X-YFN pin B Ground Short circuit

48083742_EN 31/07/2018
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both connectors.

6. Check the integrity of harness between the connectors X-ENG-2 and X-YFN.
Disconnect the connector X-YFN from the PWM FAN CONTROL.
From To Value
Connector X-ENG-2 pin P Connector X-YFN pin A Short circuit


8. Check the integrity of harness between the A-UCM and the connector X-CAB_E-2.
From To Value
Connector X-UCM2A pin 25 Connector X-CAB_E-2 pin P Short circuit

9. Replace the PWM FAN CONTROL.
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518147-03 - Short to Power FAN Reverser Low Side Driver

Control Module: UCM
Context:
The A-UCM, driving the FAN REVERSER ( Y-Y_FR), detects a short circuit to power; as a consequence the FAN
Cause:
The A-UCM detects, on pin 21 of connector X-UCM2A, a short circuit to power or a low current risen by BSP.

2. The harness between A-UCM and the connector X-YFR is damaged.
3. The connectors X-CAB_E-2 or X-ENG-2 or X-YFR or X-UCM2A are damaged.
5. The harness between connector X-ENG-2 and the power supply is damaged.
6. The FAN REVERSER is damaged.
Solution:


From To Value
Connector X-UCM2A pin 21 Ground < + 24 V

Disconnect the connector X-CAB_E-2 from the connector X-ENG-2 and visually check the integrity of pin N of
both connectors.
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6. Check the integrity of harness between the connectors X-ENG-2 and the power supply.
From To Value
Connector X-ENG-2 pin N Ground < + 24 V

7. Check the integrity of connector X-YFR.
Disconnect the connector X-YFR from the FAN REVERSER and visually check the integrity of pins 1 and 2 of the
connector.
B. If the pins are not damaged, replace the FAN REVERSER.
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518147-04 - Short to Ground at FAN Reverser Low Side Driver

Control Module: UCM
Context:
The A-UCM, driving the FAN REVERSER ( Y-Y_FR), detects a grounding connection; as a consequence the FAN
Cause:

3. The connectors X-CAB_E-2 or X-ENG-2 or X-YFR or X-UCM2A are damaged.
4. The harness between A-UCM and ground is damaged.
5. The harness between the connector X-ENG-2 and ground is damaged.
6. The FAN REVERSER is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM2A and X-YFR for any damage.


4. Check the integrity of harness between the A-UCM and the ground.
From To Value

Disconnect the connector X-CAB_E-2 from the connector X-ENG-2 and visually check the integrity of pin N of
both connectors.
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6. Check the integrity of harness between the connectors X-ENG-2 and ground.
From To Value
Connector X-ENG-2 pin N Ground Open circuit

7. Check the integrity of connector X-YFR.
Disconnect the connector X-YFR from the FAN REVERSER and visually check the integrity of pins 1 and 2 of the
connector.
B. If the pins are not damaged, replace the FAN REVERSER.
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518150-03 - Electrical Crank Power Relay- Short Circuit to B+

Control Module: SFB
Context:
Short Circuit to B+ of the Electrical Crank Power Relay.
Cause:
The Smart Fuse box measure a Short Circuit to B+ Electrical Crank Power Relay ( X3-5) when the key is OFF.

2. The harness between Smart Fuse Box and UCM is damaged.
3. The key switch Crank connector is damaged.
4. The Smart Fuse Box connector is damaged.
5. The Crank Power Relay is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and key switch Crank ( X-UCM2B pin 14).

3. Check the integrity of the key switch Crank connector ( X-UCM2B pin 14).
Disconnect key switch Crank connector and visually check the integrity of the pin.
A. If the pin is damaged, replace the connector.

A. If the pin 5 is damaged, replace the X-X3 connector.
B. If the pin 5 is not damaged, continue with Step 5.

5. Check the signal circuit for an open circuit condition on the harness between key switch Crank pin ( X-UCM2B pin
14) and + 5 V voltage.
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From To Value
Connector X-UCM2B pin 14 + 5V There should be an open circuit
A. If there is a short circuit, replace the harness.

6. Check the Smart Fuse Box signal circuit for an open circuit.
From To Value
Connector A-SFB pin OUT_03_H + 5V There should be an open circuit
A. If there is a short circuit, replace the Smart Fuse Box.

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518150-03 - Electrical Ignition Power Relay- Short Circuit to B+

Control Module: SFB
Context:
Open circuit Electrical Ignition Power Relay.
Cause:
The Smart Fuse box measure a Short Circuit to B+ of Electrical Ignition Power Relay ( X3-8) when the key is OFF.

2. The harness between Smart Fuse Box and key switch Ignition is damaged.
3. The key switch Ignition connector is damaged.
5. The Electrical Ignition Power Relay is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and Ignition Power Relay ( X-LC5 pin 86).

3. Check the integrity of the Ignition Power Relay connector ( X-LC5 pin 86).
Disconnect Ignition Power Relay connector and visually check the integrity of the pin.


5. Check the signal circuit for a Short Circuit to B+ condition on the harness between Electrical Ignition Power Relay
pin ( X-LC5 pin 86) and Smart Fuse Box.
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From To Value
Connector X-UCM2B pin14 Connector X-X3 pin 8 There should be a short circuit
Connector X-X3 pin 8 + 5V There should be an open circuit
Connector X-UCM2B pin14 + 5V There should be an open circuit
A. If there is an open circuit in the first measure, replace the harness.
B. If there is not voltage, continue to Step 6.

6. Check the Electrical Ignition Power Relay pin ( X-LC5 pin 86) circuit for a short circuit to B+.
From To Value
Connector X-LC5 pin 86 GND There should be a short circuit
A. If there is an open circuit, replace the Electrical Ignition Power Relay.

7. Check the Smart Fuse Box signal circuit for short circuit to B+.
From To Value
A. If there is a voltage, replace the Smart Fuse Box.

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518150-04 - Short to Ground at Crank Request High Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding connection at Crank Request; as a consequence the cranking request is disabled.
Cause:

2. The harness between Smart Fuse Box and UCM is visually damaged.
3. The connectors X-UCM3A or X-CAB_E or E-ENG or X-ECU or X-LC6 are damaged.
4. The harness relevant to A-UCM is damaged.
5. The harness relevant to connector E-ENG is damaged.
Solution:
2. Visually check the integrity of the harness between the A-UCM (connector X-UCM3A), the CRANK CONTROL
(connector X-LC6) and the A-ECU (connector X-ECU).


4. Check the integrity of the harness between the connector X-UCM3A and ground.
From To Value

5. Check the integrity of connectors X-CAB_E and E-ENG.
Disconnect the connectors X-CAB_E and E-ENG and visually check the integrity of pin 15.

6. Check the integrity of the harness between the connector X-ENG and ground.
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From To Value
Connector X-ENG pin 15 Ground Open circuit
A. If the measurement is correct, replace the harness between connectors X-UCM3A and X-CAB_E.

7. Check the integrity of connector X-LC6.
Disconnect the connector X-LC6 from the CRANK CONTROL (connector X-LC6) and visually check the integrity
of pin 32.

8. Check the integrity of the harness relevant to connector X-ENG.
From To Value
A. If the measurement is correct, replace the CRANK CONTROL.

9. Check the integrity of connector X-ECU.
Disconnect the connector X-ECU from the A-ECU and visually check the integrity of pin 63.

10. Check the integrity of the harness relevant to connector X-ENG.
From To Value
A. If the measurement is correct, replace the A-ECU.
B. If the measurement is not correct, replace the harness relevant to the connector X-ENG.

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518150-05 - Electrical Crank Power Relay- Open Circuit

Control Module: SFB
Context:
Open circuit Electrical Crank Power Relay.
Cause:
The Smart Fuse box measure an open circuit Electrical Crank Power Relay ( X3-5) when the key is OFF.

2. The harness between Smart Fuse Box and key switch Crank is damaged.
5. The Electrical Crank Power Relay is defective.
Solution:



5. Check the signal circuit for an open circuit condition on the harness between Electrical Crank Power Relay pin (
X-UCM2B pin 14) and Smart Fuse Box.
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From To Value
Connector X-UCM2B pin 14 Ground There should be a short circuit
A. If there is an open circuit, replace the harness.

From To Value

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518150-05 - Electrical Ignition Power Relay- Open Circuit

Control Module: SFB
Context:
Cause:
The Smart Fuse box measure an open circuit Electrical Ignition Power Relay ( X3-8) when the key is OFF.

Solution:



5. Check the signal circuit for an open circuit condition on the harness between Electrical Ignition Power Relay pin (
X-LC5 pin 86) and Smart Fuse Box.
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From To Value
Connector X-LC5 pin 86 Connector X-X3 pin 8 There should be a short circuit

6. Check the Electrical Ignition Power Relay pin ( X-LC5 pin 86) circuit for an open circuit.
From To Value
Connector X-LC5 pin 86 Connector X-LC5 pin 85 There should be a short circuit
Connector X-LC5 pin 85 Ground There should be a short circuit

From To Value

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518150-06 - Electrical Crank Power Relay- Short Circuit to GND

Control Module: SFB
Context:
Short Circuit to GND of the Electrical Crank Power Relay.
Cause:
The Smart Fuse box measure a Short Circuit to GND Electrical Crank Power Relay ( X3-5 ) on SCG when ON.

2. The harness between Smart Fuse Box and UCM is damaged.
5. The Crank Power Relay is defective.
Solution:



5. Check the signal circuit for an open circuit condition on the harness between key switch Crank pin ( X-UCM2B pin
14) and Smart Fuse Box.
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From To Value
Connector X-UCM2B pin 14 Ground There should be a short circuit

From To Value

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518150-06 - Electrical Ignition Power Relay- Short Circuit to GND

Control Module: SFB
Context:
Cause:
The Smart Fuse box measure a Short Circuit to GND of Electrical Ignition Power Relay ( X3-8) when the key is ON.

Solution:



5. Check the signal circuit for a Short Circuit to GND condition on the harness between Electrical Ignition Power
Relay pin ( X-LC5 pin 86) and Smart Fuse Box.
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From To Value
Connector X-LC5 pin 86 Connector X-X3 pin 8 There should be a short circuit
Connector X-X3 pin 8 GND There should be an open circuit
Connector X-LC5 pin 86 GND There should be an open circuit
A. If there is an open circuit in the first measure, replace the harness.

6. Check the Electrical Ignition Power Relay pin ( X-LC5 pin 86) circuit for a short circuit to GND.
From To Value
Connector X-LC5 pin 86 GND There should be a short circuit

7. Check the Smart Fuse Box signal circuit for short circuit to GND.
From To Value

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518176-03 - Joystick Steering Signal 2 High voltage

Control Module: UCM
Context:
The A-UCM detects a value from LH JOYSTICK STEERING ( B-JSS) out of higher limit.
Cause:
The A-UCM detects on pin 18 of connector X-UCM2A a voltage < 4.75 V for T> 250 ms.

2. The harness between A-UCM and the LH JOYSTICK STEERING ( B-JSS) is damaged.
3. The LH JOYSTICK STEERING is damaged.
Solution:
1. JSS Function Disabled

2. Check the integrity of the harness between the A-UCM and the LH JOYSTICK STEERING ( B-JSS).

3. Check the integrity of the LH JOYSTICK STEERING.
Replace the LH JOYSTICK STEERING.
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518176-04 - Joystick Steering Signal 2 Low voltage

Control Module: UCM
Context:
The A-UCM detects a value from LH JOYSTICK STEERING ( B-JSS) out of lower limit.
Cause:
The A-UCM detects on pin 18 of connector X-UCM2A a voltage < 0.25 V for T> 250 ms.

3. The LH JOYSTICK STEERING is not supplied.
4. The harness between the connector X-LFT_A and the LH JOYSTICK STEERING is damaged.
Solution:
1. JSS Function Disabled

2. Check the integrity of the harness between the A-UCM and the LH JOYSTICK STEERING ( B-JSS).

3. Check the LH JOYSTICK STEERING ( B-JSS) power supply.
From To Value
Connector X-CAB_L pin 7 Connector X-CAB_L pin 6 (Ref) 5V
A. If the value is not correct, continue with Step 5.

From To Value
Connector X-CAB_L pin 1 Connector X-CAB_L pin 3 (Ref) 5V
A. If the value is not correct, continue with Step 6.
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Disconnect the connectors X-UCM2A and the connector X-UCM1A from A-UCM.
From To Value
Connector X-UCM1A pin 4 Connector X-UCM2A pin 20 (Ref) 5V
A. If the value is not correct, replace the A-UCM.
B. If the value is correct, replace the harness between the connector X-CAB_L and the A-UCM.
6. Check the integrity of harness from the connector X-CAB_L and the A-UCM.
Disconnect the connectors X-UCM1B and the connector X-UCM1A from A-UCM.
From To Value
Connector X-UCM1A pin 3 Connector X-UCM2A pin 1 (Ref) 5V
A. If the value is not correct, replace the A-UCM.
B. If the value is correct, replace the harness between the connector X-CAB_L and the A-UCM.
7. Check the integrity of harness from the connector X-LFT_A and the LH JOYSTICK STEERING ( B-JSS).
Remove the connector X-JSS_JOY from the LH JOYSTICK STEERING.
From To Value
Connector X-JSS_JOY pin 1 Connector X-LFT_A pin 7 Short circuit

8. Check the integrity of harness from the connector X-CAB_L and the A-UCM.
Remove the connectors X-UCM2A from the A-UCM.
From To Value
Connector X-CAB_L pin 2 Connector X-UCM2A pin 18 Short circuit
Connector X-CAB_L pin 5 Connector X-UCM2A pin 12 Short circuit
B. If all the measurements are correct, replace the A-UCM.
C. Continue with Step 9.

9. Check the LH JOYSTICK STEERING integrity.
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B. If the functionality is not restored, replace the LH JOYSTICK STEERING.

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518176-09 - Joystick Steering Signals not plausible

Control Module: UCM
Context:
The A-UCM detects not plausible values from the Joystick; as a consequence, the function JSS is disabled:
• Set Joystick Position to Neutral
• Command PVED to cut Supply Pressure
Cause:
The A-UCM detects, on pins 12 and 18 of connector X-UCM2A, two not plausible signals (│5-( (Sig 1 Normalized +
Sig 2 Normalized)| ≤ 0.8 V T> 250 ms).

2. The harness between the A-UCM and the LH JOYSTICK STEERING is visually damaged.
3. The output JSS JOYSTICK 1 of the LH JOYSTICK STEERING is not correct.
4. The output JSS JOYSTICK 2 of the LH JOYSTICK STEERING is not correct.
Solution:
2. Visually check the integrity of the harness between the A-UCM and the LH JOYSTICK STEERING for any damage.

3. The output JSS JOYSTICK 1 of the Joystick is not functioning.
Be sure the voltage on pin 12 of connector X-UCM2A is 0.25 V < Voltage < 4.75 V.
- the procedure 518176-17 if the voltage is < 0.25 V;
- the procedure 518176-15 if the voltage is > 4.75 V.

4. The output JSS JOYSTICK 2 of the Joystick is not functioning.
Be sure the voltage on pin 18 of connector X-UCM2A is 0.25 V < Voltage < 4.75 V.
- the procedure 518176-04 – Joystick Steering Signal 2 Low voltage if the voltage is < 0.25 V;
- the procedure 518176-03 – Joystick Steering Signal 2 High voltage if the voltage is > 4.75 V.

Replace the A-UCM.
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B. If the functionality is not restored, replace the harness.
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518176-15 - Joystick Steering Signal 1 High voltage

Control Module: UCM
Context:
The A-UCM detects a value from LH JOYSTICK STEERING ( B-JSS) out of higher limit; as a consequence the
JSS Function is Disabled:
Cause:
The A-UCM detects, on pin 12 of connector X-UCM2A, a voltage > 4.75 V for T> 250 ms.

2. The harness between A-UCM and the LH JOYSTICK STEERING ( B-JSS) is visually damaged.
3. The connectors X-UCM2A or X-LFT_A or X-CAB_L or X-JSS_JOY are damaged.
4. The harness between A-UCM and the connector X-CAB_L is damaged.
5. The harness between the connectors X-JSS_JOY and X-LFT_A is damaged.
Solution:
2. Visually check the integrity of the harness between the A-UCM and the connector X-JSS_JOY.


4. Check the integrity of harness between the A-UCM and the LH JOYSTICK STEERING.
From To Value
Connector X-UCM2A pin 12 Ground 4.75 V

5. Check the integrity of connectors X-LFT_A and X-CAB_L.
Disconnect the connector X-LFT_A from the X-CAB_L and visually check the integrity of pin 5 of both connectors.
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6. Check the integrity of harness between the A-UCM and the connector X-CAB_L.
From To Value
Connector X-UCM2A pin 12 Connector X-CAB_L pin 5 Short circuit

7. Check the integrity of connector X-JSS_JOY.
Disconnect the connector X-JSS_JOY from the LH JOYSTICK STEERING and visually check the integrity of pin
5.

8. Check the integrity of harness between the connectors X-JSS_JOY and X-LFT_A.
From To Value
B. If the measurement is correct, replace the LH JOYSTICK STEERING.
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518176-17 - Joystick Steering Signal 1 Low voltage

Control Module: UCM
Context:
The A-UCM detects a value from LH JOYSTICK STEERING ( B-JSS) out of lower limit; as a consequence the
JSS Function is Disabled:
Cause:
The A-UCM detects, on pin 12 of connector X-UCM2A, a voltage < 0.25 V V for T> 250 ms.

3. The connectors X-UCM2A or X-LFT_A or X-CAB_L or X-JSS_JOY are damaged.
4. The LH JOYSTICK STEERING is not supplied.
5. The harness between the connectors X-LFT_A and X-JSS_JOY is damaged.
Solution:
2. Visually check the integrity of the harness between the A-UCM and the connector X-JSS_JOY.

3. Check the LH JOYSTICK STEERING is not supplied by the 5VREF3.
Disconnect the connector X-JSS_JOY from the LH JOYSTICK STEERING.
From To Value
Connector X-JSS_JOY pin 1 Connector X-JSS_JOY pin 2 (Ref) 5V
A. If the value is not correct, check for the absence of the power supply 5VREF3 (see procedure 518282-31 –
Error at 5VREF3 Output).

4. Check the LH JOYSTICK STEERING is not supplied by the 5VREF2.
Disconnect the connector X-JSS_JOY from the LH JOYSTICK STEERING.
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From To Value
Connector X-JSS_JOY pin 4 Connector X-JSS_JOY pin 6 (Ref) 5V
A. If the value is not correct, check for the absence of the power supply 5VREF2 (see procedure 518282-31 –
Error at 5VREF3 Output).

5. Check the integrity of connector X-JSS_JOY.
Disconnect the connector X-JSS_JOY from the LH JOYSTICK STEERING and visually check the integrity of pin
5.

Disconnect the connector X-LFT_A from the X-CAB_L and visually check the integrity of pin 5 of both connectors.

7. Check the integrity of harness between the connectors X-JSS_JOY and X-LFT_A.
From To Value


From To Value
Connector X-UCM2A pin 12 Connector X-CAB_L pin 5 Short circuit

10. Replace the LH JOYSTICK STEERING.
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518177-03 - Short to Power at Pilot Enable Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the Pilot Enable Valve, detects a short circuit to power; as a consequence:
• Pilot Lock valve disabled;
• Command Pilot lock Valve HSD PWM to 0% Bucket Function disabled.
Cause:

2. The harness between A-UCM and the connector X-PILOT_ENABLE is damaged.
3. The connectors X-PILOT_ENABLE or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM3B
are damaged.
5. The harness between connectors X-BTM_EH and X-PILOT_ENABLE is damaged.
6. The harness between connectors X-FRNT_EH and X-PILOT_ENABLE is damaged.
7. The PILOT ENABLE SOLENOID is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM3B and X-PILOT_ENABLE for any
damage.


4. Check the integrity of harness between the A-UCM and the connector X-PILOT_ENABLE.
From To Value
Connector X-UCM3B pin 18 Ground < + 24 V

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Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pin A of
both connectors.

6. Check the integrity of harness between the connectors X-BTM_EH and X-PILOT_ENABLE.
From To Value
Connector X-BTM_EH pin A Ground < + 24 V
A. If the measurement is correct, replace the harness between connector X-BTM_EH and the A-UCM.

Disconnect the connector X-BTM_FEH from the connector X-FRNT_EH and visually check the integrity of pin A
of both connectors.

8. Check the integrity of harness between the connector X-FRNT_EH and the connector X-PILOT_ENABLE.
From To Value
Connector X-FRNT_EH pin A Ground < + 24 V

9. Check the integrity of connector X-PILOT_ENABLE.
Disconnect the connector X-PILOT_ENABLE from the ELECTROHYDRAULIC VALVE ( A-EH_VLV) and visually
B. If the pins are not damaged, replace the PILOT ENABLE SOLENOID.
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518177-04 - Short to Ground at Pilot Enable Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the Pilot Enable Valve, detects a grounding connection; as a consequence:
Cause:

are damaged.
5. The harness between connectors X-BTM_EH and X-PILOT_ENABLE is damaged.
6. The harness between connectors X-FRNT_EH and X-PILOT_ENABLE is damaged.
Solution:
damage.


4. Check the integrity of harness between the A-UCM and the connector X-PILOT_ENABLE.
From To Value

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both connectors.

6. Check the integrity of harness between the connectors X-BTM_EH and X-PILOT_ENABLE.
From To Value
Connector X-BTM_EH pin A Ground Open circuit

of both connectors.

8. Check the integrity of harness between the connector X-FRNT_EH and the connector X-PILOT_ENABLE.
From To Value
Connector X-FRNT_EH pin A Ground Open circuit

B. If the pins are not damaged, replace the PILOT ENABLE SOLENOID.
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518177-05 - Open Circuit at Pilot Enable Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the Pilot Enable Valve, detects an open circuit or a low current; as a consequence:
Cause:

are damaged.
4. The harness between X-FRNT_EH and ground is damaged.
5. The harness between connector X-PILOT_ENABLE is damaged.
Solution:
damage.


of both connectors.
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5. Check the integrity of harness between the connectors X-FRNT_EH and X-PILOT_ENABLE.
Disconnect the connector X-PILOT_ENABLE from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin A Connector X-PILOT_ENABLE pin 1 Short circuit

6. Check the integrity of harness between the connector X-PILOT_ENABLE and ground.
Disconnect the connector X-PILOT_ENABLE from the ELECTROHYDRAULIC VALVE. Use a multimeter to per-
form the following check:
From To Value
Connector X-PILOT_ENABLE pin 2 Ground Short circuit

both connectors.

From To Value
Connector X-BTM_FEH pin A Connector X-BTM_EH pin A Short circuit


From To Value
Connector X-UCM3B pin 18 Connector X-CAB_EH pin A Short circuit
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11. Replace the PILOT ENABLE SOLENOID.
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518267-02 - WatchDog Reset

Context:
WatchDog Reset.
Cause:

Solution:

3. Verify the wirings to external connection.
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518280-31 - Error at 5VREF1 Output

Control Module: UCM
Context:
The A-UCM detects the 5VREF1 is not within the limits; as a consequence:
• Set Brake Supply Pressure to 0 bar
• Set Front Accumulator Pressure to 0 bar
• Set Rear Accumulator Pressure to 0 bar
• No Brake Pressure Warning available
• Set Brake Line Pressure to 0 bar
• CCO disabled (clutches will be immediately engaged if declutch was active)
• Brake Light disabled
• Disable Aux Steering Function
• Disabled advanced EH features ( RTT/Float, RTD, HC)
• If 2-Lever or 3-Lever Pilot Joystick is installed
• Set Aux FNR = N
• Disable Aux FNR
Cause:
The A-UCM detects, on pin 2 of connector X-UCM1A, a voltage > 5.2 V or < 4.8 V.

2. The connectors X-CAB_TR or X-TRANS or X-CAB_B or X-BTM or X-UCM1A are damaged.
4. One circuit connected to the A-UCM is not functioning.
Solution:
2. Check the integrity of connectors X-CAB_TR and X-TRANS.
Disconnect the connector X-CAB_TR from the connector X-TRANS and visually check the integrity of pin 26 of
both connectors.

Disconnect the connector X-CAB_B from the connector X-BTM and visually check the integrity of pin 8 of both
connectors.
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From To Value
Connector X-CAB_TR pin 26 Ground 4.8 V < Value < 5.2
A. If the value is out of the limits, continue with Step 5.
B. If the value is within the limits, continue with Step 6.

5. Replace the harness relevant to the connectors X-UCM1A, X-CAB_B and X-CAB_TR.

6. Connect the connectors X-CAB_B and X-BTM.
From To Value
Connector X-CAB_TR pin 26 Ground 4.8 V < Value < 5.2
A. If the value is within the limits, check the correct functioning of the circuit relevant to:
- the Front Brake Accumulator Pressure Sensor (see procedure 1049-04);
- the Rear Brake Accumulator Pressure Sensor (see procedure 1052-04).
B. If the value is out of the limits, check the correct functioning of the circuit relevant to:
- the Brake Supply Line Pressure Sensor (see procedure 518113-04);
- the Brake Line (declutch) Pressure Sensor (see procedure 518114-04);
- the Aux Steering Pressure Sensor (see procedure 518115-04);
- the Boom Angle Sensor Channel 2 (see procedure 518135-04);
- the Bucket Angle Sensor Channel 2 (see procedure 518136-04).
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Control Module: UCM
Context:
• Disabled advanced EH features ( RTT/Float, RTD, EH)
• Power Inch disabled
• Default Angle Position sensor to minimum value ( 0%)
• Disabled JSS
• Only if Model is PL23 or PL26
• FAX Temperature not available
• FAX warning disabled
• Set PV_VC_STS.FAxOilTempWarn = 0x3 (out of range)
• Only if 2-Lever or 3-Lever Pilot Joystick is installed
• Set Aux FNR = N
• Disable Aux FNR
Cause:

2. The connectors X-CAB_B or X-BTM or X-LFT_A or X-CAB_L or X-FRNT_EH or X-BTM_FEH or X-UCM1A are
damaged.
Solution:
Disconnect the connector X-CAB_B from the connector X-BTM and visually check the integrity of pin 4 of both
connectors.

3. Check the integrity of harness between the A-UCM and the connector X-CAB_B.
From To Value
Connector X-CAB_B pin 4 Ground 4.8 V < Value < 5.2
A. If the value is out of the limits, continue with Step 4.
B. If the value within the limits, continue with Step 7.
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Disconnect the connector X-LFT_A from the connector X-CAB_L and visually check the integrity of pin 1 of both
connectors.

From To Value
Connector X-CAB_B pin 4 Ground 4.8 V < Value < 5.2
A. If the value within the limits, check the correct functioning of the circuit relevant to:
- the Joystick Steering Signal 2 Low voltage (see procedure 518176-04);
- the Joystick Steering Signal 1 Low voltage (see procedure 518176-17).
B. If the value is out of the limits, continue with Step 6.

6. Replace the harness relevant to the connectors X-UCM1B, X-CAB_B and X-CAB_L.

Connect the connectors X-CAB_B and X-BTM.
Disconnect the connector X-BTM_FEH from the connector X-FRNT_EH and visually check the integrity of pin V
of both connectors.

8. Check the integrity of harness between the connectors X-BTM_EH and X-BTM_FEH.
From To Value
Connector X-BTM_FEH pin V Ground 4.8 V < Value < 5.2
A. If the value is out of the limits, check the correct functioning of the circuit relevant to the Inch Pedal Position
Sensor (see procedure 521-04).
B. If the value within the limits, check the correct functioning of the circuit relevant to:
- the Bucket Angle Sensor Channel 1 (see procedure 518111-04);
- the Boom Angle Sensor Channel 1 (see procedure 518110-04).
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Control Module: UCM
Context:
• Disabled JSS;
• Command the FAN as open loop.
Cause:

2. The connectors X-CAB_JSS or X-JSS_FR or X-LFT_A or X-CAB_L or X-CAB_E or X-ENG or X-UCM1A are
damaged.
Solution:
Disconnect the connector X-LFT_A from the connector X-CAB_L and visually check the integrity of pin 7 of both
connectors.

From To Value
Connector X-CAB_L pin 7 Ground 4.8 V < Value < 5.2
- the Joystick Steering Signal 2 Low voltage (see procedure 518176-04);
- the Joystick Steering Signal 1 Low voltage (see procedure 518176-17).

4. Check the integrity of connectors X-JSS_FR and X-CAB_JSS.
Disconnect the connector X-JSS_FR from the connector X-CAB_JSS and visually check the integrity of pin 3 of
both connectors.
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5. Check the integrity of harness between the A-UCM and the connector X-CAB_JSS.
From To Value
Connector X-CAB_JSS pin 3 Ground 4.8 V < Value < 5.2
- the JSS CUT OFF SENSOR 1 (see procedure TBD);
- the JSS CUT OFF SENSOR 2 (see procedure TBD).

6. Check the integrity of connectors X-ENG and X-CAB_E.
Disconnect the connector X-ENG from the connector X-CAB_E and visually check the integrity of pin 28 of both
connectors.

7. Check the integrity of harness between the A-UCM and the connector X-CAB_E.
From To Value
Connector X-CAB_E pin 28 Ground 4.8 V < Value < 5.2
A. If the value within the limits, check the correct functioning of the circuit relevant to the FAN SPEED SENSOR
(see procedure TBD).

8. Replace the harness relevant to the connectors X-UCM1A, X-CAB_E, X-CAB_JSS and X-CAB_L.
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518283-31 - Error at 24VF2 Supply Rail

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VF2 power supply; as a consequence:
• AUX II Function disabled:
• Open AUX II LSD
• Command AUX II HSD PWMs to 0%:
• Boom Function disabled:
• Open Boom LSD
• Command Boom HSD PWMs to 0%;
• Disabled advanced EH Boom features (RTT/Float, HC).
Cause:
The A-UCM detects, on pins 1 and 8 of connector X-UCM4A, a voltage < 19.6 V (Note: only one input is available in
CCS ).

2. The harness between A-UCM and the LC2 is damaged.
3. The connectors X-LC2 or X-UCM4A are damaged.
4. The harness between A-UCM and the connector X-LC2 is damaged.
5. The UCM VF2/3 ( F-2F2) is burnt.
6. The harness between the LC2 and the power supply is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM4A and X-LC2 for any damage.

Disconnect the connector X-UCM4A from the A-UCM and visually check the integrity of pins 1 and 8.

From To Value
Connector X-UCM4A pin 1 Ground ≥ + 19.6 V
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B. If the measurements are not correct, continue with Step 5.

Disconnect the connector X-LC2 from LC2 and visually check the integrity of pins 2A and 2B.

6. Check the integrity of harness between the connectors X-LC2 and X-UCM4A.
From To Value
Connector X-LC2 pin A Ground ≥ + 19.6 V
A. If the measurement is correct, replace the harness between the connectors X-LC2 and X-UCM4A.

7. Check the integrity of fuse UCM VF2/3 ( F-2F2) of LC2.
Remove the fuse from the LC2 and, by means of a multimeter, check the status of the fuse.
A. If the fuse is burnt (open circuit between the terminals), replace the fuse UCM VF2/3 .
B. If the fuse is integer (short circuit between the terminals), continue with Step 8.
8. Check the integrity of harness between LC2 and the power supply.
From To Value
Connector X-P1196 Ground ≥ + 19.6 V
A. If the measurement is correct, replace the harness between the LC2 and the JUNCTION BLOCK INTO CAB (
A-MAIN JB CAB).
B. If the measurement is not correct, check the circuits generating the + 24 V.

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Control Module: UCM
Context:
The A-UCM detects the absence of the 24VF3 power supply; as a consequence the FAN is disabled.
Cause:
The A-UCM detects, on pins 7 and 13 of connector X-UCM2A, a voltage < 19.6 V (Note: only one input is available
in CCS).

5. The UCM VF2/3 ( F-2F2) is burnt
7. Supply voltage to be checked.
Solution:


From To Value

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From To Value
Connector X-LC2 pin A Ground ≥ + 19.6 V

From To Value
A-MAIN JB CAB).

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Control Module: UCM
Context:
The A-UCM detects the absence of the 24VF4 power supply; as a consequence:
• Open AUX I LSD
• Open Boom LSD
• Command Bucket HSD PWMs to 0%
• Disabled advanced EH Bucket features ( RTD)
Cause:
The A-UCM detects, on pins 8 and 9 of connector X-UCM3B, a voltage < 19.6 V (Note: only one input is available in
CCS).

3. The connectors X-LC2 or X-UCM3B are damaged.
5. The UCM VF4/6 ( F-2F3) is burnt
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM3B and X-LC2 for any damage.


From To Value
Connector X-UCM3B pin 1 Ground ≥ + 19.6 V
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6. Check the integrity of harness between the connectors X-LC2 and X-UCM3B.
From To Value
Connector X-LC2 pin 3A Ground ≥ + 19.6 V
A. If the measurement is correct, replace the harness between the connectors X-LC2 and X-UCM3B.

From To Value
A-MAIN JB CAB).

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Control Module: UCM
Context:
The A-UCM detects the absence of the 24VF6.
Cause:
The A-UCM detects, on pins 7 and 13 of connector X-UCM3A, a voltage < 19.6 V (Note: only one input is available
in CCS).

5. The UCM VF4/6 ( F-2F3) is burnt.
Solution:


From To Value

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From To Value

From To Value
A-MAIN JB CAB).

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518287-31 - Error at 24VS1 Supply Rail

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VS1 power supply; as a consequence the following functions are disabled:
• Park Brake (engaged);
• Differential Lock (disengaged);
• Implement Coupler (engaged);
• Ride Control (disengaged);
• Pilot Lock (disengaged).
Cause:
The A-UCM detects, on pins 2 and 3 of connector X-UCM3B, a voltage < 19.6 V (Note: only one input is available in
CCS).

5. The UCM VS1/VLP ( F-2F4) is burnt.
Solution:


From To Value
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From To Value
A. If the measurement is correct, replace the harness between the connectors X-LC2 and X-UCM3B.

7. Check the integrity of fuse UCM VS1/VLP ( F-2F4) of LC2.
A. If the fuse is burnt (open circuit between the terminals), replace the fuse UCM VS1/VLP .
From To Value
A-MAIN JB CAB).

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518289-31 - Error at 24VA Supply Rail

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VA power supply; as a consequence the UCM disable all functions.
Cause:
The A-UCM detects, on pin 14 of connector X-UCM1A, a voltage < 10 V.

5. The fuse UCM ( F-5F2) is burnt.
Solution:

B. B. If the pin is not damaged, continue with Step 4.

From To Value
Connector X-UCM1A pin 14 Ground + 10 V
A. If the voltage is correct, replace the A-UCM.
B. If the voltage is not correct, continue with Step 5.


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From To Value
Connector X-LC5 pin 2A Connector X-UCM1A pin 26 Short circuit
A. If the measurement is not correct, replace the harness between the connectors X-LC5 and X-UCM1A.

7. Check the integrity of fuse UCM ( F-5F2) of LC5.
A. If the fuse is burnt (open circuit between the terminals), replace the fuse UCM.
B. If the fuse is integer (short circuit between the terminals), continue the troubleshooting by performing the pro-
cedure 520567-05.

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518290-31 - Error at 24VB Supply Rail

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VB power supply; as a consequence the UCM disable all functions.
Cause:
The A-UCM detects, on pin 26 of connector X-UCM1A, a voltage < 10 V ( UCM shutdown at 8 V).

5. The fuse UCM ( F-5F2) is burnt.
Solution:


From To Value
Connector X-UCM1A pin 26 Ground > + 10 V
A. If the voltage is correct, replace the A-UCM.
B. If the voltage is not correct, continue with Step 5.


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From To Value

7. Check the integrity of fuse UCM ( F-5F2) of LC5.
A. If the fuse is burnt (open circuit between the terminals), replace the fuse UCM.
B. If the fuse is integer (short circuit between the terminals), continue the troubleshooting by performing the pro-
cedure 520567-05.

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518291-31 - Error at 24VLP Supply Rail

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VLP power supply; as a consequence the following functions are disabled:
• Warning LED disabled;
• Aux Steering Disabled;
• FAN Commanded in Open Loop.
Cause:
The A-UCM detects, on pin 2 of connector X-UCM4B, a voltage < 10 V.

5. The UCM VS1/VLP ( F-2F4) is burnt.
Solution:


From To Value
Connector X-UCM4B pin 2 Ground ≥ + 10 V

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From To Value
Connector X-LC2 pin 4A Connector X-UCM4B pin 2 Short circuit
A. If the measurement is not correct, replace the harness between the connectors X-LC2 and X-UCM4B.

7. Check the integrity of fuse UCM VS1/VLP ( F-2F4) of LC2.
A. If the fuse is burnt (open circuit between the terminals), replace the fuse UCM VS1/VLP.
From To Value
Connector X-P1196 Ground ≥ + 10 V
A-MAIN JB CAB).

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518292-31 - Error at 24VP Supply Rail

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VP power supply; as a consequence the UCM functions are all disabled.
Cause:
The A-UCM detects, on pin 20 of connector X-UCM1A, a voltage < + 10 V.

5. The UCM VP ( F-2F1) is burnt.
Solution:


From To Value
Connector X-UCM1A pin 2 Ground ≥ + 10 V


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From To Value

7. Check the integrity of fuse UCM VP ( F-2F1) of LC2.
A. If the fuse is burnt (open circuit between the terminals), replace the fuse UCM VP.
From To Value
Connector X-P1196 Ground ≥ + 10 V
A-MAIN JB CAB).

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518293-31 - Error at 2.5V Ref1 Supply

Control Module: UCM
Context:
The A-UCM detects an error on the 2.5 V Ref1; as a consequence:

• Loss of FIN_1, FIN_2, FIN_3, FIN_4;
Cause:
IcVREF_2V5REF1_mV <= 2350 mV or IcVREF_2V5REF1_mV >= 2650 mV

Solution:
A. If the fault is present and active, replace, and send to manufacturer per repairing if possible, the UCM.
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518294-31 - Error at 2.5V Ref2 Supply

Control Module: UCM
Context:
The A-UCM detects an error on the 2.5 V Ref2; as a consequence:

• Loss of FIN_1, FIN_2, FIN_3, FIN_4;
Cause:
IcVREF_2V5REF2_mV <= 2350 mV or IcVREF_2V5REF2_mV >= 2650 mV

Solution:
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518296-31 - Error at 5VREFIN

Control Module: UCM
Context:
The A-UCM detects an error on the 5VREFIN; as a consequence:

• Loss of RIN_01, RIN_02, RIN_03, RIN_04)
- Set fan speed to max
- FAX Temperature not available
• FAX warning disabled
• Set PV_VC_STS.FAxOilTempWarn = 0x3 (out of range)
- Fuel Level Not Available
- Hydraulic Oil Temperature not available
Cause:
IcVREF_5VREFIN_mV <= 4800 mV or IcVREF_5VREFIN_mV <= 5200 mV

Solution:
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518390-00 - Hydraulic Oil Temp Sensor Over Resistance

Control Module: UCM
Context:
The A-UCM detects a value of resistance of the HYD OIL TEMP ( B-HOT) higher than the upper limit; as a
consequence:
• the Hydraulic Oil Temperature is not available;
• the Hydraulic Oil Temperature is set to - 50 °C.
Cause:
The A-UCM detects on pin 18 of connector X-UCM4A a resistance value > 2000 Ω (About 250 °C).

2. The harness between A-UCM and the HYD OIL TEMP is damaged.
3. The connectors X-TRANS or X-HOT or X-CAB_TR or X-UCM4A are damaged.
4. The harness between connectors X-HOT and ground is damaged.
5. The harness between connectors X-TRANS and the HYD OIL TEMP is damaged.
6. The harness between connectors X-UCM4A and X-CAB_TR is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM4A and connector X-HOT for any dam-
age.

3. Check the integrity of connector X-HOT.
Disconnect the connector X-HOT from the HYD OIL TEMP and visually check the integrity of pins 1 and 2 of the
connector.

4. Check the integrity of harness between the connector X-HOT and ground.
Disconnect the connector X-HOT from the HYD OIL TEMP.
From To Value
Connector X-HOT pin 2 Ground Short circuit
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5. Check the integrity of connectors X-TRANS and X-CAB_TR.
Disconnect the connector X-TRANS from the connector X-CAB_TR and visually check the integrity of pins 30 and
3 of both connectors.

6. Check the integrity of harness between the connector X-TRANS and the HYD OIL TEMP.
From To Value
Connector X-TRANS pin 30 Connector X-HOT pin 1 Short circuit


8. Check the integrity of harness between the connectors X-UCM4A and X-CAB_TR.
From To Value

9. Replace the HYD OIL TEMP.
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518390-01 - Hydraulic Oil Temp Sensor Under Resistance

Control Module: UCM
Context:
The A-UCM detects a value of resistance of the HYD OIL TEMP ( B-HOT) lower than the low limit; as a consequence:
• the Hydraulic Oil Temperature is not available;
• the Hydraulic Oil Temperature is set to - 50 °C.
Cause:
The A-UCM detects on pin 18 of connector X-UCM4A a resistance value > 500 Ω (About - 100 °C).

2. The harness between A-UCM and the HYD OIL TEMP is damaged.
3. The HYD OIL TEMP is damaged.
4. The connectors X-TRANS or X-HOT or X-CAB_TR or X-UCM4A are damaged
5. The harness of HYD OIL TEMP is damaged.
6. The harness between connectors X-TRANS and X-HOT is damaged.
7. The harness between connectors X-CAB_TR and X-UCM4A is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM4A and connector X-HOT for any dam-
age.

3. Replace the HYD OIL TEMP.

4. Check the integrity of connector X-HOT.
Disconnect the connector X-HOT from the HYD OIL TEMP and visually check the integrity of pins 1 and 2.

5. Check the integrity of harness of the HYD OIL TEMP.
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From To Value
Connector X-HOT pin 2 Connector X-HOT pin 1 Open circuit

6. Check the integrity of connectors X-TRANS and X-CAB_TR.
Disconnect the connector X-TRANS from the connector X-CAB_TR and visually check the integrity of pins 30 and
3 of both connectors.

7. Check the integrity of harness between the connector X-TRANS and the HYD OIL TEMP.
Connect the connector X-HOT to the HYD OIL TEMP.
From To Value
Connector X-TRANS pin 30 Connector X-TRANS pin 3 > 500 Ω


9. Check the integrity of harness between the connectors X-UCM4A and X-CAB_TR.
From To Value
Connector X-CAB_TR pin 3 Connector X-CAB_TR pin 30 Open circuit
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518498-00 - Engine oil temperature is very high

Context:
Engine oil temperature is very high.
Cause:

2. The UCM reports that engine oil temperature is over.
Solution:
2. Bring the machine to a safe stop, and turn the engine OFF immediately. Replace the engine oil temperature
sensor.
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518499-18 - Engine Oil pressure Low

Context:
Engine Oil pressure Low.
Cause:

2. The UCM reports that engine oil pressure is over.
Solution:
2. Bring the machine to a safe stop, and turn the engine OFF immediately. Replace the engine oil pressure sensor.
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518501-09 - Air Filter Clogged

Context:
Air Filter Clogged.
Cause:
Air Filter switch shall be considered clogged when AN_17 Voltage > 15 V and not clogged when Voltage < 10 V.

2. The air filter is clogged.
Solution:
2. Verify that the air filter is clean.
A. If the air filter is clean, replace the air filter sensor..
B. If the air filter is clogged, continue with Step 3.

3. Clean the air filter.
A. If the fault disappier after the cleaning, continue to work monitoring the fault.
B. If the fault is still present after the cleaning, bring the machine to a safe stop, and turn the engine OFF imme-
diately. Replace the air filter.
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520332-19 - TCU Source Address Cyclic Timeout

Control Module: UCM
Context:
The A-UCM does not receive messages from the TCU Source Address within the maximum interval time; as a
consequence:
• Use last TCU CAN message received;
• (sump temp blank when timeout);
• ( EPAS use TRF1.TransmOilTemp);
• Disable Differential Lock Function;
• Disable Torque Converter Lock Up Function;
• Disable CCO and ICCO.
Cause:

Solution:



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520333-19 - Keypad Source Address Cyclic Timeout

Control Module: UCM
Context:
The A-UCM does not receive messages from the Keypad Source Address within the maximum interval time; as a
consequence use last keypad CAN message received.
Cause:

2. The harness of busses CAN 1 or CAN 2 is visually damaged.
Solution:




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520334-19 - Smart Fuse Box Source Address Cyclic Timeout

Control Module: UCM
Context:
The A-UCM does not receive messages from the Smart Fuse Box Source Address within the maximum interval time;
as a consequence last SFB CAN message received.
Cause:

Solution:




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520335-19 - Joystick Steering Controller Source Address Cyclic

Timeout
Control Module: UCM
Context:
The A-UCM does not receive messages from Joystick Steering Controller Source Address within the maximum
interval time; as a consequence the JSS function is disabled:
• Set Joystick Position to Neutral;
• Command PVED to cut Supply Pressure.
Cause:

Solution:




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520444-02 - Memory Integrity RAM

Context:
Memory Integrity RAM.
Cause:

Solution:

3. Verify the wirings to external connection, if one or more wirings are damaged, proceed with the replacement.
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520444-31 - Memory Integrity ROM

Context:
Memory Integrity ROM.
Cause:

Solution:

3. Verify the wirings to external connection, if one or more wirings are damaged, proceed with the replacement.
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520519-19 - Bus Off

Context:
The Keypad unit is capable of connecting to and communicating on separate Controller Area Networks ( CAN).
Cause:
Keypad unit has sensed a “Bus Off” state to be present.
1. Faulty supply voltage or ground, missing.

2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit.
3. Faulty Keypad termination resistor or software.
Solution:
B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active.
Continue with Step 6.
Use the EST to determine if vehicle CAN faults exist.
A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that this fault is also
resolved.
B. If other vehicle CAN faults do not exist, continue with Step 3.

3. Check the Keypad unit supply voltage.
Disconnect the vehicle ( VE) harness from the Keypad unit at connector. With the key switch in the “ON” position,
use a multimeter to check for voltage on the vehicle ( VE) harness side:
From To Value
Power Supply pins Chassis ground There should be 12.0 V
A. If the voltage is present on all of the checks, leave connector disconnected and continue with Step 4.
B. If the voltage is not present for one or more of the checks, refer to the appropriate vehicle service manual and
electrical schematics to locate and restore supply power to the Keypad unit.
4. Check the Keypad unit grounding.
With the key switch in the “OFF” position, use a multimeter to check for continuity on the vehicle ( VE) harness
side:
From To Value
GND pins Chassis ground There should be continuity
A. If there is continuity on all of the checks, leave connector disconnected and continue with Step 5.
B. If there is no continuity for one or more of the checks, refer to the electrical schematics to locate and restore
the grounding circuit to the Keypad unit.
5. Determine the condition of the Keypad unit CAN circuit.
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With the key switch in the “OFF” position, use a multimeter to measure the resistance of the CAN connection on
the vehicle (VE) harness side:
From To Value
Connector X-ECU pin 46 Connector X-ECU pin 47 There should be 120 Ω
Connector X-ECU pin 46 Chassis ground There should not be continuity
Connector X-ECU pin 47 Chassis ground There should not be continuity
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the Keypad unit:
From To Value
Connector X-ECU pin 46 Connector X-ECU pin 47 There should be 120 Ω
A. If the measured resistances are correct and neither conductor is grounded, check the Keypad unit for the
appropriate software and re-flash, if necessary.
B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate
vehicle service manual and electrical schematics to locate and restore the termination resistance to the CAN
circuit.
6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals,
or broken wires.
Verify that the connectors are fully installed.
Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned.
Operate the machine while you monitor the display.
has been resolved.
B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue
operation.
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520572-03 - 24v to 12v Converter Enable - Short Circuit to B+

Control Module: SFB
Context:
24 V to 12 V Converter Enable (Short Circuit to B+).
Cause:
The Smart Fuse box detects a Short Circuit to B+ from the DC converter Relay signal ( X-X3 pin 15) when the key is
OFF.

2. The harness between Smart Fuse Box and DC converter Relay is damaged.
3. The X-LC3 connector (pin RI_86) is damaged.
5. The harness between DC converter Relay and Smart Fuse Box is defective.
6. The DC converter Relay is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and DC converter Relay.

3. Check the integrity of the DC converter Relay connector.
Disconnect DC converter Relay connector ( X-LC3 pin R1-86) and visually check the integrity of the pin.


5. Check the DC converter Relay signal circuit.
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From To Value
Connector K-3R1 pin 86 Chassis ground There should be an open circuit
A. If there is a voltage, replace the 24 V to 12 V Converter.

From To Value
A. If there is an open circuit, replace the Smart Fuse Box.

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520572-05 - 24v to 12v Converter Enable - Open Circuit

Control Module: SFB
Context:
24 V to 12 V Converter Enable (Open Circuit)
Cause:
The Smart Fuse box detects an Open Circuit from the DC converter Relay signal ( X-X3 pin 15) when the key is OFF.

Solution:



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From To Value
Connector K-3R1 pin 86 Chassis ground There should be a resistance
A. If there is an open circuit, replace the 24 V to 12 V Converter.
B. If there is a resistance value, continue to Step 6.

From To Value
Connector A-SFB pin OUT_06_H Chassis ground There should be a resistance
A. If there is an open circuit, replace the Smart Fuse Box.

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520572-06 - 24v to 12v Converter Enable - Short Circuit to GND

Control Module: SFB
Context:
24 V to 12 V Converter Enable (Short Circuit to GND).
Cause:
The Smart Fuse box detects a Short Circuit to GND from the DC converter Relay signal ( X-X3 pin 15) when the key
is ON.

Solution:



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From To Value
Connector K-3R1 pin 86 Chassis ground There should be an open circuit
A. If there is an short circuit, replace the 24 V to 12 V Converter.

From To Value

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520578-03 - Battery Isolator SET - Short Circuit to B+

Control Module: SFB
Context:
Battery voltage on K Isolator set (short circuit to B+).
Cause:
The Smart Fuse box detects a battery voltage on K isolator signal ( X-X4 pin 17) when the key is ON.

2. The harness between Smart Fuse Box and Battery Isolator is damaged.
3. The Battery Isolator connector is damaged.
4. The X-ENG-2 connector is damaged.
5. The X-CAB_E-2 connector is damaged.
6. The Smart Fuse Box connector is damaged. x
7. The Battery isolator is defective.
8. The harness between Battery Isolator and X-ENG-2 connector is defective.
9. The harness between Smart Fuse Box and X-CAB_E-2 connector is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and Battery Isolator.

3. Check the integrity of the Battery Isolator connector.
Disconnect Battery Isolator connector X-ISO and visually check the integrity of the pin 2.
A. If the pin 1 is damaged, replace the X-ISO connector.

4. Check the integrity of the X-ENG-2 connector.
Disconnect X-ENG-2 connector and visually check the integrity of the pin F.
A. If the pin F is damaged, replace the X-ENG-2 connector.
B. If the pin F is not damaged, continue with Step 5.
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5. Check the integrity of the X-CAB_E-2 connector.
Disconnect X-CAB_E-2 connector and visually check the integrity of the pin F.
A. If the pin F is damaged, replace the X-CAB_E-2 connector.


7. Check the Battery Isolator signal circuit for a short key battery power condition.
From To Value
Connector X-ISO pin 2 Chassis ground There should be an open circuit
A. If there is a short circuit to B+, replace the Battery Isolator relay.

8. Check the signal circuit for a short key battery power condition on the harness between Battery Isolator and
X-ENG-2 connector.
From To Value
Connector X-ENG-2 pin F Chassis ground There should be an open circuit
A. If there is a Short Circuit, replace the harness.

9. Check the signal circuit for a short key battery power condition on the harness between Smart Fuse Box and
X-CAB_E-2 connector.
From To Value
Connector X-X4 pin 17 Chassis ground There should be an open circuit

10. Check the Smart Fuse Box signal circuit for a short key battery power condition.
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From To Value
A. If there is a Short Circuit to B+, replace the Smart Fuse Box.
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520578-03 - Battery Isolator RESET - Short Circuit to B+

Control Module: SFB
Context:
Battery voltage on K Isolator reset (short circuit to B+).
Cause:
The Smart Fuse box detects a battery voltage on K isolator signal ( X-X7 pin 8) when the key is OFF.

Solution:


Disconnect X-ENG-2 connector and visually check the integrity of the pin G.
A. If the pin G is damaged, replace the X-ENG-2 connector.
B. If the pin G is not damaged, continue with Step 5.
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Disconnect X-CAB_E-2 connector and visually check the integrity of the pin G.
A. If the pin G is damaged, replace the X-CAB_E-2 connector.


From To Value
A. If there is a voltage, replace the Battery Isolator relay.

X-ENG-2 connector.
From To Value
Connector X-ENG-2 pin G Chassis ground There should be an open circuit

From To Value

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From To Value
Connector A-SFB pin OUT_09_H Chassis ground There should be Short Circuit
A. If there is a Short Circuit, replace the Smart Fuse Box.
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520578-06 - Battery Isolator SET - Short Circuit to GND

Control Module: SFB
Context:
Battery voltage on K Isolator set (short circuit to GND).
Cause:
The Smart Fuse box detects a short circuit to GND on K isolator signal ( X-X4 pin 17) when the key is ON.

Solution:


Disconnect X-ENG-2 connector and visually check the integrity of the pin F.
A. If the pin F is damaged, replace the X-ENG-2 connector.
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Disconnect X-CAB_E-2 connector and visually check the integrity of the pin F.
A. If the pin F is damaged, replace the X-CAB_E-2 connector.


From To Value
A. If there is a short circuit to GND, replace the Battery Isolator relay.

X-ENG-2 connector.
From To Value
Connector X-ENG-2 pin F Chassis ground There should be an open circuit
A. If there is a Short Circuit to GND, replace the harness.

From To Value
A. If there is a Short Circuit to GND, replace the harness.

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From To Value
A. If there is a Short Circuit to GND, replace the Smart Fuse Box.
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520578-06 - Battery Isolator RESET - Short Circuit to GND

Control Module: SFB
Context:
Battery voltage on K Isolator reset (short circuit to GND).
Cause:
The Smart Fuse box detects a short circuit to GND on K isolator signal ( X-X7 pin 8) when the key is ON.

Solution:


Disconnect X-ENG-2 connector and visually check the integrity of the pin G.
A. If the pin G is damaged, replace the X-ENG-2 connector.
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Disconnect X-CAB_E-2 connector and visually check the integrity of the pin G.
A. If the pin G is damaged, replace the X-CAB_E-2 connector.


From To Value
Connector X-ISO pin 1 Chassis ground There should be open circuit
A. If there is a short circuit, replace the Battery Isolator relay.

X-ENG-2 connector.
From To Value
Connector X-ENG-2 pin G Chassis ground There should be open circuit

From To Value
Connector X-X7 pin 8 Chassis ground There should be open circuit

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From To Value
Connector A-SFB pin OUT_09_H Chassis ground There should be open circuit
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520584-00 - Left Brake Indicator Light - Too many loads or faulty

load
Control Module: SFB
Context:
Too many loads or faulty load on Left Brake Indicator Light.
Cause:
The Smart Fuse box measure Too many loads or faulty load on Left Brake Indicator Light ( X6-2) with a current value
> 2.365 A when the key is ON.

3. The Left Brake Indicator Light connector is damaged.
5. The Left Brake Indicator Light is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and L-NA-TAIL ( X-LH-TAIL pin 2).

3. Check the integrity of the L-NA-TAIL connector ( X-LH-TAIL pin 2).


5. Check the signal circuit for an short circuit to GND condition on the harness between L-NA-TAIL pin ( X-LH-TAIL
pin 2) and Smart Fuse Box.
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From To Value
Connector X-CAB_E pin 10 GND There should be an open circuit
Connector X-ENG pin 10 GND There should be an open circuit
Connector X-ENG_H pin 2 GND There should be an open circuit
A. If there is an short circuit to GND, replace the harness.

6. Check the Electrical Ignition Power Relay pin ( L-NA-TAIL pin 2) circuit for an short circuit to GND.
From To Value
Connector L-NA-TAIL pin 2 GND There should be an open circuit
A. If there is an short circuit to GND, replace the Electrical Ignition Power Relay.

7. Check the Smart Fuse Box signal circuit for an short circuit to GND.
From To Value
Connector A-SFB pin GND There should be an open circuit to
OUT_19_H_CS GND
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520584-03 - Left Brake Indicator Light - Short circuit to B+

Control Module: SFB
Context:
Short circuit to B+ on Left Brake Indicator Light.
Cause:
The Smart Fuse box measure an short circuit to B+ on Left Brake Indicator Light ( X6-2) when the key is ON.

Solution:



5. Check the signal circuit for an short circuit to B+ condition on the harness between L-NA-TAIL pin ( X-LH-TAIL pin
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From To Value
Connector X-CAB_E pin 10 + 5V There should be an open circuit
Connector X-ENG pin 10 + 5V There should be an open circuit
Connector X-ENG_H pin 2 + 5V There should be an open circuit
A. If there is an short circuit to B+, replace the harness.

6. Check the Electrical Ignition Power Relay pin ( L-NA-TAIL pin 2) circuit for an short circuit to B+.
From To Value
Connector L-NA-TAIL pin 2 + 5V There should be an open circuit
A. If there is an short circuit to B+, replace the Electrical Ignition Power Relay.

7. Check the Smart Fuse Box signal circuit for an short circuit to B+.
From To Value
Connector A-SFB pin + 5V There should be an open circuit to B+
OUT_19_H_CS
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520584-05 - Left Brake Indicator Light - Open Circuit

Control Module: SFB
Context:
Short circuit to B+ on Left Brake Indicator Light.
Cause:
The Smart Fuse box measure an open circuit on Left Brake Indicator Light ( X6-2) when the key is OFF or a Current
value < 35 mA when ON.

Solution:



5. Check the signal circuit for an open circuit condition on the harness between L-NA-TAIL pin ( X-LH-TAIL pin 2)
and Smart Fuse Box.
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From To Value
Connector X-X6 pin 2 Connector X-CAB_E pin 10 There should be a short circuit
Connector X-CAB_E pin 10 Connector X-ENG pin 10 There should be a short circuit
Connector X-ENG pin 10 Connector X-ENG_H pin 2 There should be a short circuit
Connector X-ENG_H pin 2 Connector X-LH-TAIL pin 2 There should be a short circuit
B. If there is a short circuit, continue to Step 6.

6. Check the Electrical Ignition Power Relay pin ( L-NA-TAIL pin 2) circuit for an open circuit.
From To Value
Connector L-NA-TAIL pin 2 Connector X-LH-TAIL pin 1 There should be a short circuit
A. If there is an open circuit, replace the L-NA-TAIL.
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520584-06 - Left Brake Indicator Light - Short circuit to GND

Control Module: SFB
Context:
Short circuit to GND on Left Brake Indicator Light.
Cause:
The Smart Fuse box measure an short circuit to GND on Left Brake Indicator Light ( X6-2) when the key is ON.

Solution:



5. Check the signal circuit for an over current condition on the harness between L-NA-TAIL pin ( X-LH-TAIL pin 2)
and Smart Fuse Box.
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From To Value

6. 6. Check the Electrical Ignition Power Relay pin ( L-NA-TAIL pin 2) circuit for over current.
From To Value

7. Check the Smart Fuse Box signal circuit for an over current.
From To Value
OUT_19_H_CS GND
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520585-00 - Right Brake Indicator Light - Too many loads or faulty

load
Control Module: SFB
Context:
Too many loads or faulty load on Right Brake Indicator Light.
Cause:
The Smart Fuse box measure Too many loads or faulty load on Right Brake Indicator Light ( X-X3 pin 12) with a
current value > 2.365 A when the key is ON.

3. The Right Brake Indicator Light connector is damaged.
5. The Right Brake Indicator Light is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and LMP-R-NA-TAIL ( X-RH-TAIL pin 2).

3. Check the integrity of the LMP-R-NA-TAIL connector ( X-RH-TAIL pin 2).


5. Check the signal circuit for an short circuit to GND condition on the harness between LMP-R-NA-TAIL pin ( X-RH-
TAIL pin 2) and Smart Fuse Box.
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From To Value

6. Check the Electrical Ignition Power Relay pin ( LMP-R-NA-TAIL pin 2) circuit for an short circuit to GND.
From To Value

7. Check the Smart Fuse Box signal circuit for an short circuit to GND.
From To Value
OUT_20_H_CS GND
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520585-03 - Right Brake Indicator Light - Short circuit to B+

Control Module: SFB
Context:
Short circuit to B+ on Right Brake Indicator Light.
Cause:
The Smart Fuse box measure an short circuit to B+ on Right Brake Indicator Light ( X6-2) when the key is ON.

Solution:



5. Check the signal circuit for an short circuit to B+ condition on the harness between LMP-R-NA-TAIL pin ( X-RH-
TAIL pin 2) and Smart Fuse Box.
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From To Value
Connector X-CAB_E pin 21 + 5V There should be an open circuit
Connector X-ENG pin 7 + 5V There should be an open circuit
Connector X-ENG_H pin 7 + 5V There should be an open circuit
A. If there is an short circuit to B+, replace the harness.

6. Check the Electrical Ignition Power Relay pin ( L-NA-TAIL pin 2) circuit for an short circuit to B+.
From To Value
Connector LMP-R-NA-TAIL pin 2 + 5V There should be an open circuit
A. If there is an short circuit to B+, replace the Electrical Ignition Power Relay.

7. Check the Smart Fuse Box signal circuit for an short circuit to B+.
From To Value
Connector A-SFB pin + 5V There should be an open circuit to B+
OUT_20_H_CS
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520585-05 - Right Brake Indicator Light - Open Circuit

Control Module: SFB
Context:
Short circuit to B+ on Right Brake Indicator Light.
Cause:
The Smart Fuse box measure an open circuit on Right Brake Indicator Light ( X-X3 pin 12) when the key is OFF or a
Current value < 35 mA when ON.

Solution:



5. Check the signal circuit for an open circuit condition on the harness between LMP-R-NA-TAIL pin ( X-RH-TAIL pin
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From To Value
Connector X-X3 pin 12 Connector X-CAB_E pin 21 There should be a short circuit
Connector X-CAB_E pin 21 Connector X-ENG pin 21 There should be a short circuit
Connector X-ENG pin 21 Connector X-ENG_H pin 7 There should be a short circuit
Connector X-ENG_H pin 7 Connector X-RH-TAIL pin 2 There should be a short circuit
B. If there is a short circuit, continue to Step 6.

6. Check the Electrical Ignition Power Relay pin ( LMP-R-NA-TAIL pin 2) circuit for an open circuit.
From To Value
Connector LMP-R-NA-TAIL pin 2 LMP-R-NA-TAIL pin 1 There should be a short circuit
A. If there is an open circuit, replace the L-NA-TAIL.
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520585-06 - Right Brake Indicator Light - Short circuit to GND

Control Module: SFB
Context:
Short circuit to GND on Right Brake Indicator Light.
Cause:
The Smart Fuse box measure an short circuit to GND on Right Brake Indicator Light ( X-X3-pin 12) when the key is
ON.

Solution:



5. Check the signal circuit for an over current condition on the harness between LMP-R-NA-TAIL pin ( X-RH-TAIL
pin 2) and Smart Fuse Box.
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From To Value

6. Check the Electrical Ignition Power Relay pin ( LMP-R-NA-TAIL pin 2) circuit for over current.
From To Value
Connector LMP-R-NA-TAIL pin 2 GND There should be an open circuit

7. Check the Smart Fuse Box signal circuit for an over current.
From To Value
OUT_20_H_CS GND
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520588-03 - Alternator Excitation Driver - Short Circuit to B+

Control Module: SFB
Context:
Alternator Excitation Driver (Short Circuit to B+).
Cause:
The Smart Fuse box detects a Short Circuit to B+ from the Alternator Excitation Driver signal ( X-X5 pin 4) when the
key is OFF.

2. The harness between Smart Fuse Box and Alternator is damaged.
3. The X-ALT connector (pin 3) is damaged.
5. The harness between Alternator and Smart Fuse Box is defective.
6. The Alternator is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and Alternator.

3. Check the integrity of the Alternator connector.
Disconnect Alternator connector ( X-ALT pin 3) and visually check the integrity of the pin.


5. Check the Alternator signal circuit.
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From To Value
Connector G-G1 pin 15 Chassis ground There should be an open circuit
A. If there is a short circuit to B+, replace Alternator.

From To Value
A. If there is a short circuit to B+, replace the Smart Fuse Box.
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520588-06 - Alternator Excitation Driver - Short Circuit to GND

Control Module: SFB
Context:
Alternator Excitation Driver (Short Circuit to GND).
Cause:
The Smart Fuse box detects a Short Circuit to GND from the Alternator Excitation Driver signal ( X-X5 pin 4) when
the key is ON.

2. The harness between Smart Fuse Box and Alternator is damaged.
3. The X-ALT connector (pin 3) is damaged.
5. The harness between Alternator and Smart Fuse Box is defective.
6. The Alternator is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and Alternator.

3. Check the integrity of the Alternator connector.
Disconnect Alternator connector ( X-ALT pin 3) and visually check the integrity of the pin.


5. Check the Alternator signal circuit.
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From To Value
Connector G-G1 pin 15 Chassis ground There should be an open circuit
A. If there is a short circuit to GND, replace Alternator.

From To Value
A. If there is a short circuit to ground, replace the Smart Fuse Box.
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520591-00 - Backup Alarm - Too many loads or faulty load

Control Module: SFB
Context:
Over load of the Backup Alarm Signal (Too many loads or faulty load).
Cause:
The Smart Fuse box measure a current > 5.5 A on Backup Alarm signal ( X4 pin 21) when the SCG is ON.

2. The harness between Smart Fuse Box and Backup Alarm is damaged.
3. The Backup Alarm connector is damaged.
4. The X-ENG connector is damaged.
5. The X-CAB_E connector is damaged.
7. The Backup Alarm is defective.
8. The harness between Backup Alarm and X-ENG connector is defective.
9. The harness between Smart Fuse Box and X-CAB_E connector is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and Backup Alarm.

3. Check the integrity of the Backup Alarm connector.
Disconnect Backup Alarm connector X-BU2 and visually check the integrity of the pin P.
A. If the pin P is damaged, replace the X-BU2 connector.
B. If the pin P is not damaged, continue with Step 4.

4. Disconnect Backup Alarm connector X-BU1 and visually check the integrity of the pin N.
A. If the pin N is damaged, replace the X-BU1 connector.
B. If the pin N is not damaged, continue with Step 5.

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Disconnect X-ENG connector and visually check the integrity of the pin 7.
A. If the pin 7 is damaged, replace the X-ENG connector.

6. Check the integrity of the X-CAB_E connector.
Disconnect X-CAB_E connector and visually check the integrity of the pin 7.
A. If the pin 7 is damaged, replace the X-CAB_E connector.


8. Check the Backup Alarm signal circuit for an over current condition.
Use a multimeter to perform the following voltage check on the BACKUP ALARM connector:
From To Value
Connector N Connector P There should be an open circuit
A. If there is continuity, replace the Backup Alarm

9. Check the signal circuit for an over current condition on the harness between Backup Alarm and X-ENG connec-
tor.
From To Value
Connector X-ENG Connector X-BU2 There should be a short circuit
B. If there is a voltage, continue to Step 10.

10. Check the signal circuit for an over current condition on the harness between Smart Fuse Box and X-CAB_E
connector.
From To Value
Connector X-X4 pin 21 Connector X-CAB_E There should be a short circuit

11. Check the Smart Fuse Box signal circuit for an over current condition.
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From To Value
Connector A-SFB pin Chassis ground There should be an open circuit
OUT_45_H_CS_L
A. If there is a short circuit to ground, replace the Smart Fuse Box.
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520591-03 - Backup Alarm - Short circuit to B+

Control Module: SFB
Context:
Battery voltage on Backup Alarm (Short circuit to B+).
Cause:
The Smart Fuse box measure a battery voltage on Backup Alarm signal ( X4 pin 21) when the key is OFF.

Solution:



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8. Check the Backup Alarm signal circuit for an open circuit condition.
From To Value
Connector X-BU1 Connector X-BU2 There should be an open circuit
A. If there is continuity, replace the Backup Alarm.

9. Check the signal circuit for an open circuit condition on the harness between Backup Alarm and X-ENG connector.
From To Value

10. Check the signal circuit for an open circuit condition on the harness between Smart Fuse Box and X-CAB_E
connector.
From To Value

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From To Value
Connector A-SFB pin Chassis ground There should be not voltage
OUT_45_H_CS_L
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520591-05 - Backup Alarm - Open Circuit

Control Module: SFB
Context:
Low current on Backup Alarm (open circuit).
Cause:
The Smart Fuse box measure a current < 35 mA on Backup Alarm signal ( X4 pin 21) when the key is ON.

Solution:



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8. Check the Backup Alarm signal circuit for an open circuit condition.
From To Value
Connector X-BU1 Connector X-BU2 There should be an open circuit

9. Check the signal circuit for an open circuit condition on the harness between Backup Alarm and X-ENG connector.
From To Value

10. Check the signal circuit for an open circuit condition on the harness between Smart Fuse Box and X-CAB_E
connector.
From To Value

From To Value
OUT_45_H_CS_L
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55.9 [55.DTC] / 673
520591-06 - Backup Alarm - Short circuit to GND

Control Module: SFB
Context:
No Signal on Backup Alarm (Short circuit to GND).
Cause:
The Smart Fuse box measure a GND voltage on Backup Alarm signal ( X4 pin 21) when the SCG is ON.

Solution:



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8. Check the Backup Alarm signal circuit for a short circuit to GND condition.
Use a multimeter to perform the following voltage check on the BACKUP ALARM connector:
From To Value
Connector N Connector P There should be an open circuit

9. Check the signal circuit for a short circuit to GND condition on the harness between Backup Alarm and X-ENG
connector.
From To Value

10. Check the signal circuit for a short circuit to GND condition on the harness between Smart Fuse Box and X-CAB_E
connector.
From To Value

11. Check the Smart Fuse Box signal circuit for a short circuit to GND.
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From To Value
OUT_45_H_CS_L
A. If there is a short circuit to GND, replace the Smart Fuse Box.
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520596-03 - VSUP A - Out of Range - High

Control Module: SFB
Context:
VSUP A signal is out of range, too high level.
Cause:
The Smart Fuse box measure a high level of VSUP A signal (out of range), voltage > 32 V.

2. The harness between Smart Fuse Box and the Battery Isolator is damaged.
4. The Battery Isolator is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box X-X1 pin 2 and the Junction Block into the cab pin
X-P1031.

3. Check the integrity of the Smart Fuse Box X-X1 connector pin 2.
Visually check the integrity of the pin.

4. Check the integrity of the Smart Fuse Box X-LC1 connector pin 1.

5. Check the integrity of the fuse.
Visually check the integrity of the fuse F-1F6 ( 50 A).
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A. If the fuse is damaged, replace the fuse.
B. If the fuse is not damaged, continue with Step 6.

6. Check the Battery K Isolator.
From To Value
Connector X-ISO pin 3 Chassis ground There should be a short
A. Verify the Battery K Isolator Power supply (pin X-D)
B. If Battery K Isolator is right functioning, replace the Smart Fuse Box.

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520596-04 - VSUP A - Out of Range - Low

Control Module: SFB
Context:
VSUP A signal is out of range, too Low level.
Cause:
The Smart Fuse box measure a Low level of VSUP A signal (out of range), voltage <20 and not cranking.

Solution:
X-P1031.



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From To Value
A. Verify the Battery K Isolator Power supply (pin X-D).

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520597-03 - VSUP B - Out of Range - High

Control Module: SFB
Context:
VSUP B signal is out of range, too high level.
Cause:
The Smart Fuse box measure a high level of VSUP B signal (out of range), voltage > 32 V.

Solution:
X-P1031.



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From To Value
A. Verify the Battery K Isolator Power supply (pin X-D).

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520597-04 - VSUP B - Out of Range - Low

Control Module: SFB
Context:
VSUP B signal is out of range, too Low level.
Cause:
The Smart Fuse box measure a Low level of VSUP B signal (out of range), voltage <20 and not cranking.

Solution:
X-P1031.



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From To Value

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520598-03 - VSUP C - Out of Range - High

Control Module: SFB
Context:
VSUP C signal is out of range, too high level.
Cause:
The Smart Fuse box measure a high level of VSUP C signal (out of range), voltage > 32 V.

Solution:
X-P1031.



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From To Value

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520598-04 - VSUP C - Out of Range - Low

Control Module: SFB
Context:
VSUP C signal is out of range, too Low level.
Cause:
The Smart Fuse box measure a Low level of VSUP C signal (out of range), voltage <20 and not cranking.

Solution:
X-P1031.



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From To Value

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520599-03 - VSUP D - Out of Range - High

Control Module: SFB
Context:
VSUP D signal is out of range, too high level.
Cause:
The Smart Fuse box measure a high level of VSUP D signal (out of range), voltage > 32 V.

Solution:
X-P1031.



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From To Value

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520599-04 - VSUP D - Out of Range - Low

Control Module: SFB
Context:
VSUP D signal is out of range, too Low level.
Cause:
The Smart Fuse box measure a high level of VSUP D signal (out of range), voltage <20 and not cranking.

Solution:
X-P1031.



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From To Value

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522809-02 - Memory Integrity EEPROM

Context:
Memory Integrity EEPROM.
Cause:

Solution:
B. If the wirings are intact and functioning, verify the wirings to external connection, if one or more wirings are
damaged, proceed with the replacement.
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522810-09 - Joystick Steering Cut Off Valves not plausible

Control Module: UCM
Context:
The A-UCM detects not plausible values from the Joystick; as a consequence, the function JSS is disabled:
Cause:
The A-UCM detects, on pins 12 of connector X-UCM2A and 15 of connector X-UCM3B, one of the following
conditions:
• COV_A is closed and COV_B is open;
• COV_B is closed and COV_A is open;
• COV_A is closed and COV_B is closed and STAT_MSG_OP_X.OperationState_X = 0x11;
• COV_A is open and COV_B is open and STAT_MSG_OP_X.OperationState_X = 0x00

2. The harness between the A-UCM, the JSS CUT OFF SENSOR 1 and the JSS CUT OFF SENSOR 2 is visually
damaged.
3. The harness between the PVED-CLS, the valve JSS COV 1 and the valve JSS COV 2 is visually damaged.
4. The PVED-CLS is not functioning.
5. The integrity of the connectors X-JSS_FR or X-CAB_JSS or X-JSS_CO_1 or X-JSS_CO_2 or X-UCM3A or
X-UCM2A or X-UCM3B or X-UCM1A is damaged.
6. The JSS CUT OFF SENSOR 1 and the JSS CUT OFF SENSOR 2 are not supplied.
7. The harness between the connectors X-JSS_CO_1 or X-JSS_CO_2 and the connector X-JSS_FR is damaged.
8. The JSS CUT OFF SENSOR 1 or the JSS CUT OFF SENSOR 2 is damaged.
9. The harness between the PVED-CLS and the A-UCM (bus CAN 2) is visually damaged.
10. The harness between the connector X-CAB_JSS and the A-UCM is damaged.
Solution:
2. Visually check the integrity of the harness between the A-UCM, the JSS CUT OFF SENSOR 1 and the JSS CUT
OFF SENSOR 2 for any damage.

3. Visually check the integrity of the harness between the PVED-CLS and the valves JSS COV 1 and JSS COV 2
for any damage.
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4. Check the PVED-CLS correctly commands the valves JSS COV 1 and the JSS COV 2.
A. If the PVED-CLS does command the valves, replace the PVED-CLS.
B. If the PVED-CLS correctly commands the valves, continue with Step 5.

5. Check the integrity of the connectors X-JSS_FR and X-CAB_JSS.
Disconnect the connector X-SST from the connector X-BTS and visually check the integrity of pins 2, 3, 4 and 6
of both connectors.

6. Check the JSS CUT OFF SENSOR 1 and JSS CUT OFF SENSOR 2 power supply.
From To Value
Connector X-CAB_JSS pin 3 Connector X-CAB_JSS pin 4 (Ref) + 5 V
A. If the value is not correct, replace the harness between the connector X-CAB_JSS and the A-UCM.

7. Check the integrity of connectors X-JSS_CO_1 and X-JSS_CO_2.
Remove the connector X-JSS_CO_1 from the JSS CUT OFF SENSOR 1 and the connector X-JSS_CO_2 from
the JSS CUT OFF SENSOR 2 and visually check the integrity of pins 1, 2 and 4 of both connectors.

8. Check the harness between the connectors X-JSS_CO_1 and the connector X-JSS_FR.
From To Value
Connector X-JSS_CO_1 pin 1 Connector X-JSS_FR pin 3 Short circuit
A. If one value is not correct, replace the harness between the connector X-JSS_FR and the connector
X-JSS_CO_1.

9. Check the harness between the connectors X-JSS_CO_2 and the connector X-JSS_FR.
From To Value
A. If one value is not correct, replace the harness between the connector X-JSS_FR and the connector
X-JSS_CO_2.

10. Check the JSS CUT OFF SENSOR integrity.
Install the JSS CUT OFF SENSOR 1.
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From To Value
Connector X-JSS_CO_1 pin 1 Connector X-JSS_CO_1 pin 2 The sensor resistance
A. If the resistance is an open circuit, replace the JSS CUT OFF SENSOR 1.

From To Value
Connector X-JSS_CO_1 pin 1 Connector X-JSS_CO_1 pin 4 Resistance value between maximum
and minimum
A. If the resistance value is not valid, replace the JSS CUT OFF SENSOR 1.
B. If the resistance is correct, continue with Step 12.

12. Check the JSS CUT OFF SENSOR 2 integrity.
Install the JSS CUT OFF SENSOR 2.
From To Value
Connector X-JSS_CO_2 pin 1 Connector X-JSS_CO_2 pin 2 The sensor resistance
A. If the resistance is an open circuit, replace the JSS CUT OFF SENSOR 2.

From To Value
Connector X-JSS_CO_2 pin 1 Connector X-JSS_CO_2 pin 4 Resistance value between maximum
and minimum
A. If the resistance value is not valid, replace the JSS CUT OFF SENSOR 1.
B. If the resistance correct, continue with Step 14.

14. Visually check the integrity of the harness between the PVED-CLS and the A-UCM ( CAN 2) for any damage.
A. If the harness is damaged, replace the bus CAN 2.

A. If the pin is damaged, replace the harness between the connectors X-UCM3A and X-CAB_JSS.

A. If the pin is damaged, replace the harness between the connectors X-UCM3B and X-CAB_JSS.

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19. Check the integrity of harness between the connector X-CAB_JSS and the A-UCM.
From To Value
Connector X-CAB_JSS pin 2 Connector X-UCM3A pin 12 Short circuit
Connector X-CAB_JSS pin 6 Connector X-UCM3B pin 15 Short circuit
A. If the measurement is not correct, replace the harness between the connector X-BTS and the A-UCM.
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523438-31 - Joystick loss of communication

Control Module: UCM
Context:
occurs if the UCM detects a loss of communication of the joystick. The bootloader will output this message when
active.
Cause:
The UCM has detected a loss of communication of the joystick.

Solution:

been resolved.


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From To Value
From To Value
X-LC5 (Receptacle) pin 9B X-LC5 pin 6A There should be continuity

From To Value

From To Value
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From To Value

10. Check the CAN2 bus for a short circuit condition.
From To Value
X-UCM2B (Receptacle) pin 10 X-CAB_AR (Plug) pin 3 There should be no continuity
A. If there is continuity, there is a short circuit condition. Locate the fault and repair the conductor.

From To Value

From To Value
X-CAB_AR (Plug) pin 1 X-LC5 pin 6A There should be continuity

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524262-13 - Primary EEPROM configuration CRC validation fault

Context:
Primary EEPROM configuration CRC validation fault.
Cause:

Solution:
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524263-13 - Redundant EEPROM configuration CRC validation fault

Context:
Redundant EEPROM configuration CRC validation fault.
Cause:

Solution:
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524264-13 - Configuration parameter read error

Context:
Configuration parameter read error .
Cause:

Solution:
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Index
FAULT CODES - DTC

1049-01 - Front Brake Accumulator Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1049-03 - Short to Power at Front Brake Accumulator Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . 96
1049-04 - Short to Ground at Front Brake Accumulator Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . 97
1052-01 - Rear Brake Accumulator Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1052-03 - Short to Power at Rear Brake Accumulator Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . 101
1052-04 - Short to Ground at Rear Brake Accumulator Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . 103
110-00 - Engine coolant temperature is very high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
110-16 - Engine coolant temperature is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
131112-04 - Engine Controller High side supply #2 to Grid heater - Short to ground . . . . . . . . . . . . . 326
131122-12 - Coolant Temperature Test Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
131151-03 - Emergency start time expired and shutdown initiated . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
131196-02 - Injection Processor Error – Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
131196-03 - Injection Processor Error – Internal Reset / Clock Loss / Voltage Too Low . . . . . . . . . . 332
131196-04 - Injection Processor Error – Unlocked / Initialization Failure . . . . . . . . . . . . . . . . . . . . . . . 334
131196-12 - Injection Processor Error – SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 335
131246-03 - Humidity Sensor possibly saturated with water droplets – Signal Ratio above Limit . . 336
131246-04 - Humidity Sensor possibly saturated with water droplets – Signal Ratio below Limit . . 337
131252-02 - Timeout of CAN Message BC2EDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
131270-02 - Timeout of CAN message TSC1-PE Torque (When Inactive) . . . . . . . . . . . . . . . . . . . . . 341
131272-03 - Timeout of CAN Message TSC1-VR (When Active) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
131283-12 - ECM Recovery which is suppressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
1565-02 - Armrest Signals not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
158-03 - Short to Power at Key Switch Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
177-00 - Transmission oil temperature is very high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
177-16 - Transmission oil temperature is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
196685-04 - Speed limitation activates torque limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
196766-04 - Torque limitation due to turbo charger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
196804-02 - CAN message not received from XXXX1 (TSC1-AE passive) . . . . . . . . . . . . . . . . . . . . . 350
196808-02 - Timeout of CAN message TSC1-VE Speed (When Inactive) . . . . . . . . . . . . . . . . . . . . . . 353
196819-12 - ECU Recovery (Visible) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
2580 - Low Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
262302-04 - Torque Limitation due to Engine Protection (Against Excessive Torque, Engine Over-
speed and Overheat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
262344-02 - Timeout of CAN Message TSC1-VR (When Inactive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
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2661-14 - Roller X Hall cell plausibility error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2662-03 - Hall cell X1/X2 voltage abnormally high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2662-04 - Hall cell X1/X2 voltage abnormally low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2662-13 - Roller X out of neutral at power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2662-14 - Roller X Hall cell plausibility error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2663-03 - Hall cell Y1/Y2 voltage abnormally high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2663-04 - Hall cell Y1/Y2 voltage abnormally low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2663-13 - Roller Y out of neutral at power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2663-14 - Roller Y Hall cell plausibility error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2664-03 - Hall cell Z1/Z2 voltage abnormally high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2664-04 - Hall cell Z1/Z2 voltage abnormally low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2664-13 - Roller Z out of neutral at power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2664-14 - Roller Z Hall cell plausibility error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3509-02 - 5V internal fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3651-02 - Primary FNR Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
393292-04 - Overheat protection activates torque limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
393374-04 - Torque Limitation due to Fuel Quantity Limitation because of Injection System Errors 362
3997-03 - Electrical Accessory Power Relay - Short Circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3997-05 - Electrical Accessory Power Relay - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3997-06 - Electrical Accessory Power Relay - Short Circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5000-12 - Logical error at gear range signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5010-12 - Logical error at direction select signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5110-03 - Short circuit to battery voltage or open circuit at transmission sump temperature sensor
input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5110-04 - Short circuit to ground at transmission sump temperature sensor input . . . . . . . . . . . . . . . 37
5120-03 - Short circuit to battery voltage or open circuit at retarder / torque converter temperature
sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5120-04 - Short circuit to ground at retarder / torque converter temperature sensor input . . . . . . . . 41
5123-19 - Display Source Address Cyclic Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5140-03 - Short circuit to battery voltage or open circuit at engine speed input . . . . . . . . . . . . . . . . . 43
5140-04 - Short circuit to ground at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5140-12 - Logical error at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5150-03 - Short circuit to battery voltage or open circuit at turbine speed input . . . . . . . . . . . . . . . . . 49
5150-04 - Short circuit to ground at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5150-12 - Logical error at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5160-03 - Short circuit to battery voltage or open circuit at internal speed input . . . . . . . . . . . . . . . . . 55
5160-04 - Short circuit to ground at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5160-12 - Logical error at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5170-03 - Short circuit to battery voltage or open circuit at output speed input . . . . . . . . . . . . . . . . . . 61
5170-04 - Short circuit to ground at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5170-12 - Logical error at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
517755-09 - EJM Message Timeout (AUX FNR, AUX I, AUX II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
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517755-19 - BJM Message Timeout (Boom, Bucket, Kick down) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
5180-02 - Output speed zero doesn't fit to other speed signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
518032-03 - Aux FNR Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
518036-03 - Beacon Light Switch Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
518047-03 - Declutch Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
518052-03 - Differential Lock Up Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
518056-03 - Fan Mode Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
518058-03 - Float Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
518063-03 - Implement Coupler Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
518066-03 - Implement Enable Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
518069-02 - Joystick Steering Activation Button Signals not plausible . . . . . . . . . . . . . . . . . . . . . . . . . 376
518070-03 - Key_2 Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
518074-03 - Key_18 Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
518078-03 - Key_20 Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
518083-03 - Park Brake Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
518089-03 - Short to Power at Ride Control Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
518089-04 - Short to Ground at Ride Control Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 385
518089-05 - Open Circuit at Ride Control Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
518093-03 - Return ToTravel Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
518101-03 - Torque Converter Lock Up Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
518103-03 - Transmission Auto Mode Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
518106-03 - WorkLight 1 Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
518108-03 - WorkLight 2 Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
518110-02 - Boom Angle Sensor signals not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
518110-03 - Boom Angle Sensor Channel 1 Over Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
518110-04 - Boom Angle Sensor Channel 1 Under Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
518111-02 - Bucket Angle Sensor signals not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
518111-03 - Bucket Angle Sensor Channel 1 Over Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
518111-04 - Bucket Angle Sensor Channel 1 Under Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
518112-01 - Radiator Coolant Temperature Sensor under resistance Short to Ground . . . . . . . . . . . 411
518112.00 - Radiator Coolant Temperature Sensor over resistance Open Circuit/Short to Power . 413
518113-02 - Low Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
518113-03 - Short to Power at Brake Supply Line Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
518113-04 - Short to Ground at Brake Supply Line Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 417
518114-03 - Short to Power at Brake Line (declutch) Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . 420
518114-04 - Short to Ground at Brake Line (declutch) Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . 421
518115-01 - Auxiliary Steering lack of pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
518115-03 - Aux Steering Pressure Sensor Over Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
518115-04 - Aux Steering Pressure Sensor Over Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
518116-09 - Hydraulic Filter is Clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
518119-03 - Short to Power at Implement Coupler High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 431
518119-04 - Short to Ground at Implement Coupler High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . 433
48083742_EN 31/07/2018
55.9 [55.DTC] / 706
518119-05 - Open Circuit at Implement Coupler High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
518122-00 - Axle oil temperature is very high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
518122-00 - Front Axle Oil Temp Sensor Over Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
518122-01 - Front Axle Oil Temp Sensor Under Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
518122-16 - Axle oil temperature high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
518122-31 - Axle oil temperature sensor out of range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
518129-03 - Short to Power at Boom Raise Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
518129-04 - Short to Ground at Boom Raise Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 448
518129-05 - Open Circuit at Boom Raise Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
518130-03 - Short to Power at Boom Lower Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
518130-04 - Short to Ground at Boom Lower Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 455
518130-05 - Open Circuit at Boom Lower Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
518131-03 - Short to Power/Open Circuit at Boom Valve Low Side Driver . . . . . . . . . . . . . . . . . . . . . 460
518131-04 - Short to Ground at Boom Valve Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
518132-03 - Short to Power at Bucket Roll Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
518132-04 - Short to Ground at Bucket Roll Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
518132-05 - Open Circuit at Bucket Roll Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
518133-03 - Short to Power at Bucket Dump Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 471
518133-04 - Short to Ground at Bucket Dump Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . 473
518133-05 - Open Circuit at Bucket Dump Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
518134-03 - Short to Power/Open Circuit at Bucket Valve Low Side Driver . . . . . . . . . . . . . . . . . . . . 478
518134-04 - Short to Ground at Bucket Valve Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
518135-03 - Boom Angle Sensor Channel 2 Over Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
518135-04 - Boom Angle Sensor Channel 2 Under Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
518136-03 - Bucket Angle Sensor Channel 2 Over Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
518136-04 - Bucket Angle Sensor Channel 2 Under Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
518137-03 - Short to Power at AUX 1 Left High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
518137-04 - Short to Ground at AUX 1 Left High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
518137-05 - Open Circuit at AUX 1 Left High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
518138-03 - Short to Power at AUX 1 Right High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
518138-04 - Short to Ground at AUX 1 Right High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
518138-05 - Open Circuit at AUX 1 Right High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
518139-03 - Short to Power/Open Circuit at AUX 1 Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 506
518139-04 - Short to Ground at AUX 1 Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
518140-03 - Short to Power at AUX 2 Left High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
518140-04 - Short to Ground at AUX 2 Left High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
518140-05 - Open Circuit at AUX 2 Left High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
518141-03 - Short to Power at AUX 2 Right High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
518141-04 - Short to Ground at AUX 2 Right High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
518141-05 - Open Circuit at AUX 2 Right High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
518142-03 - Short to Power/Open Circuit at AUX 2 Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 524
518142-04 - Short to Ground at AUX 2 Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
48083742_EN 31/07/2018
55.9 [55.DTC] / 707
518143-03 - Short to Power/Open Circuit at Implement Coupler Low Side Driver . . . . . . . . . . . . . . . 528
518143-04 - Short to Ground at Implement Coupler Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 530
518144-03 - Short to Power at Aux Steering Enable High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . 532
518144-04 - Short to Ground at Aux Steering Enable High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . 534
518144-05 - Open Circuit at Aux Steering Enable High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
518145-03 - Short to Power/Open Circuit at Park Brake Low Side Driver . . . . . . . . . . . . . . . . . . . . . . 538
518145-04 - Short to Ground at Park Brake Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
518146-03 - Short to Power at FAN Control High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
518146-04 - Short to Ground at FAN Control High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
518146-05 - Open Circuit at FAN Control High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
518147-03 - Short to Power FAN Reverser Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
518147-04 - Short to Ground at FAN Reverser Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
518150-03 - Electrical Crank Power Relay- Short Circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
518150-03 - Electrical Ignition Power Relay- Short Circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
518150-04 - Short to Ground at Crank Request High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
518150-05 - Electrical Crank Power Relay- Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
518150-05 - Electrical Ignition Power Relay- Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
518150-06 - Electrical Crank Power Relay- Short Circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
518150-06 - Electrical Ignition Power Relay- Short Circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
518176-03 - Joystick Steering Signal 2 High voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
518176-04 - Joystick Steering Signal 2 Low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
518176-09 - Joystick Steering Signals not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
518176-15 - Joystick Steering Signal 1 High voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
518176-17 - Joystick Steering Signal 1 Low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
518177-03 - Short to Power at Pilot Enable Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 576
518177-04 - Short to Ground at Pilot Enable Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 578
518177-05 - Open Circuit at Pilot Enable Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580
518267-02 - WatchDog Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
518280-31 - Error at 5VREF1 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
518283-31 - Error at 24VF2 Supply Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
518287-31 - Error at 24VS1 Supply Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598
518289-31 - Error at 24VA Supply Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
518290-31 - Error at 24VB Supply Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
518291-31 - Error at 24VLP Supply Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
518292-31 - Error at 24VP Supply Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
518293-31 - Error at 2.5V Ref1 Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
518294-31 - Error at 2.5V Ref2 Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
48083742_EN 31/07/2018
55.9 [55.DTC] / 708
518296-31 - Error at 5VREFIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
518390-00 - Hydraulic Oil Temp Sensor Over Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
518390-01 - Hydraulic Oil Temp Sensor Under Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
518498-00 - Engine oil temperature is very high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
518499-18 - Engine Oil pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
518501-09 - Air Filter Clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
520332-19 - TCU Source Address Cyclic Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
520333-19 - Keypad Source Address Cyclic Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
520334-19 - Smart Fuse Box Source Address Cyclic Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
520335-19 - Joystick Steering Controller Source Address Cyclic Timeout . . . . . . . . . . . . . . . . . . . . . . 622
520444-02 - Memory Integrity RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
520444-31 - Memory Integrity ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
520519-19 - Bus Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
520572-03 - 24v to 12v Converter Enable - Short Circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
520572-05 - 24v to 12v Converter Enable - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
520572-06 - 24v to 12v Converter Enable - Short Circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
520578-03 - Battery Isolator RESET - Short Circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
520578-03 - Battery Isolator SET - Short Circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
520578-06 - Battery Isolator RESET - Short Circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
520578-06 - Battery Isolator SET - Short Circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
520584-00 - Left Brake Indicator Light - Too many loads or faulty load . . . . . . . . . . . . . . . . . . . . . . . . 645
520584-03 - Left Brake Indicator Light - Short circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
520584-05 - Left Brake Indicator Light - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 649
520584-06 - Left Brake Indicator Light - Short circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
520585-00 - Right Brake Indicator Light - Too many loads or faulty load . . . . . . . . . . . . . . . . . . . . . . . 653
520585-03 - Right Brake Indicator Light - Short circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
520585-05 - Right Brake Indicator Light - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657
520585-06 - Right Brake Indicator Light - Short circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659
520588-03 - Alternator Excitation Driver - Short Circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661
520588-06 - Alternator Excitation Driver - Short Circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
520591-00 - Backup Alarm - Too many loads or faulty load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
520591-03 - Backup Alarm - Short circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668
520591-05 - Backup Alarm - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 671
520591-06 - Backup Alarm - Short circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
520596-03 - VSUP A - Out of Range - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
520596-04 - VSUP A - Out of Range - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
520597-03 - VSUP B - Out of Range - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
520597-04 - VSUP B - Out of Range - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683
520598-03 - VSUP C - Out of Range - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685
520598-04 - VSUP C - Out of Range - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 687
520599-03 - VSUP D - Out of Range - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
520599-04 - VSUP D - Out of Range - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691
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521-03 - Inch Pedal Position Sensor over voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
521-04 - Inch Pedal Position Sensor under voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5211-09 - Speedlimit_Prop1 Can message timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5212-09 - Speedlimit_Prop2 Can message timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5220-09 - Brakes timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
522809-02 - Memory Integrity EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693
522810-09 - Joystick Steering Cut Off Valves not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694
5230-09 - Zftc1 Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
523438-31 - Joystick loss of communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698
524262-13 - Primary EEPROM configuration CRC validation fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
524263-13 - Redundant EEPROM configuration CRC validation fault . . . . . . . . . . . . . . . . . . . . . . . . . 702
524264-13 - Configuration parameter read error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
5260-09 - Dct1 Timeout = Vehicle_1 Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5270-09 - Jss Timeout =Vehicle_2 Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5271-09 - DISPID1 CAN message timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5280-09 - Engine Conf timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5290-09 - EEC1 Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5300-09 - EEC3 Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5310-09 - Engine speed limit function during gearshifts does not work properly . . . . . . . . . . . . . . . . . 151
5370-02 - Shift lever signal defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5390-02 - Aeb request signal defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5420-02 - Starting gear signal defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5430-02 - Enginge torque signal defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5431-09 - Engine speed limit function does not work properly during stall or output speed limit func-
tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5440-02 - Reference engine torque signal defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5450-02 - Actual engine torque signal defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5460-02 - Nom friction torque signal defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5470-02 - EEC2 Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5480-03 - Short circuit to battery voltage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5480-04 - Short circuit to ground at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5480-05 - Open circuit at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5520-03 - Short circuit to battery voltage at clutch Kv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
5520-04 - Short circuit to ground at clutch Kv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5520-05 - Open circuit at clutch Kv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
5530-03 - Short circuit to battery voltage at clutch Kr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
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5530-04 - Short circuit to ground at clutch Kr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5530-05 - Open circuit at clutch Kr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5536-00 - Hydraulic oil temperature is very high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
5536-16 - Hydraulic oil temperature is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5540-03 - Short circuit to battery voltage at converter clutch (regulator valve) . . . . . . . . . . . . . . . . . . 195
5540-04 - Short circuit to ground at converter clutch (regulator valve) . . . . . . . . . . . . . . . . . . . . . . . . . 197
5540-05 - Open circuit at converter clutch (regulator valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5560-03 - Short circuit to battery voltage at relay reverse warning alarm . . . . . . . . . . . . . . . . . . . . . . . 201
5560-05 - Open circuit at relay reverse warning alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5657-02 - Incorrect Anti-tamper checksum sent by Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . 205
5657-09 - Anti-tamper checksum not sent by Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5660-02 - Slippage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5680-02 - Slippage at clutch Kv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
5685-02 - Slippage at clutch Kr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5700-00 - Overtemp Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5710-00 - Overtemp Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
5720-00 - Overspeed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
5730-00 - Differential pressure oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
5740-02 - Slippage at converter lockup clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
5745-15 - Overspeed output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
5755-15 - Transmission input torque overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
5760-00 - Overtemp converter output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5810-03 - Short circuit to battery voltage at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . 231
5810-04 - Short circuit to ground at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
5820-03 - High voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5820-04 - Low voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
5830-02 - Error at valve power supply VPS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
5840-02 - Error valve power supply VPS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
5860-03 - Short circuit to battery voltage at display output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
5860-04 - Short circuit to ground at display output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
5880-02 - Illegal ID request via Can . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
5890-02 - General EEPROM fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
5900-13 - Configuration lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
5910-13 - Application error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
5930-07 - Clutch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
5930-13 - Clutch adjustment data lost or inchpedal calibration data lost . . . . . . . . . . . . . . . . . . . . . . . 246
5940-11 - Substitute clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
619-03 - Short to Power at Park Brake High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
619-04 - Short to Ground at Park Brake High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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619-05 - Open Circuit at Park Brake High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
624-03 - Short to Power at Warning LED High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
624-04 - Short to Ground at Warning LED High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
624-05 - Open Circuit at Warning LED High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
65562-03 - Terminal 50 - Always On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
65564-03 - Water detected in Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
65574-03 - Engine Controller battery voltage too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
65574-04 - Engine Controller battery voltage too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
65576-03 - Engine Controller High side supply #2 to Grid heater - Short to battery . . . . . . . . . . . . . . 255
65579-02 - Engine Controller Grid Heater relay circuit driver - No Load . . . . . . . . . . . . . . . . . . . . . . . . 256
65579-03 - Engine Controller Grid Heater relay circuit driver - Short circuit to Battery . . . . . . . . . . . 258
65579-04 - Engine Controller Grid Heater relay circuit driver - Short circuit to Ground . . . . . . . . . . . 260
65585-03 - Engine Coolant Temperature Sensor - Signal Above Range Max . . . . . . . . . . . . . . . . . . . 262
65585-04 - Engine Coolant Temperature Sensor - Signal Below Range Min . . . . . . . . . . . . . . . . . . . . 264
65585-12 - Engine Coolant Temperature Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . 266
65596-03 - Ambient Air Temperature Sensor failure - Signal too high . . . . . . . . . . . . . . . . . . . . . . . . . 268
65596-04 - Ambient Air Temperature Sensor failure - Signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . 270
65646-03 - Minimum Number of Injections Not Reached – Stop Engine . . . . . . . . . . . . . . . . . . . . . . . 272
65660-02 - Injection Processor (CY33X) Error – Injections Limited By Software . . . . . . . . . . . . . . . . 273
65660-03 - Injection Processor (CY33X) Error – Internal Reset / Clock Loss / Voltage Too Low . . . 274
65660-04 - Injection Processor (CY33X) Error – Unlocked / Initialization Failure . . . . . . . . . . . . . . . . 276
65660-12 - Injection Processor (CY33X) Error – SPI Communication Failure . . . . . . . . . . . . . . . . . . . 277
65683-03 - Turbine speed - Signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
65683-04 - Turbine speed - Signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
65694-04 - Torque Reduction due to Smoke Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
65717-02 - Timeout of CAN Message VCM2EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
65734-03 - Timeout of CAN message TSC1-PE Torque (When Active) . . . . . . . . . . . . . . . . . . . . . . . . 286
65736-03 - Timeout of CAN message TSC1-VE Speed (When Active) . . . . . . . . . . . . . . . . . . . . . . . . 289
65745-03 - ECM Internal SPI Communication Error – CJ940 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
65747-12 - ECM (Locked) Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
65748-12 - ECM Processor – Watchdog Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
65749-02 - Shutoff Paths During Initialization – Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . 295
65749-04 - Shutoff Paths During Initialization - Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
65749-12 - Shutoff Paths During Initialization – Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . 297
65750-12 - TPU Monitoring – Time Deviation between TPU and System Not Plausible . . . . . . . . . . 298
65752-12 - Controller Watchdog – SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
65753-02 - ADC Monitoring – Test Impulse Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
65753-03 - ADC Monitoring – Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
65753-04 - ADC Monitoring – Reference Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
65753-12 - ADC Monitoring – Queue Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
65763-03 - Overrun Monitoring – Injection Time Too Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
65764-03 - Redundant Engine Speed in Overrun Monitoring – Speed Signal Not Plausible . . . . . . 305
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65765-03 - Engine regulated 12 Volt sensor supply - Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
65765-04 - Engine regulated 12 Volt sensor supply - Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
65766-03 - Sensor Supply Voltage 1 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
65766-04 - Sensor Supply Voltage 1 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
65769-03 - ECM Internal Supply Voltage Too High – CJ940 Above Limit . . . . . . . . . . . . . . . . . . . . . . 322
65770-04 - ECM Internal Supply Voltage Too Low – CJ940 Below Limit . . . . . . . . . . . . . . . . . . . . . . . 324
746-03 - Short to Power at Differential Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
746-04 - Short to Ground at Differential Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
746-05 - Open Circuit at Differential Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
91.19 - Engine Source Address Cyclic Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
96-00 - Fuel Level Sensor Over Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
96-01 - Fuel Level Sensor Under Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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PRINTED IN ITALY
48083742_EN 31/07/2018
EN
SERVICE MANUAL
Front loader and bucket

48083742_EN 31/07/2018
82
Contents
Front loader and bucket - 82
[82.100] Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1
[82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2
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82
Arm - 100

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Contents
Arm - 100
FUNCTIONAL DATA
Front loader arm

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Front loader arm

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Front loader and bucket - Arm
Front loader arm - Exploded view
LEIL16WHL1875HB 1
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82.1 [82.100] / 3
1. Lift arm 18. Shim

2. Bell crank 19. Shim
3. Dump assembly link 20. Lube fitting
4. Wiper Rod 114.3 21. 90° elbow
5. Wiper Rod 101.6 22. Grease hose
6. Wiper Rod 127.0 23. Grease hose
7. Lift arm pin 24. Grease hose
8. Spacer 25. 90° elbow
9. Flat washer 26. Grease tube
10. Bolt, M20x50 CL 10.9 27. Clamp
11. Lift arm pin ( 4.0 in 343 mm) 28. Connector
12. Lift arm pin ( 4.0 in 266 mm) 29. Lube fitting
13. Lift arm pin ( 4.0 in 295 mm) 30. Washer 11x20x2 mm
14. Lift arm pin ( 5.0 in 472 mm) 31. Nut
15. Lift arm pin ( 4.5 in 295 mm) 32. Nut
16. Lift arm pin ( 4.0 in 276 mm) 33. Wire
17. Shim 34. Cross member
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Front loader arm - Remove

NOTE: for the numbering (from (1) to (34)) in this procedure refer to "Front loader arm - Exploded view".
1. Park the machine on a level surface and apply the park-
ing brake. Roll the bucket all the way forward and lower
the bucket to the floor. Stop the engine.
2. Loosen the filler plug in the reservoir to release the air
in the reservoir.
3. Fasten a chain hoist to the cross member (34) of the
loader frame (1).
4. Loosen and remove the bolt (10), the flat washer (9),
and the spacer (8) that fasten the pivot pin (16) to the
piston rod yoke of the right-hand lift cylinder.
5. Use an acceptable driver and drive the pivot pin (16)
out of the piston rod yoke of the right-hand lift cylinder.
Do not remove the driver.
6. Repeat Steps 4 and 5 for the left-hand lift cylinder.
7. Start the engine. Roll the bucket back and lower the
bucket so that the bucket is flat on the floor and fasten
the chain hoist to one of the lift cylinders.
8. Raise the lift cylinder slightly and remove the driver.
9. Repeat steps 7 and 8 for the other lift cylinder.
10. Connect the chain hoist to the bucket cylinder.
11. Loosen and remove the bolt (10), the flat washer (9),
and the spacer (8) that fasten the pivot pin (13) for the
piston rod eye of the bucket cylinder to the bell crank
(2).
12. Use an acceptable driver and drive the pivot pin (13)
out of the piston rod eye of the bucket cylinder.
13. Raise the bucket cylinder and use a chain or other ac-
ceptable holding equipment to hold the bucket cylin-
der in place.
14. If the machine is equipped with auxiliary hydraulics,
disconnect the two hoses from the tubes at the bracket
on the right side of the loader frame (1). Install caps
on the hoses and plugs in the tube fittings.
15. If the machine is equipped with front lamps, loosen
and remove the cap screws and lock washers that
fasten the lamp brackets to the front frame. Discon-
nect electrical connector and position harness to avoid
damage. Put the lamp brackets on the fenders.
16. Connect the chain hoist to the loader frame (1).
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17. Disconnect the electrical connector (40) from the lift

Electro-Hydraulic (EH) assembly sensor (37) on the
left-hand side of machine (Ref: Front chassis har-
ness).
LEIL16WHL1872AB 1
18. Loosen the three bolts (35) with the three washers (36)
and the hexagonal screw (38) to remove the lift EH
sensor assembly (37) and to access the pivot pin (7).
Remove the three support (39).
Remove the elbow (21) to separate the grease hose
(22) from the pivot pin (7).
LEIL16WHL1871AB 2
1021G
LEIL17WHL2086AB 3
1121G
19. Loosen and remove the bolt (10), the flat washer (9)
and the spacer (8) that fasten the pivot pin (7) to the
front frame.
20. Raise the loader frame slightly. Use an acceptable
driver and drive the pivot pin (7) out of the front frame.
Do not lose the washers (4). (17), (18) and (19) be-
tween the front frame and the loader frame (1). Keep
the washer shim packs together and note the location
from which they were removed.
21. Repeat Steps 19 and 20 for the pivot pin on the left-
hand side.
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22. Disconnect the electrical connector (41) from the tilt

EH assembly sensor (42) on the bell crank (2) on the
right-hand side of the machine. (Ref: Front chassis
harness).
LEIL16WHL1874AB 4
23. Raise the loader frame (1) out of the front frame. Care-
fully move the machine out of the loader frame (1).
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Front loader arm - Install

NOTE: for the numbering (from (1) to (34)) in this procedure refer to "Front loader arm - Exploded view".
1. Apply antiseize compound to the inner bores and outer
bores for the pivot pins of the front frame.
2. Move the machine into alignment with the loader frame
(1).
3. Lower the loader frame (1) into alignment with the front
frame.
4. Apply antiseize compound to the pivot pin (7) and that
one on the opposite side that fasten the loader frame
5. Start the two pivot pins (7) into the front frame.
Install the washers (4), (17), (18) and (19) between the
loader frame (1) and the front frame. Install washer
shim packs in the exact location from which they were
removed.
6. Install the pivot pins (7) all the way.
7. Install the bolt (10), washer (9) and spacer (8) that fas-
ten the pivot pins (7). Tighten the bolt.
8. Install the lift EH sensor assembly (37) on the pin (7)
(left-hand side of machine). Secure the lift EH sensor
assembly (37) with the three bolts (35), the three wash-
ers (36), the three spacer (39) and the hexagonal screw
(38).
Install the elbow (21) to connect the grease hose (22)
to the pivot pin (7).
LEIL16WHL1871AB 1
1021G
LEIL17WHL2086AB 2
1121G
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9. Install the electrical connector (40) on the lift Elec-

tro-Hydraulic (EH) assembly sensor (37). (Ref: Front
chassis harness).
LEIL16WHL1872AB 3
10. Disconnect the chain hoist from the loader frame (1).
11. If the machine is equipped with front lamps, hold the
front lamps in place and install the cap screws and
lock washers that fasten the front lamps to the front
frame. Tighten the cap screws. Reconnect electrical
connectors.
remove the plugs from the tube fittings and the caps
from the hoses. Connect the hoses to the tubes.
13. Connect the chain hoist to the bucket cylinder and
lower the bucket cylinder.
15. Have another person help you at this time. Move the
bucket control lever as required to align the piston rod
eye of the bucket cylinder with the bell crank (2). Stop
the engine.
NOTICE: do not use your fingers to check the alignment of
the cylinder rod . Personal injury can be the result.
16. Install the pivot pin (13) in the bell crank (2) and the
piston rod eye of the bucket cylinder.
17. Install the bolt (10), the washer (9), and the spacer (8)
that fasten the pivot pin (13). Tighten the bolt.
18. Disconnect the chain hoist from the bucket cylinder.
19. Fasten the chain hoist to one of the lift cylinders (4) or
(6).
20. Raise the piston rod yoke of the lift cylinder so the
piston rod yoke is aligned with the loader frame (1).
21. Install a driver in the piston rod yoke and the loader
frame (1).
22. Repeat Steps 19, 20 and 21 for the other lift cylinder.
23. Disconnect the chain hoist from the lift cylinder .
24. Start the engine. Raise the loader frame and roll the
bucket all the way forward. Lower the bucket to the
floor. Stop the engine.
25. Fasten the chain hoist to the cross member (34) of the
loader frame (2).
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27. Have another person help you at this time. Move the
lift control lever as required to align the piston rod yoke
of one of the lift cylinders with the loader frame (1).
NOTICE: do not use your fingers to check the alignment of
the cylinder rod . Personal injury can be the result.
28. Remove the driver and install the pivot pin (16).
29. Install the bolt (10), the washer (9), and the spacer (8)
that fasten the pivot pin (16). Tighten the bolt.
30. Repeat Steps 27, 28 and 29 for the other lift cylinder.
Stop the engine.
31. Lubricate the pivot pins with molydisulfide grease.
32. Disconnect the chain hoist from the cross member (1)
of the loader frame (2).
33. Connect the electrical connector (41) on the EH tilt
assembly sensor (42) on the right-hand side of the bell
crank (2) (Ref: Front chassis harness).
LEIL16WHL1874AB 4
34. Tighten the filler plug in the reservoir.

start the engine and run the engine at low idle.
36. Slowly extend and retract the clam cylinders four times
to remove air from the auxiliary circuit.
37. Stop the engine, check the level of the oil in the reser-
voir, and check for leaks. Add oil to the reservoir as
required.
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Index
Arm - 100
Front loader arm - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front loader arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Front loader arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Bucket - 300

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Contents
Bucket - 300
SERVICE
Bucket
Replace - Bucket teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Front loader and bucket - Bucket
Bucket - Replace - Bucket teeth

Replacement of the Tooth Points
1. Use a hammer and punch to drive the retaining pin (1)
for the tooth point (2) out of the tooth shank (3), refer to
the illustration on this page.
NOTE: if equipped with SMART FIT teeth, rotate the pin
locking tab with a socket wrench prior to attempting to re-
move the pin.
2. Remove the tooth point (2).
3. Install a new tooth point (2) on the tooth shank (3).
4. Install the retaining pin (1) into the tooth point (2) and
tooth shank (3). Make sure the shoulder on the retain-
ing pin is toward the cutting edge. Use a hammer to
hit the retaining pin (1) until the retaining pin (1) is even
with the outside of the tooth shank (3).
NOTE: if equipped with SMART FIT teeth, install the pin to
a depth that allows the pin locking tab to be rotated with a
socket wrench. The tooth point is now secure and the use
of a hammer is not required.
LEIL13WHL1147BB 1
Replacement of the Bucket Teeth

1. Loosen and remove the nuts (4), hardened washers
(5), and bolts (6) from the bucket teeth.
NOTE: if wear of the bolt or nut makes removal difficult, the
bolt or nut can be cut off.
2. Remove the tooth.
3. Install the new tooth on the bucket cutting edge (7).
4. Use new nuts (4), hardened washers (5), and bolts (6)
for the tooth being installed.
5. Tighten the nuts (4) to 1315 – 1480 N·m (970 – 1092 lb
ft).
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Front loader and bucket - Bucket
Replacement of the Bucket Corner Teeth

1. Loosen and remove the nuts (9), hardened washers
and bolts (8) from the bucket corner teeth (10).
NOTE: if wear of the bolt or nut makes removal difficult, the
bolt or nut can be cut off.
2. Remove the corner tooth (10).
3. Install the new corner tooth (10) on the bucket cutting
edge (7).
4. Use new nuts (9), hardened washers and bolts (8) for
the corner tooth being installed.
5. Tighten the nuts (9) to 1315 – 1480 N·m (970 – 1092 lb
ft).
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Index
Bucket - 300
Bucket - Replace - Bucket teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN ITALY
48083742_EN 31/07/2018
EN
SERVICE MANUAL
Platform, cab, bodywork, and decals

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90
Contents
Platform, cab, bodywork, and decals - 90
[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
[90.118] Protections and footboards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2
[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3
[90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4
[90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5
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90
Cab - 150

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Contents
Cab - 150
FUNCTIONAL DATA
Cab
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Cab
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Platform, cab, bodywork, and decals - Cab
Cab - Overview
Rollover Protective Structure (ROPS)
NOTICE: the Rollover Protective Structure (ROPS) is a special safety component of your machine. DO NOT attach
any device to the ROPS for pulling purposes. The ROPS is a certified structural support and any damage, fire, corro-
sion or modification will weaken the structure and reduce your protection. If this occurs, the ROPS MUST be replaced
so that it will provide the same protection as a new ROPS.
After an accident, fire or rollover, the following MUST be performed before returning the machine to field or job site
operation:
• The ROPS structure MUST be replaced.

• The ROPS mounting or suspension, operator seat and suspension, seat belts and mounting components and wiring
within the operator’s protective system MUST be carefully inspected for damage.
• All damaged parts MUST be replaced.
DO NOT WELD, ATTEMPT TO STRAIGHTEN OR REPAIR THE ROPS.
Maintenance and inspection of the Rollover Protective Structure (ROPS)

After every 500 hours of operation or every six months, whichever comes first, do the following:
1. Check the torque on the ROPS mounting bolts; torque should be 561 – 758 N·m (413.8 – 559.1 lb ft) for ROPS
retaining bolts and 200 – 285 N·m (147.5 – 210.2 lb ft) for viscous mount bolts. If necessary, tighten the bolts to
the correct torque.
2. Check that seat belt mounting hardware is tight and seat belt is not cut or frayed. Check the torque on operators
seat mounting bolts; torque should be 38 – 44 N·m (28 – 32 lb ft). If necessary, tighten the bolts to the correct
torque. Replace parts that are worn or damaged.
NOTICE: class 10.9 hardware is used to mount and anchor the ROPS. Parts used for replacement must be those
shown in the parts catalog.
NOTICE: do not install attachments that will make the total weight of the machine more than the weight shown in the
maximum gross vehicle weight section of the ROPS serial number plate.
NOTICE: do not change the ROPS in any way. Changes made to the ROPS which are not authorized, such as
welding, drilling or cutting will make the ROPS weaker and decrease your protection. Replace the ROPS if it becomes
damaged in any way. DO NOT TRY TO MAKE REPAIRS TO THE ROPS.
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Cab - Remove
Rollover Protective Structure (ROPS)
Stop the engine.
Actuate the brake pedal several times to discharge the
brake accumulators.
2. Put the key switch to ON position and move the joystick
to the raise and to the lower position in order to release
any hydraulic pressure in the hydraulic circuit.
3. Slowly loosen the filler cap on the hydraulic oil tank to
release air pressure.
4. Put the key switch to OFF position.
6. Put the timed disconnect switch to OFF position.
8. Discharge and recover the air-conditioning refrigerant.
Refer to Air conditioning - Charging (50.200).
9. Remove the rear fender (right-hand side), ladder (both
sides) and axle cooler cover (right-hand side).
10. Remove the relevant bolts, washers, and nuts to dis-
assemble:
• the right-hand rear cab skirt (1);

• the right-hand cab skirt (2);
• the center cab skirt (3);
• the left-hand cab skirt (4).
LEIL16WHL1189FB 1
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90.1 [90.150] / 4
11. Put identification tags and disconnect all the hoses

and electrical connectors from the steering control
valve (1) and brake pedal control valve (2). Refer to
Brake pedal control valve - Remove (33.202) and
Steering valve - Remove (41.200).
Install protective caps to the hoses and fittings to pre-
vent entry of foreign matter into hydraulic system.
LEIL16WHL1195AB 2
12. Remove the bolts and washers to unfix the HVAC

cover.
LEIL16WHL1190AB 3
13. Disconnect the PRH2 connector (1) (Ref: Engine and

rear chassis harness).
Remove the clamps (2) securing the wire to the cab
frame.
LEIL16WHL1716AB 4
14. Disconnect the ground strap from the cab weld stud.
LEIL16WHL1717AB 5
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15. Disconnect the FRNT connector (1) and FRNT_EH

connector (2) (Ref: Front chassis harness).
LEIL16WHL1187AB 6
16. Remove the clamps (1) and (6) securing wires to

bracket.
Disconnect the following electrical connectors:
(Ref: Engine and rear chassis harness)
• ENG connector (4);
• ENG-2 connector (3);
• CP connector (2);
(Ref: Transmission harness)
• TRANS connector (7);
(Ref: Rear view camera harness)
• connector (5).
NOTE: if the machine is equipped with Joystick Steering
(JSS), disconnect also the JSS_COM and JSS_FR con- LEIL16WHL1194AB 7
nectors (Ref: Joystick steering harness).
17. If machine is equipped with auxiliary steering system,
disconnect the BTS connector (Ref: Bottom cab har-
ness).
LEIL16WHL1191AB 8
18. Disconnect and plug the following hoses:

• heater hoses (1), (2);
• air-conditioning hoses (3), (4) (after removal of clamp
plate (6));
• drain hose (5).
LEIL16WHL1186AB 9
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19. Disconnect and plug the front and rear wiper hoses.
LEIL16WHL1197AB 10
LEIL16WHL1196AB 11
20. Remove the fours bolts to disassemble the roof cab

cover.
LEIL16WHL1183AB 12
21. Install lifting eyes at the four cab lifting points.
LEIL16WHL1184AB 13
22. Attach the cab to a suitable lifting equipment at the

cab lifting eyes. Take up all slack in lifting equipment.
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23. Remove the following relevant items that fix the cab
to the rear chassis at four points:
• spacers (1);
• washers (2);
• M22x160 bolts (3);
• viscous mounts (4);
• washers (5);
• M10x35 bolts (6);
• washers (7);
• M16x55 bolts (8);
LEIL18WHL0857BB 14
24. Slowly raise the cab from the rear chassis.

Check that all the tie straps and clamps have been
removed.
Check that all the hoses, tubes, and connectors are
disconnected and free.
25. Remove the cab and position it onto wood blocks to
prevent damage.
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90.1 [90.150] / 8
Cab - Install
1. Connect a suitable lifting equipment to the cab lifting
eyes. Take up all slack in the lifting equipment.
2. Position the cab over the rear chassis and slowly lower
the cab making sure the mounting holes in cab are
aligned to the associated holes in rear chassis.
3. Check the viscous mounts (4) for deterioration, tears,
deformation, or other damage; replace them as neces-
sary.
4. Fix the viscous mounts (4) to the cab. Install the
M10x35 bolts (6), washers (5), and nuts; tighten the
bolts to a torque of 70 – 94 N·m (51.6 – 69.3 lb ft).
5. Fix the viscous mounts (4) to the rear chassis.
Apply the LOCTITE® 243™ to bolts threads (8). Install
the M16x55 bolts and washers (7). Tighten the bolts
(8) to a torque of 300 – 348 N·m (221.3 – 256.7 lb ft).
6. Install the M22x160 bolts (3), washers (2), and spac-
ers (1); tighten the bolts to a torque of 561 – 758 N·m
(413.8 – 559.1 lb ft).
LEIL18WHL0857BB 1
7. Disconnect the lifting equipment from the cab.

8. Remove the cab lifting eyes from the cab.
LEIL16WHL1184AB 2
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90.1 [90.150] / 9
9. Before to install the roof cab cover, ensure that the roof
foam (1) and the four roof support foams (2) are not
damaged.
LEIL18WHL0873AB 3
10. Install the bolts to fix the roof cab cover.
LEIL16WHL1183AB 4
11. Connect the front and rear wiper hoses.
LEIL16WHL1197AB 5
LEIL16WHL1196AB 6
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90.1 [90.150] / 10
12. Unplug and connect the following hoses:

• heater hoses (1), (2);
• air-conditioning hoses (3), (4) (fix the clamp plate
(6));
• drain hose (5).
LEIL16WHL1186AB 7
13. If machine is equipped with auxiliary steering system,

connect the BTS connector (Ref: Bottom cab har-
ness).
LEIL16WHL1191AB 8
14. Connect the following electrical connectors:

(Ref: Engine and rear chassis harness)
• ENG connector (4);
• ENG-2 connector (3);
• CP connector (2);
(Ref: Transmission harness)
• TRANS connector (7);
(Ref: Rear view camera harness)
• connector (5).
Secure with the clamps (1) and (6) the wires to
bracket.
NOTE: if the machine is equipped with Joystick Steering
(JSS), connect also the JSS_COM and JSS_FR connec- LEIL16WHL1194AB 9
tors (Ref: Joystick steering harness).
15. Connect the FRNT connector (1) and FRNT_EH con-
nector (2) (Ref: Front chassis harness).
LEIL16WHL1187AB 10
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16. Connect the ground strap to the cab weld stud.
LEIL16WHL1717AB 11
17. Connect the PRH2 connector (1) (Ref: Engine and

rear chassis harness).
Secure with the clamps (2) the wire to the cab frame.
LEIL16WHL1716AB 12
18. Install the mounting bolts and washers for the HVAC
cover.
LEIL16WHL1190AB 13
19. Remove the protective plugs from the hydraulic sys-

tem hoses and caps from fittings on steering control
valve and brake pedal control valve. With the aid
of the identification tags put in cab removal phase,
connect all the hoses and electrical connectors to
the steering control valve (1) and brake pedal control
valve (2). Refer to Brake pedal control valve - In-
stall (33.202) and Steering valve - Install (41.200).
LEIL16WHL1195AB 14
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20. Install the bolts, washers, and nuts to mount:
• the right-hand rear cab skirt (1);

• the right-hand cab skirt (2);
• the center cab skirt (3);
• the left-hand cab skirt (4).
LEIL16WHL1189FB 15

22. Fill the engine cooling system.
23. Fill the hydraulic system.
24. Put the timed disconnect switch to ON position.
25. Start engine and run engine at low idle. Run engine
at operating temperature for approximately 5 min.
When coolant is at operating temperature, stop en-
gine. When engine has cooled, check coolant level
at reservoir.
NOTICE: hot coolant can spray out if radiator cap is re-
moved. To remove radiator cap: let system cool, turn to
first notch, then wait until all pressure is released. Scald-
ing can result from fast removal of radiator cap.
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Index
Cab - 150
Cab - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cab - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Protections and footboards - 118

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Contents
SERVICE
Ladder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Platform, cab, bodywork, and decals - Protections and footboards
Ladder - Remove
locked position.
RCPH11WHL039AAH 1
NOTE: for removal of left-hand and right-hand ladders described following, refer to layout with standard fenders.
Left-hand steps and ladder assembly

2. Before proceeding with ladder removal, disassemble
the rear fender fixed to the ladder.
Remove the bolt M10x30, washers (under bolt head
and nut) and nut.
LEIL16WHL1719AA 2
3. Remove the three bolts M10x40, washers (under bolt

head and nut) and nuts. Unfix the bracket (1) from the
top fender (2) and ladder.
LEIL16WHL1719AA 3
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4. Remove the two bolts M8x25 and washers (under bolt

head). Unfix the top fender (2) from the ladder.
LEIL16WHL1738AA 4
5. Remove the two bolts M12x40, washers (under bolt

head and nut) and nuts.
LEIL16WHL1720AA 5
6. Remove the four bolts M12x30 and washers.
LEIL16WHL1720AA 6
7. Disassemble the bracket (4): remove the two bolts

M10x30, washers (under bolt head and nut) and nuts
common to the bottom fender (3) and remove the bot-
tom fender (3) as well; remove the two bolts M10x35,
washers (under bolt head and nut) and nuts common to
the steps (6); remove the bolt M10x30, washers (under
bolt head and nut) and nut common to the accumulator
cover (5).
LEIL16WHL1740AA 7
8. Connect a suitable lifting and hoisting equipment to the

stairs and ladder assembly.
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head and nut) and nuts to unfix the ladder from the
hydraulic tank.
LEIL16WHL1722AA 8

M12x50, washers (under bolt head) and nuts common
to the rear chassis (8); remove the two bolts M12x40,
washers (under bolt head) and nuts common to the
steps (6)
LEIL16WHL1741AA 9
11. Unfix the accumulator cover (5): remove the three

bolts M10x30, washers (under bolt head and nuts),
nuts common to the support (9).
LEIL16WHL1724AA 10
12. Remove the nut and washer common to the stud of

rear chassis (8).
LEIL16WHL1725AA 11
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head and nuts), nuts common to the bracket (10) (not
visible in this figure).
Remove the accumulator cover (5).
LEIL16WHL1742AA 12
14. Remove the two nuts and washers to unfix the bracket
(10) from the studs of rear chassis (8).
LEIL16WHL1743AA 13
7. The ladder assembly is completely unfixed from the

machine. Remove the ladder assembly with the aid of
lifting and hoisting equipment.
Right-hand steps and ladder assembly

1. Before proceeding with ladder removal, disassemble
the rear fender fixed to the ladder.
Remove the bolt M10x30, washers (under bolt head
and nut) and nut.
LEIL16WHL1727AA 14
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2. Remove the three bolts M10x40, washers (under bolt

head and nut) and nuts. Unfix the bracket (1) from the
top fender (2) and ladder.
LEIL16WHL1727AA 15

head). Unfix the top fender (2) from the ladder.
LEIL16WHL1744AA 16

head and nut) and nuts.
LEIL16WHL1728AA 17
4. Remove the four bolts M12x30 and washers.
LEIL16WHL1728AA 18
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M10x30, washers (under bolt head and nut) and nuts
common to the bottom fender (3); remove the bottom
fender (3) as well; remove the two bolts M10x35, wash-
ers (under bolt head and nut) and nuts common to the
steps (5).
LEIL16WHL1746AA 19

7. Remove the two bolts M12x50 washers (under bolt
head and nut) and nuts to unfix the ladder from the hy-
draulic tank.
LEIL16WHL1731AA 20

head and nut) and nuts to unfix the steps (5) from the
platform support (6).
LEIL16WHL1730AA 21
9. The ladder assembly is completely unfixed from the

machine. Remove the ladder assembly with the aid of
lifting and hoisting equipment.
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Ladder - Install
NOTE: for installation of left-hand and right-hand ladders described following, refer to layout with standard fenders.
Left-hand steps and ladder assembly

2. Place the left-hand steps and ladder assembly.
3. Install two washers and nuts to fix the bracket (10) to
the studs of rear chassis (8).
LEIL16WHL1743AA 1
4. Place the accumulator cover (5). Fix the accumulator

cover (5) to the bracket (10) with two bolts M10x25,
washers (under bolt head and nuts) and nuts.
LEIL16WHL1742AA 2
5. Fix the accumulator cover (5) to the stud of rear chassis

(8) with washer and nut.
LEIL16WHL1725AA 3
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6. Fix the accumulator cover (5) to the support (9) with

three bolts M10x30, washers (under bolt head and
nuts) and nuts.
LEIL16WHL1724AA 4
7. Install the bracket (7). Fix the bracket (7) to the rear
chassis (8) with two bolts M12x50, washers (under bolt
head and nut) and nuts and to the steps (6) with two
bolts M12x40, washers (under bolt head and nut) and
nuts.
LEIL16WHL1741AA 5
8. Fix the ladder assembly to the hydraulic tank with two

nuts.
LEIL16WHL1722AA 6
9. Place the bottom fender (3) and fix to the ladder: install
two bolts M12x40, washers (under bolt head and nut)
and nuts.
LEIL16WHL1720AA 7
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10. Install four bolts M12x30 and washers.
LEIL16WHL1720AA 8
11. Fix the bracket (4) to the bottom fender (3) with two
nuts, to the steps (6) with two bolts M10x35, washers
(under bolt head and nut) and nuts, to the accumulator
cover (5) with bolt M10x30, washers (under bolt head
and nut) and nut.
LEIL16WHL1740AA 9
12. Fix the top fender (2) to the ladder with two bolts
M8x25 and washers (under bolt head).
LEIL16WHL1738AA 10
13. Fix the bracket (1) to the top fender (2) and ladder
with three bolts M10x40, washers (under bolt head
and nut) and nuts.
LEIL16WHL1719AA 11
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14. Install the bolt M10x30, washers (under bolt head and
nut) and nut.
LEIL16WHL1719AA 12
Right-hand steps and ladder assembly

stairs and to the ladder assembly.
2. Place the right-hand steps and ladder assembly.
3. Fix the steps (5) to the platform support (6) with two
nuts.
LEIL16WHL1730AA 13
4. Fix the ladder assembly to the hydraulic tank with two

nuts.
LEIL16WHL1731AA 14
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3. Place the bottom fender (3) and fix to the ladder with
two bolts M12x40, washers (under bolt head and nut)
and nuts.
LEIL16WHL1728AA 15
4. Install the four bolts M12x30 and washers.
LEIL16WHL1728AA 16
5. Fix the bracket (4) to the bottom fender (3) with two
nuts and to the steps (5) with two bolts M10x35, wash-
ers (under bolt head and nut) and nuts.
LEIL16WHL1746AA 17
6. Fix the top fender (2) to the ladder with two bolts M8x25
and washers (under bolt head).
LEIL16WHL1744AA 18
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2. Fix the bracket (1) to the top fender (2) and ladder with
three bolts M10x40, washers (under bolt head and nut)
and nuts.
LEIL16WHL1727AA 19
1. Install the bolt M10x30, washers (under bolt head and

nut) and nut.
LEIL16WHL1727AA 20
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Index

Ladder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ladder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Mechanically-adjusted operator seat - 120

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Contents
FUNCTIONAL DATA
Mechanically-adjusted operator seat

Operator seat - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Mechanically-adjusted operator seat

Remove - Standard operator seat - Mechanical suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install - Standard operator seat - Mechanical suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat
Operator seat - Exploded view

Standard operator seat – Mechanical suspension
LEIL17WHL0726GB 1
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LEIL17WHL1602GB 2
Item Description
(1) Seat base assembly
(2) Damper
(3) Knob and slotted spring
(4) Shock absorbers
(5) Roller
(6) Rollers and bushings
(7) Backrest cushion
(8) Seat cushion
(9) Left-hand and right-hand adjusters assembly
(10) Console adjusters
(11) Left-hand armrest
(12) Literature box
(13) Pivot cover
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90.3 [90.120] / 4
Mechanically-adjusted operator seat - Remove - Standard operator

seat - Mechanical suspension
1. Remove the joystick. Joystick and Electric Hy-
draulic (EH) control - Remove (55.512) or Joystick
and Electric Hydraulic (EH) control - Remove
(Two/three control levers) (55.512).
2. Remove the 8 bolts (1) with the relevant washers (1)
that secure the console (2) to the machine.
LEIL18WHL0740AB 1
NOTE: have another person help you at this time.

3. Attach a suitable lifting device to the seat.
4. Lift the seat.
5. Remove carefully the seat from the cab.
LEIL18WHL0722AA 2
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Mechanically-adjusted operator seat - Install - Standard operator

seat - Mechanical suspension
2. Lift the seat.
3. Carefully move the seat inside the cab.
4. Place the seat on the correct position inside the cab.
5. Remove the lifting device.
LEIL18WHL0722AA 1
6. Install the 8 bolts (1) with the relevant washers to se-

cure the console (2) of the seat.
7. Torque to 38.0 – 44.0 N·m (336.3 – 389.4 lb in) the 8
bolts.
LEIL18WHL0740AB 2
8. Install the joystick. Joystick and Electric Hydraulic

(EH) control - Install (55.512) or Joystick and Elec-
tric Hydraulic (EH) control - Install (Two/three con-
trol levers) (55.512).
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Index

Mechanically-adjusted operator seat - Install - Standard operator seat - Mechanical suspension . . 6
Mechanically-adjusted operator seat - Remove - Standard operator seat - Mechanical suspension 5
Operator seat - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Pneumatically-adjusted operator seat - 124

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Contents
FUNCTIONAL DATA
Pneumatically-adjusted operator seat

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Seat pneumatic lift system
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overview - Upper suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overview - Lower suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE
Pneumatically-adjusted operator seat

Remove - Optional operator seat - Air suspension, heated seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install - Optional operator seat - Air suspension, heated seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove - Optional premium operator seat - Air suspension, heated seat . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install - Optional premium operator seat - Air suspension, heated seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Seat pneumatic lift system
Remove - Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install - Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Remove - Upper suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Install - Upper suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Remove - Lower suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install - Lower suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Remove - Air-spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Install - Air-spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Operator seat rubber bellows
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
Pneumatically-adjusted operator seat - Exploded view

Optional operator seat – Air suspension, heated seat
LEIL17WHL0727GB 1
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LEIL17WHL1604GB 2
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Item Description
(1) Seat base assembly
(2) Damper
(3) Compressor
(4) Air valve assembly
(5) Air spring assembly
(6) Bumper
(7) Rollers and bushings
(8) Backrest cushion
(9) Seat cushion
(10) Left-hand and right-hand adjusters assembly
(11) Console adjusters
(12) Left-hand armrest
(13) Literature box
(14) Pivot cover
(15) Heater switch
(16) Harness
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Pneumatically-adjusted operator seat - Exploded view

Optional premium operator seat – Air suspension, heated seat
48083742_EN 31/07/2018
LEIL17WHL1605HB 1
90.4 [90.124] / 6
Item Description
1 Cover
2 Control lever
3 Suspension
4 Harness
5 Air spring
6 Reservoir
7 Suspension
8 Lower suspension
9 Bellows
10 Air compressor
11 Handle
12 Triggering assembly
13 Loop sewn
14 Handle
15 Locking lever control
16 Shock absorber
17 Shock absorber
18 Console
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LEIL17WHL1606HB 2
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Item Description
1 Backrest cushion
2 Seat cushion
3 Headrest cushion
4 Headrest guide
5 Support
6 Backrest handle
7 Actuator for backrest
8 Backrest assembly
9 Seat operator angle adjuster
10 Swivel lever
11 Leaf spring
12 Bracket
13 Cover
14 Seat operator depth adjuster
15 Rail adjustment assembly
16 Armrest
17 Armrest
18 Cover
19 Cover
20 Armrest
21 Harness
22 Harness
23 Climate distributor
24 Link
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Seat pneumatic lift system - Overview
LEIL18WHL0521GA 1
Component Description
(1) Compressor
(2) Cable tie
(3) Lower suspension part
(4) Compressed-air hose (*)
(5) Hose nozzle
(6) Pad
(7) Compressor cable
(8) Electrical connector X-SC
(9) Lifting structure
(10) Cable tie
(11) Air intake hose
NOTE: (*) Use a sharp knife for cutting into lengths.
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Seat pneumatic lift system - Overview - Upper suspension part
LEIL18WHL0689GA 1
(1) Upper suspension part
(2) Guiding rail
(3) Rear roller
(5) Front roller
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Seat pneumatic lift system - Overview - Lower suspension part
LEIL18WHL0690GA 1
(1) Lower suspension part
(2) Guiding rail
(3) End stop
(4) Buffer
(5) Fixed bearing
(7) Roller
(8) Upper suspension part
(9) Collar screw
(10) Hexagon nut
(11) Screw
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Pneumatically-adjusted operator seat - Remove - Optional operator

seat - Air suspension, heated seat
2. Disconnect the connector X-SC from the seat harness.
LEIL18WHL0721AB 1
3. Remove the 8 bolts (1) with the relevant washers (1)

LEIL18WHL0740AB 2

5. Lift the seat.
LEIL18WHL0722AA 3
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Pneumatically-adjusted operator seat - Install - Optional operator

seat - Air suspension, heated seat
2. Lift the seat.
LEIL18WHL0722AA 1
6. Install the 8 bolts (1) with the relevant washers to se-

cure the console (2) of the seat.
7. Torque to 38.0 – 44.0 N·m (336.3 – 389.4 lb in) the 8
bolts.
LEIL18WHL0740AB 2
8. Connect the connector X-SC to the seat harness.
LEIL18WHL0721AB 3

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Pneumatically-adjusted operator seat - Remove - Optional premium

operator seat - Air suspension, heated seat
2. Disconnect the connector X-SC from the seat harness.
LEIL18WHL0721AB 1
3. Remove the four bolts (1) with the relevant washers (1)
LEIL18WHL0725AA 2

5. Lift the seat.
LEIL18WHL0722AA 3
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Pneumatically-adjusted operator seat - Install - Optional premium

operator seat - Air suspension, heated seat
2. Lift the seat.
LEIL18WHL0722AA 1
6. Install the four bolts (1) with the relevant washers to

secure the console (2) of the seat.
7. Torque to 38.0 – 44.0 N·m (336.3 – 389.4 lb in) the four
bolts.
LEIL18WHL0725AA 2
8. Connect the connector X-SC to the seat harness.
LEIL18WHL0721AB 3

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Seat pneumatic lift system - Remove - Compressor

Prior operation:
Operator seat rubber bellows - Remove (90.124)
NOTE: use a suitable spacer to support the structure of the operator seat.
1. To remove the compressor (1) move the seat suspen-
sion to the highest position and secure it at the rear
between the lifting structure and the lower suspension
part.
NOTE: open the vent valve of the pneumatic system before
remove the compressor (1).
LEIL18WHL0522AA 1
2. Mark the point where the hose nozzle (5) and the intake
hose (11) are fastened with cable tie (10) and remove
the cable tie (10).
LEIL18WHL0523AA 2
3. Mark the two electrical connectors (8) and disconnect

the electrical connectors (8) from the compressor (1).
4. Disconnect the hose nozzle (5) from the compressor
(1) and push it backwards at the compressed-air hose
(4).
NOTICE: be careful that you do not damage the com-
pressed-air hose (4)
NOTE: do not lift off the compressed-air hose (4) at the
connection of the compressor (1) (for example by means
of a screwdriver or similar tools).
5. Pull off the hose nozzle (5) from compressed-air hose
LEIL18WHL0524AA 3
(4).
6. Mark the places where the compressor (1) is attached
to the lower suspension part (3) by means of two cable
ties (2). Cut the two cable ties (2).
NOTICE: be careful that you do not cause damage the
compressor (1).
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7. Remove the compressor (1) from the front of the seat.
LEIL18WHL0522AA 4
8. Remove the compressor (1) from the pad (6).
LEIL18WHL0524AA 5
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Seat pneumatic lift system - Install - Compressor

NOTICE: use a suitable spacers to support the operator's seat structure.
1. To install the compressor (1) move the seat suspension
to the highest position and secure it at the rear between
the lifting structure and the lower suspension part.
LEIL18WHL0522AA 1
2. Install the compressor (1) from the front part.
LEIL18WHL0522AA 2
3. Place the pad (6) between the lower suspension part

(3) and the compressor (1) so that the compressor (1)
is not in contact with the lower suspension part (3).
4. Align the compressor (1) in the correct position to pre-
vent collision with the lifting structure (9).
5. Install the cable tie (2) in the slots of the pad (6).
NOTE: guide the cable ties (2) through the slots located on
the lower suspension part (3) , so that the locking head of
the cable ties (2) points forwards.
6. Pull the cable tie (2) to 360 N by means of pliers.
LEIL18WHL0524AA 3
NOTE: use a sharp knife to perform a clean cut to the com-

pressed-air hose (4) (if necessary).
NOTE: the compressed-air hose (4) can be cut only one
time. Mark the correct position before perform the cut on
the compressed-air hose (4) in order to cut it one time.
7. Install the hose nozzle (5) to the compressed air hose
(4).
8. Connect the compressed air hose (4) to the compres-
sor (1).
LEIL18WHL0524AA 4
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Seat pneumatic lift system - Remove - Upper suspension part

1. Remove the seat suspension.
LEIL18WHL0673AA 1
2. Remove the front cover.
LEIL18WHL0674AA 2
3. Remove the top cover.
LEIL18WHL0675AA 3
4. Push up the bellows and fasten it to the upper suspen-

sion part. Operator seat rubber bellows - Remove
(90.124)
LEIL18WHL0676AA 4
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5. Remove the Bowden pull wire (1) and the handle for
vertical shock absorber adjustment (2) at the upper
suspension part.
NOTE: the Bowden pull wire for the vertical shock absorber
(1) remains installed at the vertical shock absorber (2).
LEIL18WHL0678AA 5
6. Remove the longitudinal horizontal shock absorber.
LEIL18WHL0679AA 6
7. Remove the fore/aft isolator unit from the upper sus-

pension part.
LEIL18WHL0680AA 7
8. Remove the locking mechanism of the fore/aft isolator

if it is not preassembled.
NOTE: the clamp remains attached to the lifting structure.
LEIL18WHL0681AA 8
9. Remove the holder for height adjustment.
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10. Remove the Bowden pull wire for height adjustment in

downward direction at the upper suspension part.
NOTE: remove the Bowden pull wire for height adjustment
in downward direction at the clamp (if installed) and pull
inwards through the opening of the U-shaped rail.
NOTE: the Bowden pull wire for height adjustment in down-
ward direction remains installed at the level control.
LEIL18WHL0682AA 9
11. Remove the cable harness for vehicle connection.
LEIL18WHL0683AA 10
12. Remove the cable harness (1) of the seat suspension

with the U-profile (2) at the upper suspension part and
do the preservation for the part.
NOTE: the cable harness of the seat suspension remains
installed at the level control and at the compressor.
LEIL18WHL0684AA 11
13. Remove the secondary belt from the upper suspen-

sion part.
LEIL18WHL0685AA 12
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14. Remove the level control at the upper suspension part

and do the preservation for the part.
NOTE: the belt retractor of the level control is tensioned;
hold the level control and carefully guide it down.
NOTE: the cable harness of the seat suspension remains
installed at the level control.
LEIL18WHL0686AA 13
15. Remove the air distributor from the upper suspension

part and do the preservation for the part.
NOTE: the air hoses remain attached at the air distributor.
LEIL18WHL0687AA 14

16. Push the upper suspension part (1) forwards until the
cut-outs on the left and right sides at the guiding rails
(2) are located at the same height with the front rollers
(5).
17. Lift the upper suspension part (1) over the front rollers
(5).
LEIL18WHL0695BA 15
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18. Turn counterclockwise the upper suspension part (1)

by approximately of 45°.
19. Lift the upper suspension part (1) above ad forward
the rear roller (3).
20. Pull and remove the two front rollers (5) and two rear
rollers (3) from the lifting structure (4).
LEIL18WHL0696AA 16
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Seat pneumatic lift system - Install - Upper suspension part

1. Install the two front rollers (5) and two rear rollers (3)
on the lifting structure (4).
Push the parts in the lifting structure (4).
2. Lubricate the two guiding rails (2), the two front rollers
(5) and two rear rollers (3) with acid-free multi-purpose.
3. Hold the upper suspension part (1) over the front rollers
(5) and over the rear rollers (3).
LEIL18WHL0696AA 1
4. Put the upper suspension part (1) into the left and right
sides at the guiding rails (2) and push until it is fit in the
correct position.
LEIL18WHL0697BA 2

5. Install the air distributor and the air hoses at the upper
suspension part.
LEIL18WHL0687AA 3
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6. Install the level control and the cable harness of the

seat suspension part.
LEIL18WHL0686AA 4
7. Install the secondary belt to the upper suspension part.

NOTE: the belt retractor of the level control must be ten-
sioned.
LEIL18WHL0685AA 5
8. Install the cable harness (1) of the seat suspension with

the U-profile (2) on the upper suspension.
LEIL18WHL0684AA 6
NOTE: the cable harness of the seat suspension is already installed at the level control and on the compressor.
9. Install the cable harness for vehicle connection.
LEIL18WHL0683AA 7
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10. Install the Bowden pull wire for height adjustment in

forward direction at the upper suspension part.
NOTE: install the Bowden pull wire for height adjustment
in downward direction at the clamp (if installed) and push
forwards in the opening of the U-shaped rail.
NOTE: the Bowden pull wire for height adjustment in down-
ward direction remains installed at the level control.
LEIL18WHL0682AA 8
11. Install the holder for height adjustment.

12. Install the locking mechanism for the fore/aft isolator
not preassembled.
NOTE: the clamp is still attached to the lifting structure.
LEIL18WHL0681AA 9
13. Install the fore/aft isolator unit on the upper suspen-

sion part.
LEIL18WHL0680AA 10
14. Install the longitudinal horizontal shock absorber.
LEIL18WHL0679AA 11
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15. Install the Bowden pull wire (1) and the handle for
vertical shock absorber adjustment (2) on the upper
suspension part.
NOTE: the Bowden pull wire for the vertical shock absorber
is still installed at the vertical shock absorber.
LEIL18WHL0678AA 12
16. Lift down the bellows to the upper suspension part.

Operator seat rubber bellows - Install (90.124)
LEIL18WHL0676AA 13
17. Install the top cover.
LEIL18WHL0675AA 14
18. Install the front cover.
LEIL18WHL0674AA 15
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19. Install the seat suspension.
LEIL18WHL0673AA 16
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Seat pneumatic lift system - Remove - Lower suspension part

1. Push up the bellows and fasten it to the upper suspen-
sion part. Operator seat rubber bellows - Remove
(90.124)
LEIL18WHL0676AA 1
2. Remove the compressor. Seat pneumatic lift system

- Remove - Compressor (90.124).
NOTE: if the compressed air hose remain installed at the
compressor, the compressor must be fixed at the lifting
structure to prevent damage.
3. Remove the webbing of the level control from the lower
suspension part.
LEIL18WHL0699AA 2
4. Remove the secondary belt from the lower suspension

part.
LEIL18WHL0685AA 3
5. Remove the air spring. Seat pneumatic lift system -

Remove - Air-spring (90.124).
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6. Loosen and discard the two micro-encapsulated

hexagonal nuts (10) from the lower suspension part
(1).
7. Loosen the two screws (11) from fixed bearing (5).
8. Push the lifting structure (6) backwards until the two
fixed bearings (5) at the lifting structure (6) fit through
the end of the left and right guiding rail (2) of the lower
suspension part (1).
LEIL18WHL0698BA 4
9. Lift the lifting structure (6) with the two fixed bearings
(5) out of the guiding rails (2) of the lower suspension
part (1) at the front.
10. Loosen the two collar screws (9).
Remove the end stops (3) with the buffer (4) from the
guiding rails (2).
11. Turn laterally the lifting structure (6) with the attached
upper suspension part (8) of approximately 45° to pull
the two rollers (7) out of the guiding rails (2).
Lift the suspension part (8) in upward direction.
12. Remove the upper suspension part (8).
LEIL18WHL0698BA 5
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Seat pneumatic lift system - Install - Lower suspension part

1. Install the two guiding rails (2) on the lower suspension
part (1).
2. Torque the two screw (11) and the two micro-encapsu-
lated hexagonal nuts (10) to 25.0 N·m (18.4 lb ft).
3. Lubricate with acid-free multi-purpose the side of the
two guiding rails (2) where the rollers are moved.
4. Put the end stop (3) with the buffer (4) into the guiding
rails (2).
LEIL18WHL0698BA 1
5. Torque to 6.0 N·m (53.1 lb in) the collar screw (9).

6. Insert the two rollers (7) into the two guiding rails (2).
7. The two rollers (7) are attached to the suspension part
(8) through the lifting structure (6).
8. Engage the two fixed bearings (5) to the lower suspen-
sion part (1).
9. With the structure in front of you, push from the back
to the front the two fixed bearings (5) on the correct
position until they stop.
LEIL18WHL0698BA 2

10. Install the air spring. Seat pneumatic lift system -
Install - Air-spring (90.124).
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11. Install the webbing of the level control on the lower

suspension part.
LEIL18WHL0699AA 3
12. Install the secondary belt on the lower suspension

part.
LEIL18WHL0685AA 4
13. Install the compressor. Seat pneumatic lift system -

Install - Compressor (90.124).
14. Lift down the bellows to the upper suspension part.
Operator seat rubber bellows - Install (90.124).
LEIL18WHL0676AA 5
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Seat pneumatic lift system - Remove

1. Push the upper seat part (1) in backward position.
LEIL18WHL0724AA 1
2. Mark the position of the screws (2) located in the front

side of the guides (3).
3. Remove and discard the screws (2).
4. Remove the end stop (5) (if equipped).
LEIL18WHL0534AA 2
5. Mark the position of the screw (2) located in the rear

side of the guides (3).
6. Remove and discard the screws (2).
7. Remove the end stop (7) (if equipped).
LEIL18WHL0543BA 3
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8. Lift and hold the upper seat part (1) that is attached to
the seat suspension (4).
NOTE: make sure you do not overstretch the cable harness
(8).
LEIL18WHL0543BA 4
9. Mark the point where the cable harness (8) is attached

to the center cover (6).
10. Cut the cable tie (9).
11. Disconnect the electrical connection between the
socket (10) and the plug (11).
LEIL18WHL0535AA 5
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Seat pneumatic lift system - Install

1. Hold the upper seat part (1) on the seat suspension (4).
LEIL18WHL0543BA 1
2. Follows the mark to find the point where the cable har-
ness (8) must be attached to the center cover (6).
3. Connect the electrical connection between the socket
(10) and the plug (11).
4. Lock the cable harness (8) with a cable tie (9).
NOTE: install the cable harness (8) in is correct position to
avoid overstretch.
LEIL18WHL0535AA 2
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5. Pull the upper seat part (1) in forward position.
LEIL18WHL0543BA 3
NOTE: follows the indication mark to find the correct posi-

tion of the end stop (7) (if equipped).
6. Install the end stop (7) (if equipped) on the guides (3).
LEIL18WHL0543BA 4
7. Install the screws (2) to attach the upper seat part (1).to
the guides (3).
Tighten the screws (2) to 25.0 N·m (18.4 lb ft).
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8. Push the upper seat part (1) in backward position.
LEIL18WHL0543BA 5
NOTE: follows the indication mark to find the correct posi-

tion of the end stop (5) (if equipped).
9. Install the end stop (5) (if equipped) on the guides (3).
LEIL18WHL0534AA 6
10. Install the screws (2) to attach the upper seat part (1)
to the guides (3).
Tighten the screws (2) to 25.0 N·m (18.4 lb ft).
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Seat pneumatic lift system - Remove - Air-spring

1. Remove the operator’s seat from the cab. Refer to
Pneumatically-adjusted operator seat - Remove -
Optional premium operator seat - Air suspension,
heated seat (90.124).
2. Remove the bellows. Refer to Operator seat rubber
bellows - Remove (90.124).
NOTE: use a suitable spacer to support the operator's seat structure.

3. Move the seat suspension to the highest position to
remove the air spring (2).
Secure the seat suspension at the rear between the
lifting structure (3) and the lower suspension part (1).
LEIL18WHL0544BA 1
NOTE: vent the pneumatic system before remove the air spring (2).
4. Pull the catch spring (5) out of the air spring (2).
5. Pull to disconnect the two quick couplings (6) of the air
intake hose (7) and the compressed-air hose (8) from
the air spring (2).
LEIL18WHL0806AA 2
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6. Loosen the screw (4) on the bottom of the lower sus-

pension part (1).
7. Turn the air spring (2) 90 °C clockwise until the bayonet
fits through the longitudinal hole in the lifting structure
(3).
8. Push the air spring (2) down.
Pull and disengage the air spring (2) from the lifting
structure (3).
LEIL18WHL0807BA 3
9. Remove the air spring (2) from the seat suspension.
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Seat pneumatic lift system - Install - Air-spring

1. Move the seat suspension to the highest position and
secure it at the rear between the lifting structure (3) and
the lower suspension part (1).
2. Hold the air spring (2) into the seat suspension.
LEIL18WHL0544BA 1
3. Push the air spring (2) to the lifting structure (3) until
you hear a click.
4. Turn the air spring (2) 90° counterclockwise until the
bayonet fits through the longitudinal hole into the lifting
structure (3).
5. Torque the screw (4) to 6.0 N·m (53.1 lb in).
NOTE: the internal thread collar of the bottom of the air
spring (2) must lie flush in the drill hole of the lower sus-
pension part (1).
LEIL18WHL0807BA 2
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6. Connect the two quick couplings (6) of the air intake

hose (7) and the compressed-air hose (8) into the air
spring (2).
7. Lock the catch spring (5).
LEIL18WHL0806AA 3
8. Install the bellows. Refer to Operator seat rubber bel-

lows - Install (90.124).
9. Install the operator’s seat in the cab. Refer to Pneu-
matically-adjusted operator seat - Install - Optional
premium operator seat - Air suspension, heated
seat (90.124).
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Operator seat rubber bellows - Remove

1. Remove the 16 bellows pins (3) that attach the upper
suspension part (2) to the bellows (1).
LEIL18WHL0530BA 1
2. Remove the six bellows pins (3) that attach the lower
suspension part (2) to the bellows (1).
3. Lift the bellows (1) over the handle (4) for vertical shock
absorber adjustment.
LEIL18WHL0532BA 2
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4. Make sure that the wire insert (5) is not damaged. Re-
place the wire insert (5) if damaged.
LEIL18WHL0531AA 3
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Operator seat rubber bellows - Install

1. Install the wire insert (5) in the middle fold of the bellows
(1).
NOTE: the correct position to install the wire insert (5) is
with the welding joint in the front of the bellows (1) (see the
arrow).
LEIL18WHL0531AA 1
2. Lower the bellows (1) from the handle for vertical shock
absorber adjustment (4).
3. Install the six bellows pins (3) that attach the lower sus-
pension part (2) to the bellows (1).
LEIL18WHL0532BA 2
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4. Install the 16 bellows pins (3) that attach the upper sus-
pension part (2) to the bellows (1).
LEIL18WHL0530BA 3
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Index

Operator seat rubber bellows - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Operator seat rubber bellows - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Pneumatically-adjusted operator seat - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pneumatically-adjusted operator seat - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pneumatically-adjusted operator seat - Install - Optional operator seat - Air suspension, heated seat
...................................................................................... 14
Pneumatically-adjusted operator seat - Install - Optional premium operator seat - Air suspension,
heated seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pneumatically-adjusted operator seat - Remove - Optional operator seat - Air suspension, heated
seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pneumatically-adjusted operator seat - Remove - Optional premium operator seat - Air suspension,
heated seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Seat pneumatic lift system - Install - Air-spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Seat pneumatic lift system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Seat pneumatic lift system - Install - Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Seat pneumatic lift system - Install - Lower suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Seat pneumatic lift system - Install - Upper suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Seat pneumatic lift system - Overview - Lower suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Seat pneumatic lift system - Overview - Upper suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Seat pneumatic lift system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Seat pneumatic lift system - Remove - Air-spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Seat pneumatic lift system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Seat pneumatic lift system - Remove - Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Seat pneumatic lift system - Remove - Lower suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Seat pneumatic lift system - Remove - Upper suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Machine shields and guards - 105

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Contents
SERVICE
Engine hood
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Platform, cab, bodywork, and decals - Machine shields and guards
Engine hood - Remove

bucket to the ground. Put the articulation lock in
LOCKED position.
LEIL15WHL1782AA 1
2. Loosen the thirteen mounting screws (2) and the re-

lated washers to remove the screen top (1) from the
engine hood.
Place the screen top (1) in a safe location.
LEIL15WHL0695AB 2
LEIL15WHL0664AA 3

NOTE: repeat the same operation for the right-hand side.
LEIL15WHL0658AB 4
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5. Remove the side body panel (2) from the left-hand side
of the engine compartment moving the latch (1).
LEIL15WHL0659AB 5
6. Remove the spring gas (4) from the left step structure
losing the stud.
7. Loosen the two bolts (2). Remove the two bolts (3) and
the related washers.
8. Lift up and remove the wide rear fender panel (1).
NOTE: left-hand side of the machine is shown. The oper-
ation is similar for the right-hand side.
LEIL15WHL0697AB 6
9. If machine is equipped with a rearview camera, tag and

disconnect the rearview camera wire harness (arrow)
from the rear chassis harness.
Then place it off to the side in a safe location.
LEIL16WHL1876AB 7
gine hood.
11. Loosen the nut (1). Remove the washers (2), the bear-
ings (3) with the spacers (4) and the bolt (7) to sepa-
rate the rod (6) from the hood roller mount (5) on the
engine hood structure.
LEIL17WHL1629AB 8
48083742_EN 31/07/2018
90.5 [90.105] / 4
12. Remove the mounting screw (1), the washer (2), the
plate tooth (3), the washer (4), and the nut (5) to sep-
arate the engine hood from the hydraulic tank.
13. Repeat the same operation for the right-hand side.
NOTE: for clarity, the engine hood panels assembly is not
shown in the figure.
LEIL15WHL0696AB 9
14. Lift the strap on the loop and remove carefully the
engine hood from the machine. Lower the hood onto a
suitable platform and disconnect the lifting equipment.
48083742_EN 31/07/2018
90.5 [90.105] / 5
Engine hood - Install

1. Attach a suitable lifting device to the engine hood.
Carefully align the engine hood into position on the
machine.
2. Install the mounting screws (1), the washers (2), the
plate teeth (3), the washers (4), and the nuts (5).
NOTE: for clarity, the engine hood panels assembly is not
shown in the figure.
LEIL15WHL0696AB 1
3. Install the bolt (7), the washers (2), the bearings (3) with
spacers (4).Tighten the nut (1) to secure the rod (6) to
the hood roller mount (5) on the engine hood structure.
LEIL17WHL1629AB 2
4. If machine is equipped with a rearview camera, connect

the rearview camera wire harness (arrow) to the rear
chassis wiring connector.
LEIL16WHL1876AB 3
48083742_EN 31/07/2018
90.5 [90.105] / 6
5. Position the wide rear fender panel (1) into position on

the machine.
Tighten the bolts (2) and (3) to install the rear fender
panel (1).
Loosen the stud of the spring gas (4) to install the spring
gas (4) on the left step structure.
NOTE: left-hand side of the machine is shown. The oper-
ation is similar for the right-hand side.
LEIL15WHL0697AB 4

Repeat the same operation for the right-hand side.
LEIL15WHL0659AB 5
7. Close the wide rear fender panel compartment.

LEIL15WHL0658AB 6

9. Carefully position the screen top (1) into position on the
machine.
Install the thirteen mounting screws (2) and the related
washers.
LEIL15WHL0695AB 7
48083742_EN 31/07/2018
90.5 [90.105] / 7
Engine hood - Alignment

NOTE: this procedure includes proper alignment of the hydraulic oil tank, proper alignment of the fiberglass side
panels, centering the hood on the machine, and the proper compression of the engine hood bumpers against the
counterweight.
Check the alignment of the hydraulic oil tank

1. Measure the distance (M) from the hydraulic oil tank (1)
and the outside edge of the chassis (2).
2. If the measured value are within the ranges specified
in table, the hydraulic oil tank (1) is centered in the
chassis.
LEIL15WHL0780AB 1
Model Maximum value Minimum value

CASE 1021F 27 mm (1.1 in) 23 mm (0.9 in)
CASE 1121F 36 mm (1.4 in) 32 mm (1.3 in)
3. If the difference of the two measured values from

the left-hand side of the machine is less than 2 mm
(0.08 in), the hydraulic oil tank is parallel to the chas-
sis.
4. If the hydraulic oil tank is not centered in the rear chas-
sis or parallel to the rear chassis, adjust the position of
the hydraulic oil tank and measure again. Repeat this
step until the hydraulic oil tank measurement are within
the specified values.
48083742_EN 31/07/2018
90.5 [90.105] / 8
Gap adjustment between the engine hood panel and the rear screen
1. Measure the gap (G) between both the right-hand and
left-hand engine hood panel and the rear screen.
2. If the measured gap (G) is between 0.5 – 3 mm (0.02
– 0.12 in), no further adjustment is necessary.
LEIL15WHL0781AB 2
3. If the gap is less than 0.5 mm (0.02 in), add one washer
(3) between the iso-mount plate (1) and the hood struc-
ture (2) for each mounting point.
4. If the measured gap is greater than 3 mm (0.12 in),
remove one washer (3) between the iso-mount plate
(1) and the hood structure (2) for each mounting point.
5. Repeat procedure until the measured gaps are be-
tween 0.5 – 3 mm (0.02 – 0.12 in) and the engine
hood panel (4) is parallel to the rear screen.
LEIL15WHL0782AB 3
Fiberglass panel alignment

1. Align (A) the fiberglass panel (1) with the edge of the
rear screen (2).
2. Align the corner.
3. Tighten the hardware.
LEIL15WHL0783AB 4
48083742_EN 31/07/2018
90.5 [90.105] / 9
Center the engine hood on the machine

1. Slowly lower the engine hood to verify that the engine
hood is not in touch with the cooling box.
2. If the engine hood is not in touch with the cooling box,
go to step 7
3. If the engine hood is in touch with the cooling box, the
engine hood must be adjusted, using the adjustable
tooth washer (1) in the hood pivot joint.
4. If the hood needs to move to the right-hand, on the
right-hand side pivot joint move the tooth washer (1) to
the rear in the hood frame slot (2), or on the left-hand
side pivot joint move the tooth washer (1) to the front in
the hood frame slot (2).
5. If the hood needs to move to the left-hand, on the right
side pivot joint move the tooth washer (1) to the front
in the hood frame slot (2), or on the left-hand side pivot
joint move the tooth washer (1) to the rear in the hood
frame slot (2). LEIL15WHL0784AB 5
6. Make the adjustments one notch at a time until the hood

will fully close.
7. Measure and record the dimensions (A) and (B).
LEIL15WHL0785EB 6
8. If the difference between (A) and (B) is between 0 –

14 mm (0 – 0.55 in), no further adjustment is required.
9. If the difference is greater than 14 mm (0.55 in), adjust
the engine hood using the steps 3, 4, 5, and 6 until the
difference is 14 mm (0.55 in) or less.
48083742_EN 31/07/2018
90.5 [90.105] / 10
Adjust the compression of the engine hood bumpers

1. Verify that the counterweight is level with the rear
frame.
2. Measure the distance from the top of the counterweight
to the top of the rear frame on the left-hand and right-
hand side.
3. The difference between the two distances should be no
greater than 3 mm (0.12 in).
4. If the differences between the two distances is greater
than 3 mm (0.12 in), readjust the counterweight.
LEIL15WHL0786AB 7
5. Tighten the bumpers so they are tight in their mounting

locations.
6. Lower the hood using the hood actuator switch until one
of the bumpers just touches the counterweight.
LEIL15WHL0787AA 8
7. Measure and record the distance (M) between the

grill and the counterweight near the bumper (1) that is
touching the counterweight.
8. Loosen the nuts on the other three bumpers and lower
them until they also just touch the counterweight.
Re-tighten the bumpers. Fully lower the hood using
the hood actuator switch.
LEIL15WHL0788AB 9
9. Measure the distance (M) between the grill and the

counterweight near the bumper where the first mea-
surement was taken. The distance should be 5 mm
(0.20 in) less than the previous measurement.
LEIL15WHL0789AB 10
48083742_EN 31/07/2018
90.5 [90.105] / 11
10. Measure and record the distance (M) between the grill
and the bumper at each of the other three bumper (1)
locations. The distances should be equal to the 5 mm
(0.20 in) compressed bumper. This ensures at least
5 mm (0.20 in) of compression on the bumpers and
the hood will be straight with the counterweight.
11. If the measurements are not equal between the grill
and counterweight at each bumper location, the hood
or counterweight will need to be adjusted.
LEIL15WHL0790AB 11
48083742_EN 31/07/2018
90.5 [90.105] / 12
Index

Engine hood - Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083742_EN 31/07/2018
90.5 [90.105] / 13
PRINTED IN ITALY
48083742_EN 31/07/2018
EN
SPECIAL TOOL INDEX
Genuine Reference PAGE

380001282 [Assembly Cart Powershift transmission - Disassemble 21.1 / 11
Complete With Tilting Device]
CAS2268 [Puller] Powershift transmission - Disassemble 21.1 / 11
381000059 [MOUNTING Powershift transmission - Disassemble 21.1 / 12
LEVER]
380001289 [Inner Ring Of Powershift transmission - Disassemble 21.1 / 14
The Taper Roller Bearing
Extractor]
CAS2268 [Puller] Powershift transmission - Disassemble 21.1 / 15
381000059 [MOUNTING Powershift transmission - Disassemble 21.1 / 22
LEVER]
381000084 [PULLER Powershift transmission - Disassemble 21.1 / 22
INSERT]
380001282 [Assembly Cart Powershift transmission - Assemble 21.1 / 26
381000131 [ADJUSTING Powershift transmission - Assemble 21.1 / 32
SCREWS M10]
SCREWS M10]
SCREWS M10]
SCREWS M10]
380001296 [Control Valve Transmission control valve - Disassemble 21.2 / 3
Screws Locking Wrench
(TX40)]
380001297 [Display] Transmission control valve - Disassemble 21.2 / 3
(TX40)]
(TX40)]
Screws (M5) Adjusting tool]
380001276 [Control Valve Transmission control valve - Assemble 21.2 / 7
(TX40)]
48083742_EN 31/07/2018
(TX40)]
(TX40)]
381000128 [ADJUSTING Transmission control valve - Assemble 21.2 / 10
SCREWS M6]
(TX40)]
380001297 [Display] Transmission control valve - Assemble 21.2 / 11
381000128 [ADJUSTING Transmission control valve - Assemble 21.2 / 12
SCREWS M6]
(TX40)]
380001282 [Assembly Cart Clutch - Disassemble 21.4 / 3
380001292 [Primary Shaft Clutch - Disassemble 21.4 / 3
Bearing Mounting Tool]
380001289 [Inner Ring Of Clutch - Disassemble 21.4 / 4
Extractor]
Extractor]
Extractor]
Extractor]
380100001 [Bearing Cup Bevel gear set and differential carrier - Backlash Model 3105 II 25.2 / 6
Installer ]
CAS2842 [Pinion Locknut Bevel gear set and differential carrier - Backlash Model 3105 II 25.2 / 8
Wrench]
380001564 [Brake Housing Bevel gear set and differential carrier - Backlash Model 3105 II 25.2 / 8
Puller Bridge]
380002318 [Slotted Nut Bevel gear set and differential carrier - Backlash Model 3115 II 25.2 / 15
Wrench]
CAS2842 [Pinion Locknut Differential - Remove Model 3105 II 25.2 / 25
Wrench]
380001546 [Flange Holder] Differential - Remove Model 3105 II 25.2 / 25
CAS2842 [Pinion Locknut Differential - Install Model 3105 II 25.2 / 34
Wrench]
380001564 [Brake Housing Differential - Install Model 3105 II 25.2 / 34
Puller Bridge]
48083742_EN 31/07/2018
CAS2841 [Pinion Shaft Seal Differential - Install Model 3105 II 25.2 / 34
Installer ]
Wrench]
380001546 [Flange Holder] Differential - Install Model 3105 II 25.2 / 35
380002318 [Slotted Nut Differential - Install Model 3115 II 25.2 / 51
Wrench]
Wrench]
380100001 [Bearing Cup Rear bevel gear set and differential - Backlash Model 3105 II 27.2 / 6
Installer ]
CAS2842 [Pinion Locknut Rear bevel gear set and differential - Backlash Model 3105 II 27.2 / 8
Wrench]
380001564 [Brake Housing Rear bevel gear set and differential - Backlash Model 3105 II 27.2 / 8
Puller Bridge]
380002318 [Slotted Nut Rear bevel gear set and differential - Backlash Model 3115 II 27.2 / 15
Wrench]
CAS2842 [Pinion Locknut Differential - Remove Model 3105 II 27.2 / 25
Wrench]
380001546 [Flange Holder] Differential - Remove Model 3105 II 27.2 / 25
Wrench]
380001564 [Brake Housing Differential - Install Model 3105 II 27.2 / 34
Puller Bridge]
CAS2841 [Pinion Shaft Seal Differential - Install Model 3105 II 27.2 / 34
Installer ]
Wrench]
380001546 [Flange Holder] Differential - Install Model 3105 II 27.2 / 35
Wrench]
Wrench]
380001168 [Nitrogen Hydraulic service brakes - Special tools 33.1 / 4
Accumulator Charging
Adapter]
CAS10280 [75 GPM In-Line Hydraulic service brakes - Special tools 33.1 / 5
Hydraulic Tester]
380001740 [Flowmeter Fitting Hydraulic service brakes - Special tools 33.1 / 5
Kit]
CAS10280 [75 GPM In-Line Hydraulic service brakes - Test 33.1 / 13
Hydraulic Tester]
380001740 [Flowmeter Fitting Hydraulic service brakes - Test 33.1 / 13
Kit]
CAS10280 [75 GPM In-Line Hydraulic service brakes - Check - Brake modulation pressure 33.1 / 16
Hydraulic Tester]
380001740 [Flowmeter Fitting Hydraulic service brakes - Check - Brake modulation pressure 33.1 / 16
Kit]
CAS10280 [75 GPM In-Line Hydraulic service brakes - Check - Brake modulation pressure 33.1 / 16
Hydraulic Tester]
380001740 [Flowmeter Fitting Hydraulic service brakes - Check - Brake modulation pressure 33.1 / 16
Kit]
CAS10280 [75 GPM In-Line Hydraulic service brakes - Check - Service brake system 33.1 / 18
Hydraulic Tester] performance
380001740 [Flowmeter Fitting Hydraulic service brakes - Check - Service brake system 33.1 / 18
Kit] performance
CAS10280 [75 GPM In-Line Brake pump - Flow test 33.1 / 26
Hydraulic Tester]
380001168 [Nitrogen Accumulator - Discharging 33.1 / 28
Adapter]
48083742_EN 31/07/2018
380001168 [Nitrogen Accumulator - Check 33.1 / 39
Adapter]
CAS1904-1 [Tool Kit] Hydraulic systems - Special tools 35.1 / 3
CAS10280 [75 GPM In-Line Hydraulic systems - Special tools 35.1 / 4
Hydraulic Tester]
380001740 [Flowmeter Fitting Hydraulic systems - Special tools 35.1 / 4
Kit]
5870 287 007 [HD Hand Hydraulic systems - Special tools 35.1 / 4
Pump]
CAS1804 [Pressure Test Hydraulic systems - Special tools 35.1 / 4
Fitting Kit]
CAS10280 [75 GPM In-Line Variable displacement pump - Service instruction - High pressure 35.3 / 8
Hydraulic Tester] pump flow test
380001738 [Gland Wrench] Accumulator - Special tools - Ride control 35.8 / 5
5870 287 007 [HD Hand Articulation frame pivot - Special tools 39.1 / 3
Pump]
5870 287 007 [HD Hand Articulation frame pivot - Disassemble 39.1 / 8
Pump]
CAS10280 [75 GPM In-Line Hydraulic control components - Special tools 41.2 / 3
Hydraulic Tester]
380001740 [Flowmeter Fitting Hydraulic control components - Special tools 41.2 / 3
Kit]
CAS1804 [Pressure Test Hydraulic control components - Special tools 41.2 / 3
Fitting Kit]
380001731 [Bevel Pinion Auxiliary steering - Test 41.4 / 9
Shaft Socket]
380001740 [Flowmeter Fitting Auxiliary steering - Test 41.4 / 9
Kit]
380001731 [Bevel Pinion Pump - Test 41.4 / 15
Shaft Socket]
380001325 [Compressor Belt Air conditioning - Special tools 50.2 / 3
Tension Checking Tool]
380001327 [Electronic Leak Air conditioning - Special tools 50.2 / 4
Detector]
CNH299147 [Belt Tension Air-conditioning compressor - Install 50.2 / 30
Tool (Same as CAS10808)]
OEM Reference PAGE
OEM1598 [A/C Refrigerant Air conditioning - Special tools 50.2 / 4
Recovery Station - Clean
(Same as OEM1415)]
OEM1598 [A/C Refrigerant Air conditioning - Charging 50.2 / 18
Recovery Station - Clean
(Same as OEM1415)]
Kit Reference PAGE
380001737 [Nitrogen Hydraulic service brakes - Special tools 33.1 / 4
Charging Kit With High
Pressure Regulator And
Hoses Complete]
380001737 [Nitrogen Accumulator - Discharging 33.1 / 28
Hoses Complete]
380001737 [Nitrogen Accumulator - Check 33.1 / 39
Hoses Complete]
48083742_EN 31/07/2018
Kit Reference PAGE
380001737 [Nitrogen Accumulator - Charging 33.1 / 40
Hoses Complete]
CAS10162A [Portable Filter Hydraulic systems - Special tools 35.1 / 3
Caddy]
CAS10192 [Vacuum Pump] Hydraulic systems - Special tools 35.1 / 3
CAS10508 [Fitting Kit For Hydraulic systems - Special tools 35.1 / 3
Unions]
CAS10162A [Portable Filter Hydraulic systems - Cleaning 35.1 / 24
Caddy]
Caddy]
Caddy]
Caddy]
Caddy]
CAS10192 [Vacuum Pump] Hydraulic systems - Cleaning 35.1 / 26
Caddy]
Caddy]
Caddy]
Caddy]
Caddy]
Caddy]
Caddy]
Caddy]
Caddy]
CAS10192 [Vacuum Pump] Electro-hydraulic control valve - Remove 35.6 / 3
CAS10192 [Vacuum Pump] Electro-hydraulic control valve - Remove 35.6 / 3
CAS10192 [Vacuum Pump] Electro-hydraulic control valve - Install 35.6 / 8
CAS10192 [Vacuum Pump] Electro-hydraulic control valve - Install 35.6 / 8
380001737 [Nitrogen Accumulator - Special tools - Ride control 35.8 / 5
Hoses Complete]
CAS10193 [ Kit For Vacuum Articulation frame pivot - Special tools 39.1 / 3
Pump]
CAS10193 [ Kit For Vacuum Articulation frame pivot - Remove 39.1 / 6
Pump]
48083742_EN 31/07/2018
PRINTED IN ITALY
48083742_EN 31/07/2018
EN

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jhon meneses

1/2 SERVICE MANUAL

Part number 48083742

1021G ZBAR - EH, NEW CAB TIER2

[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

[21.135] Powershift transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2

[21.105] Powershift transmission hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3

[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4

Four-Wheel Drive (4WD) system .................................................. 23

Front axle system ....................................................................... 25

[25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2

[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3

Rear axle system........................................................................ 27

[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2

[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

Brakes and controls .................................................................... 33

[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2

[35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

[35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6

[35.752] Hydraulic fan drive cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7

[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8

[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9

Frames and ballasting ................................................................. 39

[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2

[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

[41.910] Auxiliary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4

[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Cab climate control ..................................................................... 50

[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2

Electrical systems ....................................................................... 55

[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4

[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.5

[55.415] Loader arm and bucket control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

[55.530] Camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7

[55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8

[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9

Front loader and bucket............................................................... 82

[82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2

Platform, cab, bodywork, and decals ............................................. 90

[90.118] Protections and footboards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2

[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3

[90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4

[90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

Repairs have to be carried out only by authorized and in-

Non-authorized persons are not allowed to repair or carry

Ask your employer about the safety instructions in force

Nobody should be allowed in the cab during machine

If it is necessary to move the equipment to carry out re-

Stop the engine and ensure that all pressure is relieved

All repair and maintenance operations should be carried

Service stairs and platforms used in a workshop or in the

Before performing any work on the machine, attach a

If working conditions require, the following personal safety

• Ear plugs or acoustic ears protections

Do not wear rings, wristwatches, jewelry, unbuttoned or